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The business of sustainability
Bowties in process safety auditingMireille Busque - ERM
RAPID SCCU Facilities: Loss of Containment - U3420 MTBE - L and V
01.03 LPGs (e.g. C3/C4 cuts, Raffinate 1, 2 & 3)
Overpressure Protection System and Relief System
Process Containment
PC007 Relief System (PRV, PSV, etc)
Instrument Protective Function, Instrumented Protection System and Emergency Shutdown Systems (ESD)
Shutdown Systems
SD001 Emergency Shutdown (ESD) Control System
Process Monitoring Control System with operator intervention [Control room operator operates the plant according to standard operating procedures using the information from DCS (SOP)]
Emergency Response
ER009 Process Control & Alarms
Process Equipment and Piping Systems Operated within Specified Safe Operating Limits
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
Process Equipment and Piping Systems Designed/ Installed/ Commissioned to Specified Safe Operating Limits [Design Basis]
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
Process Upset (e.g. over-pressure, over temperature)
Instrument Protective Function, Instrumented Protection System and Emergency Shutdown Systems (ESD)
Shutdown Systems
SD001 Emergency Shutdown (ESD) Control System
Process Monitoring Control System with operator intervention [Control room operator operates the plant according to standard operating procedures using the information from DCS (SOP)]
Emergency Response
ER009 Process Control & Alarms
Process Equipment and Piping Systems Operated within Specified Safe Operating Limits
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
Process Equipment and Piping Systems Designed/ Installed/ Commissioned to Specified Safe Operating Limits [Design Basis]
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
Overfilling of Drums
Corrosion Monitoring and RBICorrosion Protection System (N2 blanketing of V-301)
Process Equipment and Piping Systems Operated within Specified Safe Operating Limits (Corrosion Allowance and Material Selection)
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
Process Equipment and Piping Systems Designed/ Installed/ Comissioned to Specified Safe Operating Limits (Corrosion Allowance, Material Selection and vessel linings as directed by licensors)
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
Internal Corrosion
Corrosion Monitoring and RBIInsulating gasket between dissimilar materialsProcess Equipment and Piping Systems Operated within Specified Safe Operating Limits (Coating Integrity)
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
Process Equipment and Piping Systems Designed/ Installed/ Comissioned to Specified Safe Operating Limits (Coating Integrity)
Process Containment
PC001 Pressure Vessels
PC002 Heat Exchangers
PC003 Rotating Equipment
PC005 Hydrocarbon Piping
External Corrosion
Periodic statutory inspection of pressure vessels
All flange are fitted with inner ring, spiral wound gasket
Process Containment
PC005 Hydrocarbon Piping
Flange Management ProgramPreventive maintenance of pumps and replacement of seals based on condition of seals
Process Containment
PC003 Rotating Equipment
Seal Leak Detection and Venting System
Process Containment
PC003 Rotating Equipment
Field operator regularly walking around
Emergency Response
ER009 Process Control & Alarms
Process Equipment and Piping Systems Operated within Specified Safe Operating Limits
All vehicle movements in process areas are subjected to permit to work system or controlled by procedures if routine
Safety distance between roads and process equipment
Main/Plant Roads Integrity as per Specification
Structural Integrity
SI001 Structures
Area Demarcation between Process and non-Process facilities
Perimeter fence to prevent access to site by unauthorized vehicles
Detection Systems
DS002 Security Systems
Impact Damage (Vehicle)
Piping design to allow flexibility during earthquake activities
Process Containment
PC005 Hydrocarbon Piping
Pile and foundation integrity
Structural Integrity
SI001 Structures
Structure design according to BOD and seismic activities specifications
Structural Integrity
SI001 Structures
Earthquake/ subsidence
Storm drains system
Emergency Response
ER010 Bunding and Drains (Hazardous and Non-hazardous)
Plant Design according to BOD and Environmental Loads Specifications
Emergency Response
ER010 Bunding and Drains (Hazardous and Non-hazardous)
Climate Extremes (eg Heavy Rain, Strong Wind)
Lightning protection system including earthing and bonding for buildings and tall structures as per IEC 62305 (e.g.Telecommunication Tower, flare stack, columns)
Integrity of Cranes, Mechanical Handling Equipment and Appliances
Structural Integrity
SI003 Heavy Lift Cranes and Mechanical Handling Equipment
Dedicated Areas with suitable foundation for supporting heavy lifting crane
Lifting Activities are strictly controlled by Permit to Work system
Dropping/ Swinging Objects
Daily visual inspection by field operatorStructures and Foundations Operated within Specified Safe Operating Limits
Structural Integrity
SI001 Structures
Structures and foundations Designed/ Constructed to Specified Safe Operating Limits
Structural Integrity
SI001 Structures
Structural failure for process structures, storage tanks and vessel supports (eg fatigue, corrosion, human error etc)
Entire system is air free using N2 before introducing hydrocarbons
Ignition Control
IC007 Inert Gas
Internal explosion inside vessel during start-up
Steam purge of reactor before opening to atmosphere
Catalyst changing activities
Control of Ignition sources (e.g. Earthing and Bonding Equipment, Vehicle/ Equipment Spark Arrestors, Thermal Insulation for high temperature explosed surfaces)
Operational control of ignition sources (e.g. Hot Work Permit, Vehicle entry restrictions etc)Ignition Control: Lightning protection system for buildings and tall structures (e.g.Telecommunication Tower, flare stack, columns) as per IEC requirement
"Bowtie is one of many barrier risk models available to assist the identification and management of risk and it is this particular model we have found (and are still finding) useful".
“We are improving our riskmanagement process through theobjective centred ‘bow tie’ approach.”
ERM is also using bowties with clients in:■ Food production■ Manufacturing■ Road transport■ Upstream O&G■ Downstream O&G■ Chemicals
The business of sustainability
Bowties provide all information necessary to develop a focussed audit protocol
Techniques typically applied to:■ Large organisations with many sites having similar hazards■ Single sites with a range of hazards■ Sites which are at an early stage of process safety maturity
May have generic bowties for large organisations■ Generic bowties must be made local – what’s different here?
May need to develop bowties where none exist■ Hazard Identification■ Develop bowties for a couple of hazards
Developing bowties in a workshop is the first part of the audit !■ Gaps or deficiencies often become apparent without even looking at the