UbSafe Consulting

Capability Statement
Process Safety and Risk Management

https://www.ubsafe.in Jan 2019

Our Vision !
UbSafe Vision
You be Safe,
Help others to be safe !

Mission
Cultivate mutual support and share global learnings
to ensure that every manmade process remain safe
for all of us, Today and Tomorrow.

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Our Capabilities !
Process Safety & Risk Management (PSRM)
• Formal Safety Assessments (HAZID, HAZOP)
• Functional Safety Analysis (SIL, LOPA)
• Risk Based Process Safety (RBPS), Process Safety
Management (PSM) Program Development
• Process Safety Auditing / Gap Assessments
• Safety Culture Diagnostic and Improvement Measures
• Failure Modes, Effects and Criticality Analysis (FMECA)
• Emergency Response Assessments and Planning (ERP)
• HSE Management (Bow-tie Analyses, Safety Critical
Elements Identification and Performance Standards)
• Warehouse & Depot handling Safety Assessment
• Technical and Safety Training

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Hazard Identification (HAZID) Study !

 Identify facility risk profiles

 Provide essential input to project development decisions safer and more
cost-effective design options

1 • Identify material hazards (types of hazards)

2 • Evolve a set of guidewords

3 • Define areas/zones

• Apply guideword to each area and identify the hazard, its possible cause and effect
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5 • Review the provision of current safeguards and their adequacy

6 • Record observations in a structured format

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HAZOP study- the Overall Process !
 Identify all hazard and operability issues, focusing on process deviation

• Parameter + Guide Word = Deviation

• Causes and Consequences of each deviation

• Review Safeguards provided in the design

• Provided recommendations, if required

Deviations Guide Word Parameter

No/Less Flow No/Less Flow
More Flow More Flow
Reverse/Misdirected Flow Reverse Flow

High Pressure High Pressure

Low Pressure Low Pressure
High Temperature More/High Temperature
Low Temperature Low Temperature
High Level High Level
Low Level Low Level
Composition Change/ As well as Composition
Contamination
Start-up/ Shutdown
Maintenance
Utility Failure
Others (e.g. Tube rupture) Other than

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Safety Integrity Level (SIL) Classification !
 Specify required risk reduction, or difference between existing and tolerable
risk levels – in terms of SIL
 Tasks
 Compare process risk against tolerable risk
 Use decision guidelines to select required risk reduction
 Document selection process

No

SIF Design of other

Required? risk reduction
facilities

Tolerable Risk Yes

Guidelines

Select RRF, Target

SIL for each SIF RRF Target SILs

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Methods of SIL Classification !
Set out in IEC 61511 Part 3 – Guidance for the Determination of the
required Safety Integrity Levels
• Qualitative Method
 Risk Graphs/Matrices to determine SIL required

• Semi-Qualitative Method
 Calibrated Risk Graphs/Matrices to determine SIL required,
Consequence and Likelihood well defined Risk Matrix

• Semi-Quantitative Method
 Determine unwanted event frequencies through methods such as Event Tree Analysis to determine
SIL required

• Layer of Protection Analysis (LOPA)

 Assess total amount of quantitative risk
reduction present by analysing current layers
of protection and determining, if further risk
reduction required (SIL of SIF)

Risk Graph

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LOPA Hierarchy !
 LOPA – Layers of Protection Analysis
Community Emergency Response
Emergency Broadcasting

Plant Emergency Response

Evacuation Procedures

Mitigation
Mechanical Mitigation Systems
Safety Instrumented Control Systems
Safety Instrumented Mitigation System
Operator Supervision

Prevention
Mechanical Protection System
Process Alarm with operator corrective action
Safety Instrumented Control System
Safety Instrumented Prevention System

Control and Monitoring

Basic Control System
Monitoring Systems (process alarms)
Operator Supervision

Process

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Safety Integrity Level (SIL) Verification !
 Review PFD for each classified SIF and ensure that it meets the SIL requirement as
per IEC61511. If not, provide appropriate recommendations
 Tasks
 Calculate SIL requirement with manufacturer data and failure rate database
 Provide appropriate recommendation, if necessary

Safety SIF Conceptual PFDavg, RRF,

Requirement Design MTTFS, SIL
Specs Reliability Calc. achieved

Manufacturer Safety Manual

Failure Rate Database

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Risk Based Process Safety Management (PSM) !

Effective
Process Safety Management
Review, Learn, and
Understand Hazards/ Manage the Risks Continuously
Evaluate Risks
Improve
8) Operational Control and Procedures, 17) Incident
6) Process Knowledge and
Investigation
Documentation 9) Safe Work Permits,
18) Measurement &
7) Hazard Identification & 10) Contractor Management
Metrics
Risk and Impact
11) Maintenance and Inspections
Assessment 19) Audit &
12) Training and Performance Assurance Compliance
13) Management of Change
20) Management
14) Operational Readiness Review
15) Conduct of Operation
16) Readiness for Emergencies

Process Safety Commitment (Leadership & Policy)

1) PS Culture 3) Regulatory Compliance 5) Stakeholder Outreach
2) PS Competency 4) Workforce Involvement

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PSM – Gap Analysis !
 Customized, Effective, World Class Gap Analysis Program

