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7/30/2019 TS1 - Taruli Sibuea
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Safety Improvement
Implementation Program atPertamina Refineries
BY Taruli Sibuea
HSSE REFINING
J uni 2011
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PERTAMINA1
Topic of Presentation
Summary4
Introduction1
SIIP Program Design2
Implementation3
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PERTAMINA
PT PERTAMINA (Persero) REFINERIES1. Introduction
RU II :
- P. Brandan- Dumai- Sei. Pakning RU III Plaju
RU IV Cilacap
RU V :
- Balikpapan- Methanol Bunyu- Kasim
RU VI Balongan
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How We Accelerate Pertaminas Transformation
Safety
Culture
Refining :
Deliver safe, top quart ile operation, expend to meet national demand
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The case for change
No Harm to People, Asset, Environment
and Reputation Pertamina vision is to transform to a
company w ith Excellent Safety
Performance by 2015
Many HSE Role models from linemanagement
Compliance to HSE Golden Rules andown safety procedures
Leadership commitment tolerance of unsafepractices.
Standards of safety performance tolerance oflow standards for implementing cri tical tasks.
Contractor safety contractors not following basic
safety rules. Knowledge and competencies in HSE are low. Safety is driven by HSE Department.
From (Result o f DuPont Safety Assessment 2006)
To / Future State
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2. SIIP Program Design
Al ignment WorkshopsFour workshop to manage thechanges and ensure succesfulimplementation.
Strengthen Safety BasicsHazard Awareness and RAMSafe Walk and TalkSafety Supervision.
Technical SafetyTechnical /Process SafetyPrimer
2008
2010
2012
2014
Close the Gaps in SafetyCritical ProcessesReview safety critical process
Gap closure Workshop (PtW,J SA)
Technical SafetyHEMP AwarenessTraining
Integrated HSEManagement SystemHSE MS TrainingHSE MS Review
Enhancing HSE CultureHeart and Minds ToolsLaunch of Behavior Based
SafetyTechnical Safety
HEMP Implementation
Sustain the ProcessReview the progress ofimplementation
A Step wise Journey to Excel lence in Safety
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Deployment for Safety Improvement Implementation Program (SIIP)
Program Design Implementation
1. Preparation
a. Establish task groupb. Establish unit to be evaluated
2. Implementationa. Evaluate the present statusb. Identified Deviationsc. Do Correction
PIC HSE Personal competencies
Process Eng.ProductionME
Metric
Measurement
0
5
10
w1 w2 w3
Audit (Health Check, MWT)
% Compliance to definedoperating windows setting
% Compliance to defined alarmsetting
% Compliance to defined safeguarding setting
Verify
performance
Leadership Commitment1 2
3
4
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PERTAMINA
Chairman
(Refining Director)
Steering
Committee-2Steering
Committee-3
Executor
Chairman
(GM RU)
Refine
ryUnit
Ce
ntral
SteeringCommittee
Secretary (Man. HSE Ref.)
Line Organization
Secretary (Man. HSE RU)
ExecutorSteering
Committee
Line Organization
Standards,
Procedures, Incident
Investigation
Steering
Committee-2Steering
Committee-3
Manager
SVP
Organization & Responsibilit ies (Organization Of Safety Committee Meeting)
SMOM
Manager
Standards,
Procedures, Incident
Investigation
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PERTAMINA
Lagging Indicator:
Leading Indicator
KPI
HSE KPIs For Pertaminas Refineries
1. Number of Safety Walk & Talk (SWAT)2. Number of Management Walk Through (MWT)3. % Follow up on Incident Investigation Recommendation4. % Compliance to Management of Change (MOC) Personal, Facility & Technical5. % Fire Protection Readiness6. % Compliance to Setting of Operating Windows, Alarm and Safeguarding.7. % Compliance to Schedule Testing of Alarm & Safeguarding8. % Overdue Inspection for Tank, Vessel, Piping, Pressure Safety Valve (PSV),
Compressors, Pumps, Column, Boiler & Furnace
1. Total Recordable Incident Rate (TRIR)2. Number of Incident
3. Implementation
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PERTAMINA
IssuesEquipmentProcess
People
Safety
Some Safeguard system are not working or by pass
Some monitoring equipments are not working ( TI,FI )
Some operating windows are exceeded
Some Supervisors and Operators competencies needto upskill regarding Safe operations .
