GU-648 - Guide For Applying Process Safety in Projects
GU-648 - Guide For Applying Process Safety in Projects
GU-648 - Guide For Applying Process Safety in Projects
Document ID GU-648
Security Unrestricted
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This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part
of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
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i Document Authorisation
Authorised For Issue 15th December 2010
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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
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TABLE OF CONTENTS
1 Introduction........................................................................................................................... 6
1.1 Background..................................................................................................................... 6
1.2 Purpose........................................................................................................................... 6
1.3 Objective......................................................................................................................... 6
1.4 Distribution / Target Audience.......................................................................................... 6
1.5 Review and Improvement............................................................................................... 7
1.6 Step-out Approval............................................................................................................ 7
2 Roles and Responsibilities.................................................................................................... 8
2.1 Risk Management........................................................................................................... 8
2.2 Design and Construction................................................................................................. 8
3 Process Safety Management................................................................................................ 9
4 The Objectives of AI-PS in Projects....................................................................................11
4.1 People and Systems...................................................................................................... 11
4.2 Design Integrity............................................................................................................. 12
4.3 Technical Integrity.......................................................................................................... 13
4.4 Operating Integrity......................................................................................................... 14
5 Project Phases.................................................................................................................... 15
5.1 Identify........................................................................................................................... 15
5.2 Assess........................................................................................................................... 16
5.3 Select............................................................................................................................ 18
5.4 Define............................................................................................................................ 21
5.5 Execute......................................................................................................................... 24
6 Process Safety Basic Requirements...................................................................................31
Appendix 1 Reference Material...............................................................................................32
Appendix 2 Abbreviations........................................................................................................ 34
Appendix 3 End of Delivery Map (to be developed)...............................................................35
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1 Introduction
1.1 Background
Asset Integrity Process Safety (AI-PS) is about prevention and mitigation of incidents
(such as fire or explosion) that result from unintentional release of energy or hazardous
substances contained in the process assets we operate.
Successful AI-PS management is based on four principles:
1. Committing to process safety
2. Understanding process hazards and risk
3. Managing process risk to ALARP
4. Learning from experience.
These principles are applicable to all phases of the Opportunity Realisation Process
(ORP).
1.2 Purpose
This guideline will be part of the Project Delivery documentation and its aim is to
provide clarity with regards to AI-PS requirements throughout the phases from project
identification to execution. It does not add any new processes or requirements to
existing ORP deliverables, but extracts from the existing ORP documentation all the
relevant information necessary to meet the AI-PS requirements at handover. It also
provides further clarity with regards to the assurance processes which underpin the
project teams ability to demonstrate that AI-PS requirements are met at the end of
every project phase. This will allow PDO to make the statement that Our Asset is
Safe and we know it after each project phase.
Delivery of AI-PS requires that all major and high risk hazards (Highs and 5s on the
risk Assessment Matrix) are identified and mitigated against using the Hazard and
Effects Management Process (HEMP). The systems and their subsidiary components
critical to managing risks must be properly designed, procured, built, installed, tested
and maintained such that the risk of a major or high risk accident event is ALARP. The
HSE case (SP-2062 - HSE Specification: Specifications for HSE Cases) is the main
vehicle to demonstrate ALARP and is a fundamental AI-PS tool for the project manager
and project team.
1.3 Objective
The main objective of this guideline is to explain the key AI-PS objectives and
deliverables throughout the project phases that demonstrate the facility is fit for the
safe introduction of process fluids and that systems, processes and procedures are in
place so that AI-PS can be safeguarded in the subsequent operate phase.
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Learning from incidents involves investigating process safety incidents to identify and
address the root causes; applying lessons from incidents that occur at other facilities
within PDO and within the industry; measuring performance and striving to
continuously improve in areas that have been determined to be risk significant; auditing
process safety management systems; and holding periodic management reviews to
determine if the management systems are working as intended and if the work
activities are helping the facility effectively manage risk.
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4.1.1 People
PDO project leadership regularly demonstrates in words and actions that they
are committed to deliver AI-PS requirements
Competent contractor has been appointed to deliver the project
Competent Technical Authorities have been assigned to the project team
Independent competent and experienced Engineering and Operations staff are
involved in project reviews, e.g. VAR2-4, Design Reviews, PER, etc.