 Team of 2 to 3 professionals onsite at each

“Front End” facility for a period of
approximately one week. “Back-end” facilities
can be considered after “Front-end”
implementation.
 Review existing operations / policies /
procedures with respect to the requirements of
RBPS utilizing a customized electronic protocol .
 Conduct an assessment of the existing culture
and competencies at the facility using a
customized questionnaire covering RBPS
elements and by conducting employee
interviews.
 As optional task – conduct a High Level Risk
Assessment (Screening PHA, Bowtie, etc.) to
identify process hazards, areas for additional
control or mitigation, and/or more detailed
HAZOP study. Our Score

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PSM – Implementation Program !
•Leadership Development •Global RBPS Standard and
•Train the Trainer Guidelines
•eLearning Modules •Operating Procedures
•Refresher Trainings •MOC/Operational Readiness
•Behavioral Diagnostics •Contractor Management
•Emergency Response

People Procedures

Operations Technology
•Complex Chemistry
Determinations
•MOC Process •Process Safety Information and
•Operational readiness Design Review
reviews •Relief System Design
•MI Inspection/Testing •Ventilation System Design
Strategy

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Failure Modes, Effects and Criticality Analysis !
 To identify and analyze
 all potential failure modes of various parts of a system
 the effects these failures may have on system
 how to avoid failures, and/or mitigate effects of the failures on system

The methodology for a FMECA study

1 • Define System to be Analysed

2 • Construct Functional Diagrams

3 • Identify Failure Modes

4 • Perform Failure Effects/Cause Analysis

5 • Identify Methods for Failure Detection

6 • Identify Compensating Provisions

7 • Assign Severity Ranking

8 • FMECA Workshop

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Overall HSE Management !
 Continuity management

 Safety case development

 Project risk management

 Corporate Safety Management

Bowtie Analysis

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Warehouse & Depot Safety Assessment !
• Hazard categorization: Categorize the Process safety & Occupational safety hazards at
facility;
• Operational concerns: Notify activities that may intrude safety of people and environment;
• Risk Assessment: Assess the risks associated with the key Hazards & Operations;
• Safeguard Evaluation: Understand and Evaluate current risk control measures;
Warehouse • Gap Identification: Pinpoint gaps in control measures w.r.t. national / international
standards and the best practices;
Safety Assessment : • Recommendations: Advise suitable risk control / mitigation measures for improvement;
Objectives and Tasks • Reporting: Issue the report on findings and recommendation to management for follow-up.

• Key points…. • Regular checks? • Emergency Control & Handling?

► Are you aware of hazards in your facility? ∮ Loading dock safety?  Spill Management
► Do you have latest Safety Data Sheets (SDS) ∮ Stable pallet loads?  First-aid supplies
of the material? ∮ Safe stacking?  Emergency Response Plan
► How safe you are in handling the material & ∮ Handling drums, cans safely?  Evacuation routes
equipment?
∮ Slips, trips, and falls?  Fire extinguishers
► What are your controls on potential ignition
sources? ∮ Housekeeping?  Alarms and communication
► How do you rate your housekeeping? ∮ PPE availability & use?  Sprinklers, Fire fighting
► What type of PPE’s you use? ∮ Ignition control?  Hazardous waste control
► How you manage and contain the Spill? ∮ Electrical panels?  Co-industry Support
► Do you measure & monitor safety indices? ∮ Emergency equipment?  Regulatory backing

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Safety Transformation Programs !
WHY ITS NEEDED ???
A selection of replies of some of the site Assessments;
• That’s the way things are in here !
• I have no idea what this document for !
• I can’t understand this, its not in my language !
• Some points every day I see but I’m not able to recognize !
• I cannot reach the valve without standing on the pipe !
• This is not actually required… (in relation to ineffective control) !
• That’s already happened here before !
• So many years here that my eyes don’t see it !
• This is as per the procedure !
• This is safer than the original (in relation to a modification) !
• Maybe as best practice we can consider !
• We cannot trust 100% (in relation to interlocks) !
• At the top we know but lower levels are not fully there yet !

….. to Verify the Safety between our “Knowing & Doing”

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Our Process Safety Competency *****
 K. Shashikant, an International Expert in  K. Sham, an International Expert in
Functional safety, Process Safety and Risk process safety, project management
management; serving the process and operations serving the process
industry over two decades industry over two decades
 For many international clients across  For many international clients across
South East Asia and the Middle East, he South East Asia and the Middle East,
has; he has;
 chaired numerous interactive workshops  involved in Operations and Project
for HAZOP, SIL, Alarm rationalization management support;
and Bow-tie assessment;  conducted PSM Audits as well
 conducted PSM Audits as well provided provided Implementation support;
Implementation support;  Lead many optimization and overall
 provided in-depth Training on functional safety improvement studies;
safety & Risk Management.  provided Training on process safety
 He is; & project Management
 B.Tech in Chemical Engineering,  He is;
 Functional safety Professional (FSp) by  B.Tech in Chemical Engineering,
TUV SUD, and  MBA
 Certified Functional Safety EXPERT (CFSE)  PMP
by Exida CFSE Board.

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 UbSafe Consulting
PROCESS SAFETY SOLUTIONS
Read more at our website; https://www.ubsafe.in
Contact

K. Shashikant Sham Kumbhar

B.Tech. CFSp, CFSE B.Tech. MBA, PMP
Lead – Functional Safety Lead – Process Safety
Email Email
ubsafe.skant@outlook.com ubsafe.ksham@outlook.com
Mob / W'sapp Mob / W'sapp
+91 8779383091 +91 8291784737