Management consequences needs to be stronglyimplemented
Need improvement to Permit To Work implementation.
Risk Containment Acitivities (Accelarated Preventive Response, APR)
APR to identify gap and mitigate in the area of critical process safety. Involvement more people / teamfor the program.
Related to PSM Element :
Process Safety Information Process Hazard Analysis Operating Procedure Training Mechanical Integrity Management of change Compliance Audit
Key Learning from Balikpapan and Cilacap Furnace incident
APR For : Boiler & Furnace Storage Tank Fire Protection Facility Pressure Vessel and Piping
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PERTAMINA
50
60
70
80
90
100
2008 2009 2010 2011
50
60
70
80
90
100
2008 2009 2010 2011
50
60
70
8090
100
2008 2009 2010 2011
PPE Contractor
(% Safe)
100%
Week
Scaffolding
(% Safe)
Gap Gap Closure Remark
1. Unstandard Blind formaintenance work (workpermit).
2. Unsafe Scaffolding use by small
Contractor (no bracing, baseplate, stair, toe).
1. Intervention
2. Review to improve
scaffolding standard.
Week
50
60
70
8090
100
2008 2009 2010 2011
Week
100%
90% Target
85% - 90% Target
< 85% Target
Electrical Tools & Distribut ion
(% Safe)
Work Permit
(% Safe)
Week
Sample Results of SIIP in Refinery
100%100%
Before After
Before After
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PERTAMINA
Lock and tags System to manage Bypass
Avai labil it y of Good Fire Fighting Equipment Avai labil it y of informat ion during emergency
KPIs on display
Sample Impact of Safety Leadership in Refinery
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PERTAMINA
Good House-keeping, Painting & Insulation
Good Scaffolding Material Good Plant Housekeeping
Good Chemical Handling
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PERTAMINA
Safety Golden Rules deal with Compliance issues on Key Safety Rules
There has to be investigation and appropriatemaximum consequence for those breaking rules..
If you choose to break the rules,
You Choose not to work for Pertamina
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PERTAMINA
Overall Safety Effort : Reduce and Eliminate Hazard to Prevent Incident
People risks
Observable behaviour
Man-Machine Risks
Unseen behaviour
Integrity Risks
Understanding assets
Reactive
Catastrophic
Incident
Multiple fatality
Near Miss
Major Incident
Loss Incident
Fatality
Serious Injury
First-aid Incident
Unsafe Acts and Conditions
Process Safety
Preventative
Assess the effort
to eliminate both
behavioural and
process safety
hazards
Behavior
? ?
??
?
?
??
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PERTAMINA
Key Learning For Continues Improment
Maintain The Processes(Safety Committee Structure, Safety moment in every meeting, Safety board and leading
indicators)
Do More(Incident Investigation, Safety Observation and Intervention, Safety Action Plans)
Change the Process(Involve Contractor in Safety Culture development, Improve operating discipline)
Introduce the Process(Develop a matrix of knowledge and competency for capabil ity development, develop
system to maintain the mechanical integrity safety critical equipment)
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PERTAMINA
4. Summary
- We have got some improvements by implementing SIIP.
- We learnt f rom incident in Pertamina and other refineries and conducted RiskContainment (Accelerated Preventive Response) for cri tical process safety.
- We have to cont inuously identify the gap and follow up to achieve SafetyExcellent.
Achieving Safety Excellence is a Long Journey
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PERTAMINA |17
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