Upload
others
View
4
Download
1
Embed Size (px)
Citation preview
Together we make the difference
Process Safety at Tata Steel IJmuidenProcess Safety at Tata Steel IJmuiden
Peter AmentPeter Ament
Together we make the difference
Together we make the difference
Introduction to Tata SteelIntroduction to Tata Steel
Tata Steel
Introduction to the Tata Group
Process Safety at Tata Steel IJmuiden Slide 3
Founded in 1868
Operations in more than 100 countries and 600,000 employees
Total revenues of more than $109 billion (68% from outside India)
Ranked world’s 11th most reputable and 17th most innovative company
Promoter company Tata Sons 66% owned by philanthropic trusts
£100 million invested in community projects every year
Tata Group
One of the world’s fastest-growing and most reputable corporations
Tata Steel
Tata Steel Group
Process Safety at Tata Steel IJmuiden Slide 4
11th largest global steel producer
Annual crude steel capacity of more than 28 million tonnes
Around 75,000 employees
Manufacturing operations in 26 countries across five continents
Present in both mature and developing markets
Turnover in 2015-16: approximately $ 17.7 billion (€15.5 billion)
Fortune 500 company
Tata Steel Group
One of the world’s most geographically-diversified steel producers
Tata Steel
Tata Steel Group
Process Safety at Tata Steel IJmuiden Slide 5
A global network serving demanding markets worldwide
Western Europe
Steel making operations
Distribution and
downstream assets
North America
WesternEurope
Scandinavia
CIS
WesternAfrica
South Africa
Latin America
ChinaJapan
IndiaHong Kong
New ZealandSales offices
SE Asia
Key
Turkey
CEE
Tata Steel
Tata Steel: Europe’s second largest steel producer
Process Safety at Tata Steel IJmuiden Slide 6
Comprehensive range of steel products and related services supplying into demanding markets
Manufacturing sites in the UK and the Netherlands, Germany, France, Canada the US and Belgium. Presence in more than 35 countries
12.9 mtpa crude steel capacity
2015-16: Turnover €8.66 billion
23,000 employees
Our advanced capabilities
Products and services that create advantage
Tata Steel
Tata Steels European assets
Process Safety at Tata Steel IJmuiden Slide 7
3 steelmaking sites
25 downstream manufacturing locations
including electrical, plated and
pre finished steels, tubes
30 distribution and service centres
16 countries with sales office presence
6 businesses manufacturing products
for building systems
Tata Steel in Europe
Steel making sites
Port Talbot
Rotherham
IJmuiden
Tata Steel
Our key markets
Process Safety at Tata Steel IJmuiden Slide 8
Serving the most demanding markets worldwide
Packaging
Automotive Construction
Energy & power
Aerospace Consumer products
Defence & securityLifting & excavating
Tata Steel
Tata Steel in IJmuiden
Process Safety at Tata Steel IJmuiden Slide 9
Tata Steel
Tata Steel in IJmuiden: high-quality processes
Process Safety at Tata Steel IJmuiden Slide 10
TS IJmuiden produces high-quality hot-rolled, cold-rolled and coated steel
Raw materials - Pig iron - Steelmaking - Casting - Rolling - Coating
Together we make the difference
Process Safety in the Steel IndustryProcess Safety in the Steel Industry
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 12
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 13
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 14
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 15
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 16
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 17
Tata Steel
Blast furnace no. 5 Port Talbot
Process Safety at Tata Steel IJmuiden Slide 18
Explosion
Explosion in blast furnace no.5 in Port Talbot 18 November 2001.
An explosion in the blast furnace resulted in lifting the shaft of the furnace with 75 cm (±5000 tons of weight. About 200 tons of hot matter was released.
3 fatalities, 12 serious injuries.
Direct cause
Water into the blast furnace. The exact mechanism is still not fully understood.
Follow up
The accident was the start of structured program to improve process safety within Tatasteel Europe.
Management
Role and function if the safety department is essential (involvement in process risk evaluation).
