Question 3-5
Question 3-5
The incident at the BP Texas City Refinery revealed critical failures in various elements of the management
system, as outlined in the Energy Institute framework. The identified deficiencies encompassed a wide
range of factors contributing to the catastrophic event. In technical writing style, here are the extracted
elements of the management system that failed:
1. Leadership Commitment:
Inadequate oversight by the BP Board of Directors, resulting in a lack of effective leadership
commitment to safety culture and major accident prevention programs.
2. Policy and Strategic Objectives:
Failure in articulating and enforcing policies that prioritize process safety over cost-cutting
measures, leading to impaired safety performance.
3. Organizational Structure:
Absence of a member within the BP Board specifically responsible for assessing and verifying the
performance of major accident hazard prevention programs, indicating deficiencies in
organizational structure.
4. Communication Protocols:
Poor communication between supervisors and operators during critical shift turnovers, contributing
to a lack of awareness regarding the hazardous conditions during the startup process.
5. Training and Competence:
Inadequate operator training programs, with reductions in central training department staff and
unavailability of simulators for practicing abnormal situations, such as startups and unit upsets.
6. Fatigue Management:
Extended working hours (12-hour shifts for 29 or more consecutive days) leading to operator
fatigue during critical operational phases.
7. Mechanical Integrity Program:
Deficiencies in the mechanical integrity program resulting in a "run to failure" approach for process
equipment, jeopardizing overall process safety.
8. Reporting Culture:
Lack of a reporting and learning culture, where personnel were not encouraged to report safety
problems, and fear of retaliation hindered the reporting of incidents and near-misses.
9. Safety Metrics Focus:
Emphasis on improving personal safety metrics and worker behaviors rather than addressing
process safety and management safety systems.
10. Timely Response to Safety Issues:
Delayed and insufficient responses to identified safety problems, with surveys, studies, and audits
highlighting deep-seated issues that were addressed inadequately and belatedly.
11. Risk Assessment Methods:
Reliance on a low personal injury rate as a primary safety indicator, failing to provide an accurate
representation of process safety performance.
12. Incident Investigation Procedures:
Ineffectual assessment of changes involving people, policies, or the organization that could impact
process safety, indicating shortcomings in the incident investigation procedures.
13. Equipment Safety Standards:
Failure to replace outdated and unsafe equipment, such as blowdown drums and atmospheric
stacks, despite previous incidents warning about their hazards.
14. Supervisory Oversight:
Lack of supervisory oversight during hazardous startup periods, exemplified by the omission of an
extra board operator during ISOM startups.
15. Cultural Shift towards Safety:
A prevailing "check the box" mentality, where personnel completed paperwork without ensuring
that safety policy and procedural requirements were met, contributing to a superficial adherence to
safety standards.
These identified failures underscore systemic deficiencies in crucial aspects of the management system,
emphasizing the need for comprehensive improvements to ensure effective process safety management.
Improvements to the identified elements in the management system at the BP Texas City Refinery should
involve a comprehensive and integrated approach to enhance safety culture, operational practices, and
organizational structure. Performance indicators are crucial to monitor and measure the effectiveness of
these improvements. Here are suggested improvements and corresponding performance indicators for the
identified elements:
1. Leadership Commitment:
Improvement: Establish a Safety Oversight Committee within the Board of Directors responsible for
regularly assessing and verifying the performance of major accident hazard prevention programs.
Performance Indicator: Regular reports and assessments from the Safety Oversight Committee on safety
culture and major accident prevention initiatives.
2. Policy and Strategic Objectives:
Improvement: Revise policies to prioritize process safety over cost-cutting measures, emphasizing a long-
term commitment to safety.
Performance Indicator: Percentage reduction in safety incidents compared to the previous year,
demonstrating a positive correlation with safety-focused policies.
3. Organizational Structure:
Improvement: Appoint a dedicated executive responsible for major accident hazard prevention within the
BP Board.
Performance Indicator: Successful execution of safety initiatives and a decrease in major accidents under
the oversight of the appointed executive.
4. Communication Protocols:
Improvement: Implement a robust communication protocol during shift turnovers, emphasizing critical
information exchange.
Performance Indicator: Regular audits ensuring adherence to shift turnover communication requirements.
5. Training and Competence:
Improvement: Increase investment in operator training programs, including simulator availability for
practicing abnormal situations.
Performance Indicator: Increase in the percentage of operators completing advanced training modules and
simulations.
6. Fatigue Management:
Improvement: Implement a fatigue management program, including defined rest periods and limitations on
consecutive working days.
Performance Indicator: Reduction in incidents related to operator fatigue during critical operational phases.
