Adapting and Applying Process Safety Management (PSM ... · • Retail station fires Between 1993 and 2004, there were 243 reported incidents of fires breaking out at petrol stations

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Adapting and Applying Process Safety Management (PSM) Concept in Fuel/NGV Retail Stations

Ms Sulo Belawan

CCPS Asia Pacific Regional TSC Meeting, Singapore

2nd Oct 2018

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• US OSHA PSM 1910.119

(a)(1)(ii)(B) atmospheric storage tank (AST) exemption

(a)(2)(i) retail facilities exemption

• API RP 754 Guide to reporting

1.3 Applicability outside the scope of RP 754- k) retail service station

• UK Chemical Act (Control of Major Accident Hazards Involving Dangerous Substances) Regulation 2015

3. (3) these regulations shall not apply to

(c) the transport of dangerous substances and directly related intermediate temporary storage

(d) the transport of dangerous substances in pipelines, including pumping stations, outside establishments

International PSM Regulations and Standards does not cover retail business

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• Major incident involving storage facilities includes:

2005, Buncefield Oil Storage Depot, UK UK HSE later issued requirement for LOPA

2009, Indian Oil Corporation Depot hammer blind valve at transfer line, 11 fatalities

2015, Tianjin Storage Facility, China - 300 buildings destroyed, 173 fatalities

• Retail station fires

Between 1993 and 2004, there were 243 reported incidents of fires breaking out at petrol stations around the world. - Australian Transport Safety Bureau (ATSB)

However, history has proven that process safety risk is inherent in storage and retail facilities dealing with hydrocarbon and chemicals

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Explosion at retail station

PETRONAS is also exposed to process safety risk in its Retail business


• Safe operation is good for business.

• Maintain brand reputation among our retail stakeholders, customers and other end users

• Keeping up with international standard

In 2015, OSHA issued a letter of interpretation tightening up its definition of

Enforcing Process Safety Management in retail stations is PETRONAS commitment to manage our Process Safety Risk across the supply chain

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2016

2017

2018

2019 & beyond

Identify relevant process safety aspects

Our challenges and journey in implementing PSM in retail business

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Develop business caseConduct PHA Process Safety for NGV


1. Change management is poorly implemented

2. Technical integrity - Inspection, testing and preventive maintenance program is not comprehensive

3. Inadequate/poor quality of risk assessment

4. Operation discipline inadequate OP / noncompliance to OP

5. Safe System of Works - Inconsistent implementation of Permit To Work system, bypass of Safety Critical Protective Devices, energy isolation

6. Technical competency lack/inadequate knowledge and skill to operate/maintain the assets

Audit and investigation findings provided input in developing a business case for Process Safety enforcement in our retail operations and activities

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Gas supply from GMB@ 260 psig

RegulatorSet @ 200 psig

Metering

Temporary storage tank@ 3600 psig

3-stage compressionInlet : 200 psigOutlet : 3600 psig

Recovery tank

PRVSet @ 400 psig

PLC Panel

Electrical Room

Isolation Valve

Main Valve

Local gauges

Enclosure Ventilation inlet

Start/ESD panel

Compressor Bay FencingEntrance gate

Compressor Bay Fencing

Mai

n S

wit

ch

Bo

ard

Control Room

Gas detector

Priority panelGas detector

Applicable Process Safety Aspects at an NGV Station

MECHANICAL INTEGRITY- Inspection of PRV

PROCESS SAFETY INFORMATION- Pressure Relief

Valve (PRV) Datasheet

- PRV setting

PROCESS SAFETY INFORMATION- P&ID Drawings- Equipment data

sheet

MECHANICAL INTEGRITY- Gas detector testing and calibration

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Public drain

MECHANICAL INTEGRITY

- Inspection of underground tank

MECHANICAL INTEGRITY

- Inspection of fittings and connection

- Inspection of hose conditions

OPERATING PROCEDURE- Loading and

unloading activities

Process Safety Information- P&ID Drawings- Isometric drawings- Safety Data Sheet (SDS)

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Applicable Process Safety Aspects at a Retail Fuel Station



2016

2017

2018

2019 & beyond


Internal

Develop business case

Process Safety Fundamentals Training

Retail Design Manual

IPFs revalidation

Development of OP

Leading KPIs

Conduct PHA Process Safety for NGV

Asset Integrity Management System

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• Develop retail business specific process safety training pack

• Conduct knowledge level workshop for retail business on the fundamentals of process safety


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2016

2017

2018

2019 & beyond



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Technical safety in retail

Group PSM framework and initiatives


ITPM for retail business

Retail Design Manual

IPFs revalidation

Development of OP

Leading KPIs

Conduct PHA Process Safety for NGV

Asset Integrity Management System


Incorporating Inspection, Testing & Preventive Maintenance activities in our retail business

Pipe Misalignment

Worn-out Gasket

Product pipe material deterioration

Cracked Sump Tank

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2016

2017

2018

2019 & beyond


Internal


Technical safety in retail

Group PSM framework and initiatives


Sustaining PSM in retail

ITPM for retail business

Retail Design Manual IPFs revalidation

Development of OP

Leading KPIs

Conduct PHA Process Safety for NGVAsset Integrity Management System

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• Specify process safety requirements for retail stations in Group Process Safety Management Framework.

• Include retail business in the Group Process Safety Performance Monitoring and Reporting monitoring.

• Incorporating process safety aspect in retail business auditing scope.

• Reviewing the capability and competency development program

Creating a sustainable effort in managing process safety risk in retail business

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Thank you

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Documents

Adapting and Applying Process Safety Management (PSM ... · • Retail station fires Between 1993 and 2004, there were 243 reported incidents of fires breaking out at petrol stations