In the steel industry efforts on preventive process safety studies were insufficient.
Operational
Cooling of the blast furnace was not reliable enough.
Fast detection of cooling water leakage and procedures for corrective measures and training on these procedures was insufficient.
Engineering
Engineering did not pay sufficient attention to process safety risks (reliability engineering).
Safety critical equipment was not identified and treated as such (e.g. cooling water pumps).
Lesson learnedIncident
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 19
Together we make the difference
Process Safety in Study Design and BuildProcess Safety in Study Design and Build
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 21
Six-stage Hazard Study Process
(plus two)
HHF/HHI assessment: High-level classification
Feeds into company HHF register; audit programme;
high-level KPIs; PHR programme management
Use of detailed study tools
e.g. HazOp, FMECA,
FTA, CTA, Bowtie
Plant improvements, SIL
determination, operating
procedures, maintenance
routines, training, audits etc.
Process Hazard Review -
recommended methodology for cyclic
study of existing plant:
Reconfirms PHR0 and requires more in-
depth information gathering to understand
in principle the worst PS incident.
PHR1 is similar to HS1 and also defines
the PHR2 plan for the facility.
PHR2 is an ‘installation-level’ study similar
to HS2 using guideword-driven team study
to understand the process hazard event
scenarios and layers of protection.
Cyclic PHR is not as onerous as the ‘first-
time round’
ALARP demonstration (ongoing)
Level 3 study
‘PHR0’
PHR1
PHR2
HS7 - Cyclic study
(ongoing)
HS3
HS0
HS2
HS4
HS5
HS6
HS1
Deviation analysis (HazOp ):
•From design expectations
•What if?
•Operability considered
•Also SIL, FMECA etc. studies at this time
Detailed design phase
Early study that considers:
•The nature of the process hazard
•The worst that can happen
•HHF effects
Scale-up / concept phase
Inherent SHE considerations
R&D phase
Field check:
•Did we build what the detailed design
called for?
End of construction – before commissioning
Early operational review:
•Incidents
•Issues
•Learning
After 6 months operation
Guideword-driven study:
•Identifies process hazard event scenarios
•Layers of protection required in detailed
design
Flowsheet design phase
Field check:
•Is it safe / compliant with OHS rules?
End of construction – before commissioning
Ongoing cyclic study
See ‘existing plant’
Pictorial representation of recommended process hazards analyses through plant life cycle
Tata Steel
Tata Steel IJmuiden risk grid
Process Safety at Tata Steel IJmuiden Slide 22
Consequence severity consequence word model
Category Description Safety and health Environment Financial A B1 B2 C1 C2 D1 D2 E1 E2 F
5 catastrophicOff-site fatality; multiple on
site fatalities (≥5)
MATTE; Very large excess of
allow able emissions; Very
serious contamination of
ground or w ater course;
Long term loss of aquatic life
> € 100 mln 5A 5B1 5B2 5C1 5C2 5D1 5D2 5E1 5E2 5F
4b On-site fatalities (2 to 4)€ 10 - 100
mln4bA 4bB1 4bB2 4bC1 4bC2 4bD1 4bD2 4bE1 4bE2 4bF
4a
Single on-site fatality; one or
few on-site major injuries;
high level of carcinogen
exposure
Excess of allow able
emissions and serious
damage to the environment
MATTE at EC threshold
