Improve process safety analysis and culture at TATA Steel with BowTie Server

Transcription

1 Improve process safety analysis and culture at TATA Steel with BowTie Server

2 Introducing Tata Steel Tata Steel Slide 2 Tata Steel Group One of the world s most geographically-diversified steel producers Tata Steel Group 11 th largest global steel producer Annual crude steel capacity of more than 27.5 million tonnes Around 74,000 employees Manufacturing operations in 26 countries across five continents Agreement for the formation of a joint venture with the European steel activities of Thyssenkrupp.

3 Introducing Tata Steel Tata Steel Slide 3 Tata Steel Group A global network serving demanding markets worldwide Western Europe Scandinavia Western Europe CIS North America CEE Western Africa Turkey India China Hong Kong SE Asia Japan Key Steel making operations Distribution and downstream assets Sales offices Latin America South Africa New Zealand

4 Introducing Tata Steel Tata Steel Slide 4 Tata Steel in IJmuiden Raw materials - Pig iron - Steelmaking - Casting - Rolling - Coating

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6 But there are also hazards. Tata Steel Slide 6 Drivers for Process Safety Piper Alpha (167 ) Macondo Well (11 ) Bophal ( ) Texas City (15 ) World Industry Furnace explosion(4 ) Ternium Steel (10 ) CSN, Brazil 2006 China steel ladle(32 ) Steel Industry BF 5 explosion (3 ) GH explosion (1 ) BF hot blast line PT ladle drop Tata Steel BF bleeder valve Pickling line fire Coke Gas heating alley Tata Steel local

7 What is Process Safety? Tata Steel In essence: keeping control of identified Safety and environmental Major Hazard scenarios - low frequency of occurrence / major consequences. Slide It s a tough subject : Difficult to predict; Hard to imagine; Difficult to keep the overview. (e.g. Macondo incident *) * Prof. Andrew Hopkins; Disastrous Decisions, may 12. ISBN

8 What s process safety? Tata Steel Slide 8 Companies must ask 3 questions*: Do we know what can go wrong? Do we know what barriers we have to ensure that it doesn t go wrong? Do we know that our barriers are effective and working properly? * REGULATOR S REACTION TO BUNCEFIELD

9 Tata Steel Slide 9 Mission, Vision and Strategy Mission: Eliminate all major process safety events by controlling all Major Hazard scenario s within Tata Steel Europe, through the thorough application of our process safety management framework. Vision: This will be achieved, among other things, by : The thorough application of Barrier Management to manage Process Safety Critical Equipment and Process Safety Tasks (PSCE & PSCT) Strategy: BowTie Server - improve risk communication / encourage to learn from each other; BowtieXP template - keep high standard to identify PSCE and PSCT / speak the same language. AuditXP framework - Develop standards to report on the barrier health status.

10 Process Safety Management Foundations L3 Tata Steel Slide 10 Implementing the strategy Back to the primary process: The art of steelmaking starts with conversation

11 Tata Steel Slide 11 Challenges Language: How to relate the phases of process safety and align the approaches: BowTie HAZARD IDENTIFICATION : PHR0 : Delivers HHF and HHI indentification PROCESS HAZARD ANALYSIS : PHR2 (minimum), HAZOP or FMECA. Delivers barrier identification Barrier investigation : HSE - scenarios with consequence 4 on Risk Grid with BowTie. Delivers Process Safety Critical Equipment overview and SCT regarding to maintenance PS-toolbox. Process Safety Code of Practice PSC-03.1 PS-toolbox. Process Safety Code of Practice PSC-03.2 PS-toolbox. Process Safety Code of Practice PSC-06.1 Delivers overview of Process Safety Critical Task (SCT) for operations. PS : Process Safety team IJmuiden HHI : operators and engineers from High Hazard Installation LOPA : delivers reliability requirements for SCE and SCT. AMD + HHI SCE performance setting : SCE management process of AMD. HHIengineer implement maintenance plan for SCE into SAP. Regimes and drawings (P&ID) DELIVERS ASSET INTEGRITY SCT performance setting : Set requirements for Operating procedures. PS + HHI PS toolbox : several PSGs DELIVERS OPERATIONAL CONTROL SIMPLIFIED Link to SAP PM Link to local managementsystem Server in rekencentrum IJmuiden : A BowTie / HAZID / AUDIT tool to execute barrier Management. DELIVERS HAZARD CONTROL : APPROACHABLE TO ALL ORGANIZATIONAL LEVELS PS + AMD + HHI

12 Process Safety Management Foundations L3 Tata Steel Slide 12 The 3 level barrier approach of Tata Steel 1 Barrier: Passive, Active, Procedural or Mix 2 Barrier component: detect decide final (act) 3 SMS Element: Performance Standard Operation or -Equipment Execution of maintenance, instructions, Assurance of Safety Instrumented Functions or -Operational Interventions

13 Process Safety Management Foundations L3 Tata Steel Slide 13 Change in practice Cokes Factory 1 Pilot Current situation: HAZOPs are performed There is an with the first Process Hazard studies, preparing for the barrier management approach. Pilot Goals: Enabling ownership of the analysis proces to the factory assisted by the local PS experts. Enabling the plant to use their bowties in operator involvement AND management involvement for risk reducing actions. Preparing for barrier health checks Intermediary results: Old data is reused and imported in BowTieServer Crews are involved and enthusiastic Ramping up for the improvement cycle

14 Process Safety Management Foundations L3 Tata Steel Slide 14 Culture and strategy What do we learn from marketing

15 Process Safety Management Foundations L3 Tata Steel Slide 15 Learning points the way forward Influencers for success: Interaction between individuals Culture Politics Changes Management commitment Compliance pressure User acceptance of and onboarding of the tools Next steps in closing the circle: Barrier health checks (focus on the elements and components) Incident learning what scenario s did we miss, what control mechanisms did work and which didn t? Focus on what works bringing it back to simple.

16 Process Safety Management Foundations L3 Tata Steel Slide 16 Topics to tackle in the next steps of risk ownership Tata Steel barrier approach: The model is a choice and has up- and downsides. Ownership of hazards Defining the best approach. Implementing risk reducing actions Defining good practices combining other action tools. Defining good practices combining other improvement actions protocols considering e.g. CAPEX and OPEX decisions.