Competent resources in place ready for the Operate phase
4.1.2 Systems
Quality documentation and data is managed throughout the project phases and
made available for the Operate phase in a user friendly format
Management of Change (MOC) is in place and effective
Discipline Controls and Assurance Framework (DCAF) is in place and used
consistently
QA/QC systems are in place and adhered to
Regular assurance of AI-PS deliverables takes place and results are captured
in the HSE Case
Clear set of AI-PS metrics in place at project level
Lessons are applied from Process Safety incidents and assurance findings at
other facilities within PDO and within the industry
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In Severity Five and High Risk hazard situations, where the circumstances are not
fully within the scope of good practice, additional measures may be required to reduce
risks ALARP. Furthermore, where the potential consequences are Severity Five on
the PDO risk assessment matrix, Project Managers should take a precautionary
approach by giving more weight to the use of sound engineering and operational
practice than to arguments about the probability of failure. The Figure below shows the
hierarchy of good engineering principles.
In simple terms, in Severity Five and High Risk hazard situations, Project Managers
should:
review their accident scenarios and risk management arrangements (for
prevention, control and mitigation);
identify what good practice is relevant;
comply with the applicable good practice;
ask the question Are there any other measures which would be effective in
further reducing the risks?; and
determine whether the extra measures are reasonably practicable and
implement those that are.
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5 Project Phases
The Opportunity Realisation Process (ORP) is split into six phases punctuated by
decision gates. Each phase has clear milestones and decision gates, activities,
deliverables and decision requirements. The phases are:
This guideline follows the six ORP phases and details what deliverables need to be
achieved at each decision gate, in order to meet the AI-PS requirements at the end of
the execute phase.
5.1 Identify
The Identify phase is the first step of the project cycle and evaluates if we understand
what were getting ourselves into and should we spend resources in assessment of this
opportunity.
The following DCAF deliverables for the Identify Phase have critical AI-PS content:
Deliverable ATA RTA(s)
Risk Register Field development Surface production, HSE
HSE & SD Plan HSE (technical safety)
PCAP Field development
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5.2 Assess
Decision Gate 2 at the end of the Assess Phase confirms the feasibility of the
development and that there is a high enough likelihood of success.
The following DCAF deliverables for the Assess phase have critical AI-PS content:
Deliverable ATA RTA(s)
Risk Register* Field development Surface production, project
engineering, HSE
(technical safety)
HSE & SD Plan* HSE (technical safety)
PCAP* Field development
Initial Operations Surface production Logistics
Assessment
Conceptual HAZID Report HSE (technical safety) Process engineering
HEMP Findings and Close- HSE (technical safety) Well engineering,
Out Report completions & well
interventions, process
engineering
* Updated from previous phase
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5.3 Select
The objectives of the Select phase are to get all strategic decisions of a project
approved by the appropriate authority. The word strategic is used loosely, as the nature
of the decisions to be taken is often dictated by time schedules, lead times for
Government approvals and contracting tactics. It is the phase in which most strategic
decisions on how the project will be executed and operated are made. By the end of
the select phase, the correct AI-PS culture must have been established by the Project
Manager through visible commitment and (plans for) dedicated AI-PS assurance
activities. The project team must be able to demonstrate ALARP and that the selected
option is also the lowest HSE risk option. This ALARP demonstration will continue with
the creation of the design HSE case during the Define phase.