€ 10 - 100
mln4aA 4aB1 4aB2 4aC1 4aC2 4aD1 4aD2 4aE1 4aE2 4aF
3 severe
One or few off-site MTCs;
one or few on-site major
injuries (LTIs, disablements);
distressing exposure,
irreversible effects
Repeated limited excess of
allow able emissions disturing
visual evidence; f ish killed,
vegetation killed; possible
MATTE
€ 0,5 - 10 mln 3A 3B1 3B2 3C1 3C2 3D1 3D2 3E1 3E2 3F
2 moderate
Off-site distress; one or few
on-site MTCs (serious
injuries); release 2-5 times
OEL; sustained or repeated
nuisance, noise, smell, dust,
f laring or venting; LoC w ith
safety consequences
Excess of allow able
emissions; notif iable release,
possible w arning from
Competent Authority
€ 100.000 -
500.0002A 2B1 2B2 2C1 2C2 2D1 2D2 2E1 2E2 2F
1 minor
Off-site nuisance; one or few
on-site FACs; release above
OEL, short duration nuisance,
noise, smell, dust, f laring,
venting, LoC
Small amount relased to
w ater course; reelease may
be notif iable to Competent
Authority
€ 10,000 -
100,0001A 1B1 1B2 1C1 1C2 1D1 1D2 1E1 1E2 1F
0 not signif icant
Incident leading to no injuries
or exposure on site; minor
damage only; no off-site
effects
Incident w ith no signif icant or
persistent environmental
effects
< € 10.000 0A 0B1 0B2 0C1 0C2 0D1 0D2 0E1 0E2 0F
Category A B1 B2 C1 C2 D1 D2 E1 E2 F
Frequency range (/yr) 10-9 to 10-8 10-8 to 10-7 10-7 to 10-6 10-6 to 10-5 10-5 to 10-4 10-4 to 10-3 10-3 to 10-2 10-2 to 10-1 10-1 to 1 1 to 10
Descriptionbarely
conceivablepossible probable regular
Likelyhood word model Never heard of Theoretically
possible but
never heard of
in our industry
Foreseeable
event but
extremely rare
in industry
Foreseeable
event but
chance of
occuring is
very low -
requires the
failure of many
layers of
protection
Foreseeable
event but
chance of
occuring is
low - requires
the failure of
several layers
of protection
Incidents
know n in
industry;
Unlikely event
not expected
during lifetime
of installation;
Probably
requires tw o
layers of
protection to
fail
Incidents
know n in
industry. May
require tw o
layers of
protection to
fail
Could occur
during
remaining
lifetime of
installation.
Root causes
have been
seen during
lifetime of the
installation
Has occured
during lifetime
of facility
Has occured in
recent lifetime
of installation
and likely to
recur in the
next year
unlikely
major
Likelyhood
extremely unlikely very unlikely
Tata Steel
Process Safety approach for projects in high hazard installations
Process Safety at Tata Steel IJmuiden Slide 23
HAZID HAZOP LOPA - SIL SRS SAP
HS2 study in the form
of Hazard
Identification
High level assess-
ment of process
hazards in an early
project stage.
HS3 study:
Hazard and
Operability Study
(HAZOP)
including risk
assessment
using the TSE risk
grid, identification of
safety critical equip-
ment.
Detailed study on the
basis of P&IDs.
First assessment of
SIL requirements.
HS3 study:
Layer Of Protection
Analysis (LOPA)
resulting in
requirements for
Safety Integrity
Systems (SIS) and
Safety Integrity
Levels (SIL) for
identified safety
loops.
Safety Requirement
Specifications (SRS)
describing the safety
loops and how the
requirements from
standard IEC 61511
are met.
This includes
testing, inspection
and maintenance
requirements.
Incorporation of the
testing, inspection
and maintenance
requirements in the
site maintenance
system (SAP).