7. Mechanical Integrity Program:
Improvement: Strengthen the mechanical integrity program to include proactive maintenance and timely
equipment replacements.
Performance Indicator: Reduction in unplanned downtime due to equipment failure.
8. Reporting Culture:
Improvement: Foster a reporting and learning culture by implementing a confidential reporting system and
protection against retaliation.
Performance Indicator: Increase in the number of reported incidents and near-misses compared to the
previous year.
9. Safety Metrics Focus:
Improvement: Shift focus towards improving process safety metrics and management safety systems.
Performance Indicator: Reduction in process-related incidents and near-misses, with a concurrent increase
in process safety compliance metrics.
10. Timely Response to Safety Issues:
Improvement: Establish a proactive safety improvement task force to promptly address identified safety
problems.
Performance Indicator: Decrease in the time taken to implement corrective actions following safety
assessments.
11. Risk Assessment Methods:
Improvement: Implement a comprehensive risk assessment framework that goes beyond personal injury
rates.
Performance Indicator: Adoption of a more holistic risk assessment methodology and a demonstrated
decrease in major safety incidents.
12. Incident Investigation Procedures:
Improvement: Enhance incident investigation procedures to include assessments of organizational changes
impacting process safety.
Performance Indicator: Successful implementation of recommendations from incident investigations
related to organizational changes.
13. Equipment Safety Standards:
Improvement: Establish a robust equipment replacement program based on safety standards.
Performance Indicator: Regular inspections confirming the replacement of outdated and unsafe equipment
according to safety standards.
14. Supervisory Oversight:
Improvement: Ensure adequate supervisory oversight during hazardous periods, including additional
operators during critical phases.
Performance Indicator: Decrease in incidents during startup periods and increased supervisory presence
during critical operational phases.
15. Cultural Shift towards Safety:
Improvement: Promote a genuine commitment to safety rather than a "check the box" mentality through
training and awareness programs.
Performance Indicator: Increase in employee engagement surveys indicating a positive shift in safety
culture perceptions.
Question 4 – HAZOP on Gas Reception Terminal
Plan for the HAZOP study on the Gas Reception Terminal Stabilization Process:
1. Overpressure: Evaluate potential overpressure scenarios, such as relief valve failure, emergency
shutdown valve failure, and their consequences.
Justification: Overpressure scenarios pose a significant risk to the gas reception terminal. A failure
in relief valves could result in uncontrolled pressure buildup, leading to equipment damage,
potential leaks, and, in extreme cases, catastrophic failure. Evaluating these scenarios is crucial for
maintaining safe operating conditions and preventing equipment overloads.
2. Temperature Deviation: Analyze deviations in temperature indicators, potential overheating
risks, and the impact on equipment integrity.
Justification: Temperature control is vital for the stability of the gas reception terminal process.
Deviations in temperature indicators could indicate potential overheating risks, jeopardizing the
integrity of equipment and causing material degradation. Analyzing temperature deviations helps
ensure that the system operates within safe temperature limits.
3. Flow Control: Investigate issues related to flow control, including failures in control valves and
their impact on the stabilization process.
Justification: Flow control issues, such as failures in control valves, can impact the proper
functioning of the stabilization process. Inadequate control can lead to irregularities in product
separation and distribution, affecting the overall efficiency and safety of the system. Investigating
flow control ensures the reliable and consistent operation of the stabilization unit.
4. Emergency Shutdown: Assess the effectiveness of the emergency shutdown system, potential
failures, and the consequences of delayed or ineffective shutdown.
Justification: The emergency shutdown system is a critical safety measure for rapidly halting
operations in case of emergencies. Assessing its effectiveness and potential failures is essential for
preventing or mitigating incidents that could result in severe consequences. Delays or failures in
the shutdown process may exacerbate the impact of hazardous events.
5. Fire Protection: Scrutinize the fire protection measures, including water deluge and foam injection
systems, to ensure their reliability in case of fire incidents.
Justification: Fire protection measures, such as water deluge and foam injection systems, are
integral for preventing and controlling fires. Scrutinizing these systems ensures their reliability
during fire incidents. Effectiveness in containing and extinguishing fires is vital for minimizing
damage to equipment, protecting personnel, and preventing the escalation of fire-related risks.
6. Human Factors: Consider potential human errors in initiating safety systems, response time during
emergencies, and adherence to operating procedures.
Justification: Human errors can significantly contribute to accidents and incidents. Considering
factors such as the initiation of safety systems, response time during emergencies, and adherence
to operating procedures is crucial. Understanding and mitigating potential human errors enhance
the overall reliability of the gas reception terminal.
