Page 1 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess SEMS in a box. SEMS and and
Page 1 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
SEMS in a box.
SEMS
and
and
Page 2 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
SEMS
SEMS stands for: Safety Environmental Management System Applications: “…all oil and gas operations on offshore facilities in all phases of work in new & existing facilities”
Page 3 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Consulting Engineering
Services
Process Safety Management
Chemtech Design & Engineering Process Optimization
PS Change Manager PS Information Manager
PS PPM PS AIM OGM
XHQ Operational Intelligence
Conceptual Engineering Services
Page 4 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Our Customers Oil & Gas E&P‘s, Refiners and LNG
Long-term ongoing trust in oil and gas industry. Exxon/Mobil is just one example of a trusting work relationship and respect begun in 1994. From 1-man office in Exxon we are now 1500+ Conceptual Engineering Services professionals and XOM continues in a global contract with us as Siemens CES-Process Safety Management . Our tradition is that of a long-term trusted partner.
Page 5 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Conceptual Engineering Locations
Houston
Rio de Janeiro
Singapore
Oslo
Abu Dhabi
Regional/Engineering Center Consulting Business Center
Mumbai
OTHER OIL AND GAS LOCATIONS - ERLANGEN, GERMANY - NETHERLANDS
Bucharest
Lima
Page 6 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Our CES Engineering Staff
Chemical 100
Electrical 5
Petroleum 2
Mechanical 24
By Discipline
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Siemens and SEMS in Romania
Siemens Bucharest Director: Peter Grobmueller Process Safety Experts: Dr. Ciprian Tolescu Dr. Sorin Dinu
Page 8 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess 23 dead in USA 28 dead in UK
Process Safety deals with…
…real world events that keep Process Managers awake at night
Page 9 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Our Process Safety Services
What do we offer? • Pressure relief design analysis & training • Mechanical integrity & risk-based inspection program development • Process safety management
How are we different? • Our Patented equipment based process safety methods • Industry leading edge patented software tools • Contract method, no quess work (Lump Sum)
• Ensure regulatory compliance • Improve safety • Improve reliability • Improve profitability
Page 10 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Mar-2011 Aluminum giant Alcoa sues Apache Energy & partners for $158 million
The Veranus 2008 explosion wiped out one-third of Western Australia’s domestic gas supplies, including supply to big industrial users such as Alcoa, causing what the WA Chamber of Commerce estimated was a $2.4 billion hit to the state economy.
14% of business closures in the state occurred in months after the disruption!
Process Safety’s Greater Upside
2008 Apache Energy fined $87,000 for Veranus Gas Plant incident in Western Australia
Process Safety’s is not about Fines! IMPROVED PERFORMANCE is the greater upside So what?
<14%> 1000’s of people lost their jobs & income
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People and Community
Page 12 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Common SEMS Issues
1
2
Hazard analysis recommendations not closed or implemented.
3 MOC and MI program is manual or not used efficiently.
4 Relief systems not verified & documented prior to facility modifications.
P&IDs, H&MB, operating procedures not up-to-date.
Page 13 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Common SEMS Issues
5
6
Inadequate comprehensive & periodic training program.
7 Audit of various programs lack focus and follow-up.
8 Inspections don’t occur at intended frequencies
Lessons learned from incidents or near misses not shared among all groups.
Page 14 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
SEMS - 13 Elements Based on 4 Core Principles
Principle 1: COMMIT TO SAFETY
Principle 2: UNDERSTAND HAZARDS & RISKS
Principle 3: MANAGE RISKS
Principle 4: LEARN FROM EXPERIENCES
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COMMITMENT TO SAFETY
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13 Elements of SEMS That Improve Oil & Gas business performance
13 ELEMENTS OF
SEMS
OPERATING PROCEDURES SAFETY &
ENVIRONMENTAL INFORMATION
GENERAL
RECORDS & DOCUMENTS
HAZARD ANALYSIS
INCIDENT INVESTIGATION
SEMS AUDIT
EMERGENCY RESPONSE
SAFE WORK
PRACTICES
MECHANICAL INTEGRITY
PRE-STARTUP SAFETY
REVIEW MANAGEMENT
OF CHANGE
Operation Exploration Development Transportation
Page 17 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
Understand Your Hazards and Risks
Safety and Environmental Information, SEI
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Hazard Analysis and Job Safety Analysis
Understand Hazards and Risks in your O&G business
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MANAGING RISKS
Management of Change
Operating Procedures
Safe Work Practices
Training
Pre-Start up review
Quality Assurance and Mechanical Integrity of Critical Equipment
Emergency Response and Control
Documentation and Recordkeeping
Page 20 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
SEMS compares closely to OSHA, API & EPA
SEM Elements OSHA 29 CFR API RP 75 EPA 40 CFR
REQUIREMENTS
ARE NOT THE SAME BUT
THEY ARE SIMILAR
Safety and Environmental Information
OSHA 1910.119 (d) PSI API RP 75 (2), 250.1910 68.65
Hazard Analysis & Job Safety Analysis (HA & JSA)
OSHA 1910.119 (e) - PHA API RP 75 (3) 250.1911
68.67
Management of Change (MOC)
OSHA 1910.119 (l) API RP 75 (4) 250.1912
68.75
Operating Procedures (OP) 1910.119 (f) API RP 75 (5) 250.1913 68.69
Safe Work Practices 1910.119 (h, k) API RP 75 (6) 250.1909
68.85 68.87
Training 1910.119 (g) API RP 75 (7) 250.1915 68.71
Assurance of Quality and Mechanical Integrity
OSHA 1910.119 (j) API RP 75 (8) 250.1916
68.73
Pre-startup Safety Review (PSSR)
OSHA 1910.119 (i) API RP 75 (9) 68.77
Emergency Response and Control
OSHA 1910.119 (n) API RP 75 (10) 68.95
Investigations of Incidents OSHA 1910.119 (m) API RP 75 (11) 68.81
Audit of SEM elements OSHA 1910.119 (o) API RP 75 (12) 68.79
Record and Documentation API RP 75 (13)
Page 21 March 2012 Copyright © Siemens AG 2011. All rights reserved. Charles Siess
UNIQUE PROPRIETARY PROCESS SAFETY TOOLS & CAPABILITIES
SEMS – MANAGEMENT OF CHANGE
SEMS – SAFETY AND ENVIRONMENTAL INFORMATION
SEMS – HAZARD ANALYSIS
Process Safety Programs Process
Hazards Analysis
Safety Systems (PRV, ESD F&G, HIPPS)
Process Safety Information
Management of Change
Mechanical Integrity
Oil and Gas Manager (OGM) Change Manager (PSCM) - MOC Pressure Protection Manager (PSPPM) Asset Integrity Manager (PSAIM)
SEMS – Q.A. & MECHANICAL INTEGRITY
Siemens Software
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COMOS, now in oil & gas, amazing!
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XHQ Operational Intelligence
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XHQ Operational Intelligence
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XHQ Operational Intelligence
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XHQ enables SEMS Dashboards Presents lagging & leading indicators
INSPECTION KPI’s OPERATIONAL RISK KPI’s
MOC TREND FOR 2008
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RESULT ”SEMS IN A BOX”