consequence
4 & 5
scenario’s
Together we make the difference
Process Safety in Use Phaseby Integrity RegimesProcess Safety in Use Phaseby Integrity Regimes
Tata Steel
Tata Steel Europe Process Safety Critical Equipment approach
Process Safety at Tata Steel IJmuiden Slide 25
Tata Steel
Process Safety and Technical Integrity
Process Safety at Tata Steel IJmuiden Slide 26
Design
IntegrityTechnical
Integrity
Operational
Integrity
Hardware barrières are
present and in a good
condition
Operators are
competent and stick to
the procedures
Our risks are As Low
As Reasonably
Possible (ALARP)
Tata Steel
Parallel approach
Process Safety at Tata Steel IJmuiden Slide 27
PHR 2
PHR 3 Bow Tie Integrity Management
Active barrier Passive barrierProcedural barrier
• Similar to study design
build process
• For highest risk
installations
• No brainer: should do
• Barrier management
approach
• Study for scenario’s with
risk category 4 and 5
• Based on standardized
technical approach
• Also other equipment
than process safety
critical
• Only active en passive
barriers
Tata Steel
Approach to implementation of Integrity Management
Process Safety at Tata Steel IJmuiden Slide 28
Group level
PHR 0
PHR 3
Active barrier management
Inspection &
Tests
SAP PM,
Procedures,
Instructions
Passive barrier management
RegimesInspection &
Maintenance
Site level
PHR 1
PHR 2
Organizational management
InstructionsProcedures
Audits
Safety
Report
Safety
loops
Laws and
regulations
Performance
standards
Tata Steel
Integrity Management
Process Safety at Tata Steel IJmuiden Slide 29
Availability
Product quality & production continuity
“License to Operate”
Reduction of (unplanned) stops
Continuously being to demonstrate the integrity of the installation
Support maintenance choices
Used for CAPEX / OPEX investment proposals
Basis for repairs and modifications
Safety
Assurance of process safety
Input for Process Hazard Reviews
Environment
Reduces Loss of Containments
Integrity Management
according Lloyd’s:
‘The physical asset complies with the
relevant laws and regulations
and to the requirements set by the organization
in terms of risk, performance and costs’
“Make sure in a cost efficient way that we don’t get surprises that
could have been foreseen”
Tata Steel
Strategy Integrity Management
Process Safety at Tata Steel IJmuiden Slide 30
To ensure the technical integrity of installations by:
1. classify the installation in inspection regimes
2. monitor and perform the integrity inspections centrally
Prerequisite is the centralization of process, knowledge and assessment ability
Regime = same type of installation,same inspection and test approach
Tata Steel
Inspections and Integrity Management
Process Safety at Tata Steel IJmuiden Slide 31
Determination when a part
needs to be replaced
Integrity
Management
Inspections
Re
pla
ce
Determine when process
settings need to be adjusted
Maintenance
Inspection
Determined by
degradation mechanism
that occurs
Integrity Inspection
Determined by
degradation mechanism
that might occur
Determine the actual
condition of the installation
Determine the remaining
life time of the installation
Ad
just
Inte
grity
End-o
f-lif
e
Tata Steel
Current Integrity Regimes
Process Safety at Tata Steel IJmuiden Slide 32
Integrity Management
Law- and Regulations
Process Safety
Law- and Regulations
Pressure Vessels
Blast Furnaces
Works Arising Gas Systems
Atmospheric Storage Tanks
Proces Vessels
Process Piping
Critical constructions
Cranes and crane tracks
Chimneys
All installations
Inspection Management
Local, FMECA, Optimiser+
Safety Systems
Tata Steel
Relation between Integrity Management and Process Safety
Process Safety at Tata Steel IJmuiden Slide 33
Barrier Management
ProceduralActivePassive
PS
CE
HS
E C
EM
AN
CE
DT
D
DH
R
TIR
WA
GS
PP
IR
PV
IR
SIS … … …
Insta
llati
on
s
Law- and
regulations
Company
policy
… …
Integrity Regimes
Process Safety
Tata Steel
Organization of Integrity Regimes
Process Safety at Tata Steel IJmuiden Slide 34
Level 3
Set up and secure inspection regime
Determine inspection plan
Assessment ability
Monitoring and auditing
Level 2
Inspect
Report
Advise
Level 1
Measure (e.g. NDT)
Level 1
Measure
Level 2
Inspect
Level 3
Asses
Integrity Regime
Tata Steel
Manning the Integrity Regimes
Process Safety at Tata Steel IJmuiden Slide 35
Regime 2Regime 1 Regime ..
Own staff
Hired staff / Outsourcing
Level 3
Level 2
Level 1
Together we make the difference
Tata SteelProcess Safety at Tata Steel IJmuiden Slide 37