DCAF deliverables with key AI-PS content at Select phase are:
Deliverable ATA RTA(s)
Risk Register* Field development Surface production, project
engineering (concept),
HSE (technical safety)
HSE & SD Plan* HSE (technical safety)
PCAP* Field development
HEMP Findings & Close- HSE (technical safety) Process engineering
out Report*
Layout Design / Site Project engineering / field Surface production,
Selection Report development mechanical static,
electrical, civil, pipelines,
project, HSE (technical
safety)
Selection of Engineering Project engineering All engineering disciplines,
Design Standards (concept) including technical safety
(HSE)
Operations Philosophy Surface production Generally all disciplines are
either RTA or C/I
Corrosion Management Materials corrosion & Production chemistry,
Strategy / Materials inspection process engineering
Selection Report
ALARP Demonstration HSE (technical safety) Generally all disciplines are
Report either RTA or C/I
Detailed HAZID Report HSE (technical safety) Generally all disciplines are
either RTA or C/I
Concept Risk Assessment HSE (technical safety) Process engineering
HSE Philosophy HSE (technical safety) Surface production, project
engineering (concept)
Fire and Explosion HSE (technical safety) Process engineering
Assessment
Technical Integrity Field development Project engineering
Verification Report (concept), HSE
Process Safeguarding Process engineering
Report
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mass balance data, plot layout, process and project descriptions, HSE and Operations
Philosophy, IIA reports, etc.
1.1.8 Concept Risk Assessment
Quantitative Risk Assessment (QRA) is required for new production / gathering
facilities, major expansion of existing production / gathering facilities, or for critical high
risk sour gas projects of any scale. The scope of the QRA during concept selection is
to identify major risk contributors and effective safety measures and to aid in the
selection of the lowest HSE risk or ALARP development option. QRA provides input to
the facility sighting and layout activities and is linked to the facility Fire and Explosion
Assessment.
1.1.9 HSE Philosophy
A HSE philosophy is required to guide and drive the design intent of HSE critical
systems. The philosophies are prepared during the Select phase to be implemented in
later project stages and are used as input into the functional specifications. The main
process safety aspects of the philosophy includes emergency shut down and
blowdown; fire and gas detection; active and passive fire protection (including
guidelines for fire fighting systems and fire protection); sighting and layout; and process
containment.
1.1.10 Fire and Explosion Assessment
Fire & Explosion Assessments (FEA) are required for the introduction of new
hydrocarbon equipment, or new occupied or functionally significant buildings. The FEA
provides input to the facility layout and spacing requirements and defines the FERM
strategy that should be applied to the asset. Facilities with FERM strategies 2 and 3
will include fixed active fire protection SCEs.
1.1.11 Technical Integrity Verification Plan
The Technical Integrity Verification Plan is the guide to deliver Technical Integrity on the
project. It covers all phases from Select through Define and Execute. The purpose of
the Technical Integrity Verification (TIV) Plan is ensure that, over the complete lifecycle
of the project, independent verification takes place to confirm that the Safety Critical
Elements are suitable for their intended use and are able to perform their function as
required. Compliance to design performance standards is a key part of this verification.
The TIV plan must be part of the key assurance events in the PCAP.
1.1.12 Process Safeguarding Report
The process safeguarding system should prevent excursions of the process outside the
equipment design envelope and reduce the fire and explosion escalation risks. A
process safeguarding system is required to reduce the risks of a malfunction of plant
equipment to ALARP, in terms of hazards to personnel, environment and economic
loss.
1.1.13 Operations Readiness & Assurance Plan
The Operations Readiness & Assurance (OR&A) plan is established to ensure that
operational aspects related to personnel, procedures and technical systems will be
developed and ready in time for hand over and startup. The OR&A Plan describes how
and when these activities will be carried out and is an integral part of the project
schedule.
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5.4 Define
The objective of ORP Phase 4, Define (or Concept Definition) is to translate the project
concept into a structured plan, with associated costs. This project plan must contain
sufficient level of detail including a comprehensive Design HSE Case to enable the
Decision Executive to decide whether to proceed or not. The Define phase ends with
the Final Investment Decision (FID) which is, traditionally, seen as the point of no
return for the project.
The deliverables from Define also form the basis of handover to the execution
contractors. The main deliverables of Define are the Basis for Design (BfD), the
Project Specification and the Design HSE Case. Together they are commonly referred
to as Front End Engineering Design (FEED).
There are many Define phase deliverables that are necessary to meet AI-PS
objectives, including critical drawings (e.g. PSFS, PFS and UFS, PEFS and UEFS,
HACs, F&G location, F&G C&E, C&E) and critical studies (e.g. relief, flare and vent
study, facilities layout, pipe stress analysis, materials selection report, etc.).
