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Health and Safety Executive
KP4 website: www.hse.gov.uk/offshore/ageing.htm
HSE’s Ageing and Life Extension Key
Programme (KP4) and Human Factors
Peter Fearnley, Energy Division - Offshore
……..Covering…….
• Why?
• Ageing and Life Extension
• Equipment, Systems and People
• What can I do, what can I ask
Why?
• UKCS operates a Safety Case Regime
• The Safety Case describes measures in place reducing major accident risks to people to the lowest reasonable level
• *There are proper arrangements in place for an independent audit of the systems (?)*
• The systems are complex and need all our attention to remain effective
People
FitnessCompetenceMorale/TrustPerceptionBehaviour
Why?
Facilities & Equipment
DesignWork Environment
MaintenanceReliabilityDemand
To be safe all 3 have to work well, together
Systems
Hazard identificationRisk assessment
Management CommitmentProcedures, TrainingIncident investigation
MonitoringChangeLearning
Why?
Facilities & Equipment
• Design• Work Environment• Maintenance• Reliability• Demand
Systems
Hazard identificationRisk assessment
Management CommitmentProcedures, TrainingIncident investigation
MonitoringChangeLearning
People
FitnessCompetenceMorale/TrustPerceptionBehaviour
History of Development
Ageing and Life Extension
WHAT ARE AGEING & LIFE EXTENSION?
AGEING“Ageing is not about how old your
equipment is; it’s about what you know about its condition, and how that’s changing over time”
Condition Management is the key
LIFE EXTENSION• When assets exceed design life = Life
Extension phase• Half UKCS production platforms in LE
phase• Some platforms anticipate 50-70 years
production • Plus 5-10 years to removal from sea
bed
Across the European Union’s hazardous industries ageing is implicated in:
30% of incidents
28% of loss of containment
What Is ALE?It’s All About Managing Ageing
Forth Rail Bridge
• Opened 4th March 1890 (~123 years old)• Robust structure• 200 trains per day• Continuous painting programme
What Is ALE?It’s All About Managing Ageing
Forth Road Bridge
• Opened 4th September 1964 (~48 years old)• Highly engineered structure• 32 000 vehicles per day• IM programme didn’t identify cable corrosion risk• 2003: numerous wire strands in suspension cables found to be corroded and failed• Weight restrictions applied• Needs replacing ~£1.4 Billion
• Raising awareness of consequences of ALE
• Understanding & forecasting degradation mechanisms & rates of Safety Critical Elements
• Obsolescence management
• Sharing ALE knowledge for the benefit of all
• Working with industry for a common goal
• Reducing Hydrocarbon Releases
*MAINTAINING AND IMPROVING SAFETY*
WHAT IS KP4?
WHAT HAS KP4 COVERED?
• Process Safety, Fire and Explosion
• Structures
• Marine
• Mechanical and Corrosion
• Electrical, Control and Instrumentation
• Pipelines
• Human and Organisational Factors
HYDROCARBON LEAKS:EQUIPMENT, SYSTEMS, PEOPLE
Norwegian study found:
• 60% of leaks due to human interventions;– key issues:
• failure to check pre and post-work isolations and integrity;
• Technical degradation caused ~21% of HC leaks
• No relationship between age and leak frequency – condition management!
• 100% management system failure?
Equipment, Systems, People
EQUIPMENT, PEOPLE AND SYSTEM ISSUES
• When equipment doesn’t work as designed (ALE), carry out risk assessment
• Risk Perception & Assessment
– HSE still finding problems with Operational Risk Assessments (ORA) – risk assessment can be too difficult
– Failures identifying and addressing MAH risks, see ORA guidance rolled out by OGUK
– Clear procedures guiding correct thought process, e.g. ORA default should be shut-down unless there are good reasons to continue operations
WORKFORCE INVOLVEMENT IN ALE
• Need to equip people at all levels of the organisation with the right skills to recognise and respond to risk– Hazard awareness, assessment & anticipation
• Need to understand and actively manage the factors that influence human performance, e.g. operating wrong valve, not following a procedure– Distractions, badly written procedures, poor
communication, lack of feedback
• Need to develop a culture where ‘speaking up about concerns’ is managed appropriately– acceptable for ‘bad news’ to travel up the line
What Can I Do, What Can I Ask?
• Getting ALE and People (HF) issues right requires a focus – where is it in your organisation?
• Does your organisation have an ALE policy?
• How well are they doing?
• What are they planning to improve?
• Are you clear what your part is in this?
What Can I Do, What Can I Ask?
• Does your organisation have a clear approach to dealing with people issues/human factors?
• Do you see it worked out in incident and near-miss investigations?
• Are the reasons for mistakes understood and does this make a difference to the way jobs/tasks are planned and carried out?
• Are audits, monitoring and other learning seen as vital to stopping incidents before they happen?