PROCESS SAFETY BARRIER MANAGEMENT

Nageswara Rao
HSSE Manager
Shell Technology Center Bangalore

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WHAT IS A BARRIER?
Ba rriers a re mea sures tha t reduce the proba bility
of relea sing a ha za rd, a nd reducing the
consequence of a relea sed ha za rd
Ba rriers ca n be ha rdwa re, huma n intervention,
or a combina tion
Two types of Barriers
Control BarriersReduce likelihood (pro-a ctive/ preventa tive) e.g.

High Pressure
a la rm/ opera tor response; Automa tic high pressure interlock; Pressure relief va lve

Recovery BarriersMitiga te consequences (re-a ctive), e.g.

Ga s detection a la rm
/ opera tor response; a utoma tic sprinkler system, emergency response
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Bo w -Tie a p p r o a ch to m a n a g e sa f ety

Bow tie : It is a gra phica l representa tion of threa ts & potentia l consequences
rela ting to a ha za rd, a nd the ba rriers.
Step 5
Step 5
Step 1

H
A
Z
A
R
D

Recovery
Measures

Step 4

Controls
Threat
1
Threat
2

Step 3

Step 2

Consequence
1

Top
Event

Consequence
2
Consequence
3

Threat
3
HSSE Critical Activities
List of HSSE Critical Equipment
HSSE Critical Processes

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Step 6

Confidential

EXAMPLE - LION AT THE ZOO

Hazard

Lion

Control
Barriers

Threat

Top
Event

Human
Error;

Materials
of Const.;

Loss of
Control;

Improper
cage
design etc.

Zoo
Keeper
Rounds
etc.

Lion gets
out

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Recovery
Measures

Zoo
Emergency
Response
Plan

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Consequences

Injuries,
Fatalities

EXAMPLE - VEHICLE ACCIDENT

Sta te Inspection
Driver inspections
Preventive Ma intena nce

Loss of
Control

Sta te Inspection
Driver inspections
Preventive Ma intena nce
Corrective Ma intena nce

Vehicle not
a dequa tely
ma inta ined
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Instrument/ wiring
fa ilure

Sa fety
Equipment
(a irba g, ABS,
sea tbelts)

Instruments/
wa rning
Devices

Vehicle
Mecha nica l
Fa ilure

Design

HAZARD- Road Transportation

Threats- driver impa irment/ distra ction, tire fa ilure, mecha nica l
fa ilure, wrong vehicle, etc.

Rules a nd Regula tions

Sta te Inspection
Ma nufa cturers Requirements
Tra ining

Not a va ila ble or

not used

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Collision/
Injury

PROCESS EXAMPLE - BARRIER BASICS

Exa mples of Control a nd Recovery Ba rriers
Ca n you think of other potentia l Ba rriers?

Design

H2S

Over pressure

Inspection

PSV

Sensor
Ala rms
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Injury

LOPC
(Leak)

Emergency
Response

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BARRIERS DEPENDENT AND INDEPENDENT

Control

Control

Control

Pressure Relief Valve

High Pressure
Alarm

Threat

Overpressure

This is an
Independent and Valid barrier

Recovery
Measure
Loss of
Control

Gas Detection

Recovery
Measure

Operator
Response

Operator
Response

These two barriers together make one

Independent and Valid barrier

Recovery
Measure

Recovery
Measure

Deluge System

Emergency
Response

Consequence

Rupture causing
Fire,
explosion/
fatalities

These three barriers together make one independent

valid barrier

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Loss of
Control

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BARRIER VALIDITY CRITERIA

Effective

Strong Enough/ Fa st Enough a nd Big enough

Active ba rriers ha ve to ha ve a sensor, Logic a nd Actua tor

Independent

Not dependent on a ny other ba rrier

Not ha ving a common sensor or logic in common with a nother ba rrier
Not rela ted to the threa t

Audita ble

Being ma inta ined / inspected (CA a nd responsible pa rty) to gua ra ntee the PFD
ta ken into a ccount
Ha ve a PFD <= 0.1 (ba rrier counting)

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PERSONAL SAFETY VS PROCESS SAFETY

The Lion Personal Safety

Hunts in groups
Is often visible (a udible etc )
Commonly seen in its own environment
Is a killer
Ca n never be fully ta med
Ca n never be left ungua rded
Needs consta nt vigila nce

The Tiger Process Safety

Hunts alone
Is secretive a nd ha rd to detect
Not commonly seen
Is a killer
Ca n never be fully ta med
Ca n never be left ungua rded
Needs
consta nt vigila nce
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RAISING PROCESS SAFETY EMPHASIS AND PERFORMANCE

Goal Zero

Personal Safety
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Process Safety
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PERFORMANCE STEP CHANGE NEEDED

Goal Zero

Personal Safety

Process Safety

Everyone on the Pitch

Increased Focus and Urgency

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Leadership Action - Be mindful of HSSE risks

Demonstrate wariness/ chronic unease
Know the main hazards in an operation
if you don't - ask
Engage with those doing the work
what could go wrong, and what controls
are in place to prevent it?
Welcome bad news what do you not
want to tell me - a nd rea ct a ppropria tely
Watch traffic light reporting challenge

the greens and support the reds

Let us get Barrier thinking to be

part of the way we do our work
everyday to ensure we prevent
major process safety incidents in
our business.

Yes
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Tha nk you for Active listening!

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June 2013

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