The following selected DCAF deliverables have a with key role in delivering AI-PS in
the Define phase:
Deliverable ATA RTA(s)
Risk Register* Project engineering HSE (technical safety)
HSE & SD Plan* HSE (technical safety)
PCAP* Project engineering
Facilities Layout Mechanical static Surface production, C&A,
mechanical rotating, HSE
(technical safety)
Operations Philosophy* Surface production Generally all disciplines are
either RTA or C/I
Corrosion Management Materials corrosion & Production technology,
Strategy / Materials inspection process engineering,
Selection Report pipelines
HSE Philosophy* HSE (technical safety) Surface production, project
engineering
Technical Integrity Project engineering Maintenance & integrity,
Verification Plan* HSE (technical safety)
OR&A Plan* Surface production
Basis for Design Field development Generally all disciplines are
either RTA or C/I
Process Safeguarding Process engineering C&A, mechanical rotating
Memorandum
Functional Specifications Process engineering C&A, mechanical rotating
and Process Data Sheets
for Equipment
Coarse HAZOP Report HSE (technical safety) Process engineering,
project engineering
Coarse SIL Assessment C&A Process engineering, HSE
(technical safety)
Design HSE Case Project engineering HSE (technical safety)
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5.5 Execute
The Execute phase delivers the asset to the asset owner, ready for startup. The phase
can last several years and includes numerous areas of very diverse expertise. All the
areas of expertise will have to be integrated and managed to deliver a demonstrably
safe asset.
Execute activities are primarily carried out by contractors. The challenge to PDO is to
select the right method of management, contracting strategy, QA/QC and supervision
of those contracts and contractors to ensure the end product is as per the customers
requirements. Vendor and supplier activity supervision is equally critical. The customer
will verify before handover that the asset is safe using the Statement of Fitness review
and the Pre Start Up Audit.
There are many Execute phase deliverables that are necessary to meet AI-PS
objectives, including critical drawings throughout execution (e.g. PSFS, PFS and UFS,
PEFS and UEFS, HACs, F&G location, F&G C&E, C&E) and critical studies (e.g. relief,
flare and vent study, facilities layout, pipe stress analysis, materials selection, etc.).
DCAF deliverables with key AI-PS content for the Execute phase are;
Deliverable ATA RTA(s)
Risk Register* Project engineering
HSE & SD Plan* HSE Project engineering
PCAP* Project engineering
Operations Philosophy* Surface production Maintenance & integrity
Corrosion Management Material corrosion & Maintenance & integrity
System inspection
HSE Philosophy* HSE (technical safety) Surface production
Technical Integrity Maintenance & integrity All engineering disciplines
Verification Plan*
OR&A Plan* Surface production Electrical
Process Safeguarding Process engineering C&A, mechanical rotating
Memorandum*
Detailed HAZOP Report HSE (technical safety) Process engineering,
project engineering
SIL Assessment C&A Process engineering,
mechanical static
Design HSE Case* Project engineering HSE (technical safety)
PTW System Surface production
Performance Standards for Project engineering All engineering disciplines
SCEs (Operate phase)
Operating Procedures Surface production Maintenance & integrity,
(Plant Operating Manual) process engineering
Commissioned Facilities Project engineering Surface production,
Engineering and Vendor mechanical static,
Data mechanical rotating,
pipelines
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Actions to take if or when certain situations arise that could compromise safe
operating limits. These situations are identified from:
o The Threats and Escalation Factors identified as part of the Bow-Tie
assessments for the RAM 5 Hazards
o An assessment of other operations and activities that could contribute to
the escalation of an incident (e.g. continuing with hot work when fire pumps
are unavailable).
Statement of Fitness
The Statement of Fitness is an integral part of the Operations HSE Case and by
signing the Statement of Fitness the new asset owner agrees that:
Process safety risks have been identified and documented in the HSE Cases
and are managed to ALARP;
Employees or contractors executing HSE Critical Activities identified in the
Operations HSE Case are competent and fit to work;
Safety Critical Equipment (SCE) meets its Design Performance Standards;
Design and construction of the facility meet the design and engineering
requirements, i.e. as a minimum compliance with the SHALL [PS]
requirements in PDO specifications and Shell DEPs; the Process Safety Basic
Requirements are met; and AI-PS project actions are closed or have risk-
assessed plans for closure;
As-built drawings, documentation and data pertinent to maintaining AI-PS are
provided.