7. Environmental Factors: Evaluate the environmental conditions, such as wind direction and
stability, to understand the potential impact of hazardous events on the surroundings.
Justification: Environmental conditions, including wind direction and stability, play a pivotal role
in the dispersion of hazardous substances in case of a release. Evaluating these factors helps
estimate the potential impact on surrounding areas, enabling the implementation of adequate safety
measures and emergency response plans.
8. Reliability of Safety Systems: Assess the reliability of safety-critical systems, including relief
valves, level indicators, pressure indicators, and emergency shutdown valves.
Justification: The reliability of safety-critical systems is paramount for the overall integrity of the
gas reception terminal. Assessing the reliability of relief valves, level indicators, pressure
indicators, and emergency shutdown valves ensures that these systems can be depended upon to
function as intended during critical moments, reducing the likelihood of accidents and enhancing
overall safety.
c) Mark candidate nodes on the Stabilisation Process PFD and submit this with your assignment.
Justify your selection of these nodes in the narrative submission. (7 marks)
1. Slugcatcher (V101): The Slugcatcher is critical as it initiates the separation of gas and liquids.
Overpressure scenarios pose a hazard, especially if the pressure exceeds the design limits, leading
to potential equipment failure. Liquid carryover can result in downstream contamination, affecting
the efficiency of subsequent processes. Failure of level control may lead to inadequate liquid
removal, impacting the overall stability of the gas reception terminal.
2. Stabilizer Column (V102): The Stabilizer Column is a key component in separating Natural Gas
Liquids (NGLs). Temperature control deviations may result in inefficiencies, affecting the
separation process and compromising product quality. Reflux system failures can lead to improper
separation, impacting the composition of the products. Pressure-related incidents, such as
overpressure, pose a risk to the structural integrity of the column and associated equipment.
3. Reboiler (E102): The Reboiler is crucial for maintaining the pressure within the Stabilizer Column.
Overheating hazards can lead to thermal degradation of the condensate, impacting product quality.
Control valve failures may disrupt the heat input, affecting the stabilizing process. Pressure-related
incidents, such as inadequate pressure control, can influence the entire column operation, leading
to potential safety risks.
4. Condenser (E103): The Condenser is vital for condensing column overheads. Cooling system
failures can result in insufficient condensation, affecting product separation and potentially causing
downstream issues. Pressure deviations may impact the column's overall stability and efficiency.
Overpressure scenarios pose risks to the structural integrity of the condenser and associated
components.
5. Pressure Relief Valve (PRV1): The Pressure Relief Valve is essential for relieving excess pressure
and preventing overpressure scenarios. Potential hazards include PRV failure, which may result in
the inability to vent excess pressure, posing risks to the entire stabilization unit. Inadequate relief
capacity can lead to uncontrolled pressure buildup, impacting the integrity of connected equipment
and processes.
6. Reflex Drum (V103): The Reflex Drum plays a crucial role in collecting condensed overheads
from the Stabilizer Column. Hazards may include liquid carryover, affecting downstream
processes. Inadequate reflux flow control can impact the efficiency of the stabilization process,
influencing product quality. Overpressure scenarios may pose risks to the structural integrity of the
drum.
7. Emergency Shutdown Valve (ESDV1): The Emergency Shutdown Valve is critical for rapidly
isolating the Slugcatcher in case of low liquid levels. Failure of this valve may result in inadequate
isolation, allowing potential hazards like liquid carryover to propagate downstream. Proper
functioning of the ESDV1 is essential for preventing unsafe conditions and ensuring a swift
response to abnormal situations.
2. Causes:
a. Equipment Failure:
Storage system components, such as tanks and valves, are susceptible to wear and tear over time.
Regular equipment inspections are essential to identify potential failures before they escalate. A
breakdown in these components could compromise the integrity of the entire system, leading to the
loss of containment.
b. Human Error:
Operational and maintenance activities involve human intervention. Mistakes during these
activities can pose a significant risk to the storage system's integrity. Employee training programs
are crucial to minimizing the risk of human error by ensuring informed decision-making during
critical tasks.
c. External Factors:
Events beyond the facility's control, such as natural disasters (e.g., earthquakes or floods), can
introduce unforeseen challenges. While these events are unpredictable, their potential impact on
the storage system's containment capabilities must be considered and addressed in the facility's
overall risk management strategy.
