Process Safety Key Performance Indicators - CSB

1 Process Safety Key Performance IndicatorsMartin Sedgwick Head Of Engineering and R&D Iberdrola Group23rd July 2012 Process Safety Key Performance IndictorsIberdrola Group and ScottishPowerScottishPower is part of Iberdrola, a world leader in energy2ndwind company3rdplayer in gas storageOne of thefifthlargest generator / retailers1stindcompanOne of thefifthlargest generator / retailers, 1stwind companyg1st privateproducer in Mexico1tdi t ib ti1stwindcompanyMain a clear focus on clean, sustainable energy provision1stdistributor in BrazilMain energycompany23rd July 2012 Process Safety Key Performance IndictorsWhat if Process Safety risks were as visible as Health & Safety risks? Process SafetyWhich warning signs are most likely to help you avoid an incident ?23rd July 2012 Process Safety Key Performance IndictorsVisible Process Safety Management SystemBased on Key Concepts in HSG 254, API 754 and on Key Concepts in HSG 254, API 754 and July 2012 Process Safety Key Performance IndictorsUnderstanding hazards & creating barriers (People, Process & Plant ).

2 Swiss Cheese Model3 Classifications Of Lagging Indicators42 Risk Control Systems3 Classifications Of Lagging IndicatorsFatalitiesProbability1 Remote risk with current but no in the UK in 10 in the UK in a Year 115 Expectation more than once a year10 Event FrequencyRankingRefe of HP feed system pipeworkgg g90 Hazardsgg g90 HazardsScottishPower Energy Wholesale Requirements Specification Process Safetyypp2PS 2 Loss of Containment from a High T emperature Pipework3PS5. rupture and catastrophic weld failure from a major low temperature steam line4PS7. External Boiler Tube arc flash explosion whilst locally operated and Gratings7PS3. of boiler integral furnace circulating and saturated steam pipework, fabricated in C steel materials with an internal diameter > 65mm8PS10. failure of boiler feedwater Vessel Rupture10PS4. of boiler drains pipework systems including blowdown systems.

3 11PS25. Steam and minor systems12PS11. PFS2 generated over pressurisation of enclosures and due to contact with live claddings and objects from buildings of buildings fabric to personnel access. of concrete from structures23rd July 2012 Process Safety Key Performance Indictors100+ Leading IndicatorsIncidentReportingProcessProces s Safety Management System 13th January 2009 Version [Working Draft] ScottishPower 2008 Commercial in Confidence this document contains information which is confidential and of value to ScottishPower. It may be used only for the purpose for which it has been provided. Prior written consent is required before any part is reproduced or distributed to 3rd parties. Classification Of Incidents3 tier approach based on API (Lagging Indicators )MajorProcess3 tier approach based on API July 2012 Process Safety Key Performance IndictorsMinorProcessSafetyIncidentProce ss Safety Management SystemPhilosophy is to visualise Swiss Cheese GuidanceNot All Indicators are of Equal Control IndicatorsLagging IndicatorsGenericLagging IndicatorsProgramme IndicatorsLeading IndicatorsLagging Indicators Active Monitoring and Logging: Breaches Of Plant Limiting Conditions (eg overpressure, overspeed, overtemp) Control Loops Out Of Control Equipment In Manual Operation of protection systems Failure of protection systemsLeading Indicators Inspection and Maintenance of Control Systems and Critical Lagging Indicators Incident Reporting and Investigation.

4 Near Misses (eg demand on Safety system) Loss Of Containment (eg release of high pressure steam) Process Safety Incident (eg major equipment damage)Leading Indicators Critical processes undertaken correctly Operations MaintenanceLeading Indicators Statutory Inspections Completed (egPSSR) Audits To Programme Action Closure Training and Competence Procedures Up To Date Improvement programmes23rd July 2012 Process Safety Key Performance IndictorsySystems Alarm Management Control Loop Performance Completion Of Operational Routine Checks / Testing Shift Logging & Handover Plant Overrides and Defeat of interlock Safety Critical Systems not available EngineeringHighLowPredictive of IncidentKPI Risk RankingOperational Indictors are the key to avoiding July 2012 Process Safety Key Performance IndictorsMajor Hazard AccidentsIndicators Need To Be Visible to prevent July 2012 Process Safety Key Performance IndictorsProcess Safety Management SystemReal Time Visibility and Drill Down Information Is July 2012 Process Safety Key Performance IndictorsReview LevelGovernance BodyReview GuidanceClid t dFrequencyGroup Governance ProcessCascade up WholesaleEnergy WholesaleGenerationGenerationEnergy Wholesale BoardOperational Risk Group (ORG)

5 Consolidated IndicatorsMajor or Key IncidentsBusiness Wide IndicatorsSignificant IncidentsTrendsGroup IndicatorsMonthlyMonthlyGeneration GroupsGeneration GroupsPower StationsPower StationsCoal PRMLN, CK, DDGas PRMRH , DC, SH, BB, HTHydro PRMCN, GW, LKSignificant & Moderate IncidentsClose-out ratesLocal IndicatorsAll IncidentsMonthlyDaily1223rd July 2012 Process Safety Key Performance Indictors