Procedures are in place to operate SCE within its Operational Limits.
The Statement of Fitness should be signed prior to the Pre-Startup Audit (PSUA),
which is the last official technical review of the suitability of a facility to accept
hydrocarbons.
1.1.32 Critical Documents and Drawings
The critical drawings available at project handover will be the "'Red Lined"" marked up
drawings, not the normal As Built drawings, as producing As Built drawings and
uploading them into Livelink can take several months after commissioning. Typical
critical drawings are Hazardous area plot drawings, PEFS's and Cause and Effect
drawings. An example of a critical document is the Equipment Vendor Operations and
Maintenance manual.
1.1.33 Commissioning and Start-Up (CSU) Plan
A detailed CSU execution plan and related CSU deliverables are developed for each
hardware delivery group to support the execution of CSU requirements during the
Execute and Startup phase. The Level 4 (including resources) CSU execution plans
are aligned with construction plans to create an integrated Mechanical Completion/
CSU plan (Completions Milestones) that includes all hold/ witness points, including
certifying/ verification authorities to verify Technical Integrity of the procured and built
equipment.
Startup procedures, inclusive of coarse Startup on paper exercises are critical due to
the number of historical process safety incidents during facility or equipment startup.
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Inhibit Management
An Inhibit Management System should be in place at handover to manage the new
facility operation. This should be controlled and documented via operating procedures
in POM's and also by MoC when inhibits or overrides are in place for extended periods.
Approval levels should be stated and personnel responsible informed.
Key Registers
Key Registers must be in place, auditable and up to date. Typical Key Registers are
competence, inhibits, temporary repairs, deviations, etc.
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Operations Handovers
A robust and structured handover process between key Process Safety critical positions
must be in place for both daily and shift (tour) handovers. LINK
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8. Operate Product Surface Flow Assets CP-115 - This Code of Practice defines
the Strategies and Controls that need to be implemented in PDO for the
effective Operation of Surface Product Flow Assets. It makes reference to
Shell Standards and Processes when they are applicable and where there is no
equivalent available within PDO
9. Specification for HSE Cases SP-2062 This Specification establishes the
minimum requirements for the content of Preliminary Design, Design and
Operations HSE Cases. The Specification contains information on the
contents of each type of HSE Case and gives guidance and examples of
information to be contained in specific sections.
10. Commissioning and Start-Up PR-1159 - The purpose of this procedure is
enable Projects, Contractors and Operations personnel to adopt a uniform
approach to the preparation, organisation and execution of commissioning and
Startup activities on their projects. This will assist in achieving consistency of
approach to definition, division of responsibilities and execution across all
projects.
It references the relevant Operational Readiness and Assurance (OR&A)
processes and comprises a collection of best practice processes, procedures
and guidelines, the application of which will assist project teams in realising the
value of the opportunity.
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Appendix 2 Abbreviations
AI-PS Asset Integrity - Process Safety
ALARP As Low As Reasonably Practicable
BfD Basis for Design
BOM Bills of material for selected equipment
DCAF Discipline Control and Assurance Framework
DE
DEP Design Engineering Procedure
DRB Decision Review Board
ESP Ensure Safe Production
ESP Ensure Safe Production
E-SPIR Spare parts interchangeability record
FEED Front End Engineering and Design
FERM Fire Explosion and Risk Management
FSR Facility Status Report
HAZID Hazard Identification
HEMP Hazard and Effects Management Process
MAE
MoC Management of Change
MOPO Matrix of Permitted Operations
OR&A Operations Readiness & Assurance
ORM
ORP Opportunity Realization Process
PCAP Project Controls and Assurance Plan
PEFS Process Engineering Flow Schematic
POM Plant Operating Manual
PTW Permit to Work
QA Quality Assurance
QC Quality Control
RAM Risk Assurance Matrix
RBI Risk Based Inspection
SCE Safety Critical Element
SIL Safety Integrity Level
SoF Statement of Fitness
SP Specification
TIV Technical Integrity Verification
VAR Value Assurance Review
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