3. Consequences:
a) Release of Fuel into the Environment:
An unintended spill or leakage of fuel beyond the facility's boundaries can have severe
environmental implications. Implementing spill containment measures is crucial to limit and
control the spread of spilled fuel, minimizing the impact on the surrounding environment.
b) Fire and Explosion:
The potential ignition of released fuel poses a significant threat. Emergency response and
firefighting capabilities are paramount to swiftly control and contain incidents, preventing the
escalation to a fire or explosion.
c) Impact on Human Health and Safety:
Risks to personnel due to exposure to fuel or associated hazards must be addressed through
adequate training and awareness programs. These initiatives ensure that personnel are well-
prepared to respond effectively during emergencies, reducing the potential impact on human health
and safety.
d) Property Damage:
The release of fuel can lead to potential damage to infrastructure within the facility. Safety audits
and risk assessments play a crucial role in identifying and rectifying weaknesses in safety measures,
mitigating the risk of property damage.
e) Environmental Pollution:
Contamination of the surrounding environment due to the release of fuel requires proactive
measures. Environmental monitoring helps detect anomalies promptly, enabling timely responses
to limit environmental pollution.
4. Safety Barriers:
a. Proactive Barriers:
I. Regular Equipment Inspections:
Periodic checks are essential to identify and rectify potential equipment failures before they
escalate. Proactive inspections contribute to early detection, preventing the progression to a
critical failure.
II. Employee Training Programs:
Education initiatives are aimed at empowering personnel to make informed decisions, minimizing
the risk of human error during operational and maintenance activities. Well-trained personnel are
a crucial proactive barrier to prevent incidents.
III. Safety Protocols and Procedures:
Established guidelines ensure consistent and safe operations within the facility. Following
standardized protocols minimizes deviations that could lead to the loss of containment.
IV. Environmental Monitoring:
Continuous tracking of environmental conditions allows for the prompt detection of anomalies.
Proactive monitoring contributes to early intervention, reducing the likelihood of environmental
pollution.
V. Installation of Safety Valves:
Mechanisms to control pressure and prevent overloads are crucial in preventing equipment
failures that could lead to the loss of containment. Safety valves act as a proactive barrier against
critical system failures.
b. Event:
I. Represents the Actual Occurrence of the Top Event:
This component serves as a focal point, acknowledging the actual occurrence of the top event, the
"Loss of Containment." It is a critical aspect that connects causes and consequences in the Bowtie
diagram.
c. Reactive Barriers:
I. Emergency Response and Firefighting Capabilities:
Swift actions are required to control and contain incidents immediately after the loss of
containment. Effective emergency response and firefighting capabilities are reactive barriers that
minimize the impact on human health, safety, and property.
II. Safety Audits and Risk Assessments:
Periodic evaluations are necessary to identify and rectify weaknesses in safety measures. Reactive
safety audits and risk assessments contribute to continuous improvement, reducing the likelihood
of similar incidents in the future.
III. Adequate Training and Awareness Programs:
Ongoing education ensures effective emergency responses by personnel. Reactively, well-trained
personnel contribute to an efficient and coordinated response, mitigating the consequences of the
loss of containment.
IV. Spill Containment Measures:
Strategies to limit and control the spread of spilled fuel are crucial reactive measures. Prompt
implementation of spill containment measures reduces the environmental impact and prevents the
escalation of consequences.
V. Emergency Shutdown Systems:
Mechanisms to rapidly halt operations in emergency situations are essential reactive barriers.
Emergency shutdown systems prevent the continuation of processes that could exacerbate the
situation after the loss of containment.
VI. Fire Detection and Suppression Systems:
Early detection and control of fire incidents are reactive measures to prevent the escalation of
consequences. Fire detection and suppression systems are crucial in limiting the impact of potential
fires.
VII. Community Emergency Plans:
Collaborative plans to safeguard the surrounding community are reactive measures that come into
play in the event of a significant incident. Community emergency plans ensure a coordinated
response to protect residents in the vicinity of the fuel storage facility.
Q5b
Environmental Monitoring:
Before Scenario: A larger workforce may facilitate more effective environmental monitoring, allowing for
prompt detection of anomalies and early intervention.
After Scenario: A reduced staff might result in less frequent or less comprehensive environmental
monitoring, potentially delaying the detection of abnormal conditions.
b. Reactive Barriers:
Emergency Response and Firefighting Capabilities:
Before Scenario: A higher number of staff could contribute to more efficient and coordinated emergency
response and firefighting capabilities.
After Scenario: A reduced staff might result in delays or inefficiencies in responding to incidents,
potentially allowing them to escalate.
Safety Audits and Risk Assessments:
Before Scenario: A larger workforce may facilitate more thorough safety audits and risk assessments,
leading to better identification and rectification of weaknesses.
After Scenario: A reduced staff might result in less frequent or less comprehensive safety audits, potentially
overlooking critical safety vulnerabilities.