Adapting and Applying Process Safety Management (PSM) Concept in Fuel/NGV Retail Stations Ms Sulo Belawan CCPS Asia Pacific Regional TSC Meeting, Singapore 2 nd Oct 2018 2018 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, Petroliam Nasional Berhad (PETRONAS) photocopying, 2018 recording or otherwise) without the permission of the copyright owner. 1
International PSM Regulations and Standards does not cover retail business 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 Petroliam Nasional Berhad (PETRONAS) 2018 2
However, history has proven that process safety risk is inherent in storage and retail facilities dealing with hydrocarbon and chemicals 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) Petroliam Nasional Berhad (PETRONAS) 2018 3
PETRONAS is also exposed to process safety risk in its Retail business Explosion at retail station Petroliam Nasional Berhad (PETRONAS) 2018 4
Enforcing Process Safety Management in retail stations is PETRONAS commitment to manage our Process Safety Risk across the supply chain 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 Petroliam Nasional Berhad (PETRONAS) 2018 5
Our challenges and journey in implementing PSM in retail business 2018 2019 & beyond 2017 2016 Conduct PHA Process Safety for NGV Develop business case Identify relevant process safety aspects Petroliam Nasional Berhad (PETRONAS) 2018 6
Audit and investigation findings provided input in developing a business case for Process Safety enforcement in our retail operations and activities 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 Petroliam Nasional Berhad (PETRONAS) 2018 7
Main Switch Board Applicable Process Safety Aspects at an NGV Station PROCESS SAFETY INFORMATION - Pressure Relief Valve (PRV) Datasheet - PRV setting MECHANICAL INTEGRITY - Inspection of PRV Electrical Room Control Room PLC Panel Enclosure Ventilation inlet Recovery tank PRV Set @ 400 psig Gas detector 3-stage compression Inlet : 200 psig Outlet : 3600 psig Start/ESD panel Local gauges Gas supply from GMB @ 260 psig Main Valve Metering MECHANICAL INTEGRITY - Gas detector testing and calibration Temporary storage tank @ 3600 psig Isolation Valve Priority panel Gas detector PROCESS SAFETY INFORMATION - P&ID Drawings - Equipment data sheet Compressor Bay Fencing Entrance gate Regulator Set @ 200 psig Compressor Bay Fencing Petroliam Nasional Berhad (PETRONAS) 2018 8
Applicable Process Safety Aspects at a Retail Fuel Station OPERATING PROCEDURE - Loading and unloading activities MECHANICAL INTEGRITY - Inspection of underground tank MECHANICAL INTEGRITY - Inspection of fittings and connection - Inspection of hose conditions Process Safety Information - P&ID Drawings - Isometric drawings - Safety Data Sheet (SDS) Public drain Petroliam Nasional Berhad (PETRONAS) 2018 9
Our challenges and journey in implementing PSM in retail business 2018 2019 & beyond 2017 IPFs revalidation Retail Design Manual Development of OP Process Safety Fundamentals Training Asset Integrity Management System 2016 Conduct PHA Process Safety for NGV Develop business case Identify relevant process safety aspects Leading KPIs Petroliam Nasional Berhad (PETRONAS) 2018 10 Internal
Process Safety Fundamentals Training Develop retail business specific process safety training pack Conduct knowledge level workshop for retail business on the fundamentals of process safety Petroliam Nasional Berhad (PETRONAS) 2018 11
Our challenges and journey in implementing PSM in retail business 2017 Identify relevant process safety aspects 2018 IPFs revalidation Retail Design Manual 2019 & beyond Technical safety in retail Group PSM framework and initiatives ITPM for retail business Leading KPIs Development of OP Process Safety Fundamentals Training Asset Integrity Management System 2016 Conduct PHA Process Safety for NGV Develop business case Petroliam Nasional Berhad (PETRONAS) 2018 12
Incorporating Inspection, Testing & Preventive Maintenance activities in our retail business Pipe Misalignment Product pipe material deterioration Worn-out Gasket Cracked Sump Tank Petroliam Nasional Berhad (PETRONAS) 2018 13
Our challenges and journey in implementing PSM in retail business 2017 Identify relevant process safety aspects 2018 IPFs revalidation Retail Design Manual 2019 & beyond Technical safety in retail Group PSM framework and initiatives ITPM for retail business Leading KPIs Development of OP Process Safety Fundamentals Training 2016 Conduct PHA Process Safety for NGV Develop business case Asset Integrity Management System Sustaining PSM in retail rnal Petroliam Nasional Berhad (PETRONAS) 2018 14
Creating a sustainable effort in managing process safety risk in retail business 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 Petroliam Nasional Berhad (PETRONAS) 2018 15
Thank you Petroliam Nasional Berhad (PETRONAS) 2018 16