PROCESS SAFETY DAY 2016

I KEEP MY BARRIERS STRONG

Team Leader or Supervisor Led Reflective Learning Session

First and secondary Emergency Exits

Emergency contact numbers

Assembly Point

Fire drills scheduled

Alarm sirens/bell

First aid kits and first aid number (do we have a first aider in the room?)

Location of toilets

Location of coffee and tea

SAFETY FIRST

FOR THIS MEETING, PLEASE REVIEW

THE FOLLOWING FOR YOUR LOCATION

AGENDA

1. Welcome and setting the scene for Process Safety Day (10 minutes)

2. Distribute and explain the two hand outs (5 minutes)

3. Video Part 1 - Two Incidents a world apart (5 minutes)

4. Discussion Break 1 (15 minutes)

5. Video Part 2 - When things change (5 minutes)

6. Discussion Break 2 (15 minutes)

7. Video Part 3 – I keep my barriers strong (5 minutes)

8. Discussion Break 3 & relating video to PDO incident (20 minutes)

9. Personal Commitments (10 minutes)

Total 90 minutes

PROCESS SAFETY INCIDENTS ARE STILL HAPPENING

REOCCURING ISSUES Risk Assessment not appropriate

Procedures not followed

Design & construction related failures

Normalization of risks

Management of Change

Corrosion related failures

Erosion of barriers overtime

MOL Corrosion Coupon Incident & Spill (25 Feb 2016) Sadad LLRTP Fire and MTC (5 Jun 2016) ZAZ-10 Well H2S leak (11 Jan 2016)

Rima Runib 20" SRV trip & Pit Overflow (18 Dec 2015) Barik South Manifold Condensate leak (21 Dec 2015)

Kauthar - Heat exchanger gas leak (24 Oct 2015) Lekhwair C Test Header leak (1 Oct 2015)

WTU-3 Birba - Flare-out H2S well (24 Oct 2015)

PROCESS SAFETY DAY JOURNEY

2014 Theme: Know Your Role Play Your Part

2015 Theme: I Own My Barriers

2016 Theme: I Keep My Barriers Strong

HAND OUT - 1

For this session we use the Reflective learning method Reflective learning is not about watching a video; it’s about discussing together what these

leanings mean for us & what we can do to prevent these incidents

Part 1 : Two Incidents - A World Apart (4 minutes video)

NO LEAKS – I KEEP MY BARRIERS STRONG

Internal PDO users please Click Here

External users (Contractor Staff) please Click Here* *Please use windows media player program to play the videos

• What is changing in these two scenarios?

• Which barriers are getting weaker ?

• What “weak signals” can you identify ?

DISCUSSION BREAK 1

Part 2 : When Things Change(3 minutes video)

NO LEAKS – I KEEP MY BARRIERS STRONG

Internal PDO users please Click Here

External users (Contractor Staff) please Click Here* *Please use windows media player program to play the videos

• Can you recall an incident that happened as a result of change to a plan?

• What intervention could had been done and when ?

• How do you manage changes to equipment and process ?

DISCUSSION BREAK 2

NO LEAKS – I KEEP MY BARRIERS STRONG

Internal PDO users please Click Here

External users (Contractor Staff) please Click Here*

Part 3 : I Keep My Barriers Strong (3 minutes video)

*Please use windows media player program to play the videos

RELATING VIDEO TO OUR INCIDENT

The Pig Launcher incident in the video is based on an actual incident at PDO. Do you recollect which one? If not refer to handout – 2 Yibal B Pig Launcher Incident

HAND OUT 2 -YIBAL B PIG LAUNCHER INCIDENT

Description of the Incident

On the 7th of June 2014 at around 10:10 hrs Mechanical Crew were performing a routine Trap Maintenance & Pig Launching activity on one of the gas line near the Yibal B station. The crew were attempting to open the launcher door after de-pressurizing the line. The door was defective with missing bleed screws and safety inter lock and swung open violently due to remnant pressure in the line and severely injured one person who was in the path of door swing. Two other persons sustained first aid injuries.

Underlying Causes and latent failures:

Pressure relieving was not done completely before opening the door*

The bleed screws (with safety interlocking device) which are required to release the remnant pressure were broken off long time ago (could be more than 20 years) and had been bypassed by sealing the bleed screw holes with unknown material. The missing bleed screws and interlocking devices were an “accepted” condition (risk tolerance) for several years

A substandard modification was done several years ago to the launcher barrel for a temporary purpose of kicking a stuck pig without following the management of change process.

What is a Pig Launcher/Receiver?

Pigging in the maintenance of pipelines refers to the practice of using pipeline inspection gauges or 'pigs' to perform various operations on a pipeline without stopping the flow of the product in the pipeline. Pigs get their name from the squealing sound they make while traveling through a pipeline. These operations include but are not limited to cleaning and inspection of the pipeline. This is accomplished by inserting the pig into a Pig Launcher - a funnel shaped Y section in the

pipeline. The launcher is then closed and the pressure of the product in the pipeline is used to push it along down the pipe until it reaches the receiving trap - the 'pig catcher'.

* This is like trying to open a pressure cooker when there is still pressure inside

• What personal examples can you give of risk normalization* or being too optimistic ?

• How can you make sure your barrier stays strong when things change ?

* The gradual process through which unacceptable practice or standards become

acceptable. As the deviant behavior is repeated without catastrophic results, it becomes the social norm. eg. Driving without seat belts, using mobile phones while driving etc.

DISCUSSION BREAK 3

PERSONAL COMMITMENT AND FURTHER ACTIONS

• What will you do differently now to prevent incidents when things change? Upload your team commitments here

• Please mark you attendance for this session by clicking here

• Upload pictures of your event on the Process Safety Day Webpage in the Gallery section

• Participate in the process safety day quiz and win amazing prizes

SHUKRAN

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