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Adapting and Applying Process SafetyManagement (PSM) Concept inFuel/NGV Retail StationsMs Sulo BelawanCCPS Asia Pacific Regional TSC Meeting, Singapore2nd Oct 2018 2018 PETROLIAM NASIONAL BERHAD (PETRONAS)All rights reserved. No part of this document may be reproduced, stored in a retrievalsystem or transmitted in any form or by any means (electronic, mechanical,photocopying,recording or otherwise) without the permission of the copyright owner. Petroliam Nasional Berhad (PETRONAS)2018Open1
International PSM Regulations and Standards does notcover 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) Regulation2015 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, outsideestablishments Petroliam Nasional Berhad (PETRONAS) 2018Open2
However, history has proven that process safety risk isinherent in storage and retail facilities dealing withhydrocarbon 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 stationsaround the world. - Australian Transport Safety Bureau (ATSB) Petroliam Nasional Berhad (PETRONAS) 2018Open3
PETRONAS is also exposed to process safety risk in itsRetail businessExplosion at retail station Petroliam Nasional Berhad (PETRONAS) 2018Open4
Enforcing Process Safety Management in retail stations isPETRONAS commitment to manage our Process SafetyRisk across the supply chain Safe operation is good for business. Maintain brand reputation among our retail stakeholders, customers and otherend users Keeping up with international standard In 2015, OSHA issued a letter of interpretation tightening up its definition of Petroliam Nasional Berhad (PETRONAS) 2018Open5
Our challenges and journey in implementing PSM in retail business2019 &beyond201820172016Conduct PHA Process Safety for NGVDevelop business caseIdentify relevant process safety aspects Petroliam Nasional Berhad (PETRONAS) 2018Open6
Audit and investigation findings provided input indeveloping a business case for Process Safety enforcementin our retail operations and activities1. Change management is poorly implemented2. Technical integrity - Inspection, testing and preventive maintenance program is notcomprehensive3. Inadequate/poor quality of risk assessment4. Operation disciplineinadequate OP / noncompliance to OP5. Safe System of Works - Inconsistent implementation of Permit To Work system, bypass ofSafety Critical Protective Devices, energy isolation6. Technical competencyassetslack/inadequate knowledge and skill to operate/maintain the Petroliam Nasional Berhad (PETRONAS) 2018Open7
Applicable Process Safety Aspects at an NGV StationGas supplyfrom GMB@ 260 psigStart/ESD panelMain ValveMeteringElectrical RoomMain SwitchBoardPROCESS SAFETYINFORMATION- Pressure ReliefValve (PRV)Datasheet- PRV settingMECHANICALINTEGRITY- Gas detectortesting andcalibrationEnclosureVentilation inletRecovery tankControl RoomPRVSet @ 400 psigMECHANICALINTEGRITY- Inspection of PRVTemporary storage tank@ 3600 psigGas detectorLocalgaugesPLC Panel3-stage compressionInlet : 200 psigOutlet : 3600 psigIsolation ValvePROCESS SAFETYINFORMATION- P&ID Drawings- Equipment datasheetPriority panelRegulatorSet @ 200 psigCompressor Bay FencingEntrance gate Petroliam Nasional Berhad (PETRONAS) 2018OpenGas detectorCompressor Bay Fencing8
Applicable Process Safety Aspects at a Retail Fuel StationOPERATINGPROCEDURE- Loading andunloading activitiesMECHANICALINTEGRITY- Inspection offittings andconnection- Inspection of hoseconditionsMECHANICALINTEGRITY- Inspection ofunderground tankProcess SafetyInformation- P&ID Drawings- Isometric drawings- Safety Data Sheet (SDS) Petroliam Nasional Berhad (PETRONAS) 2018OpenPublic drain9
Our challenges and journey in implementing PSM in retail business2019 &beyond20182017IPFs revalidationLeading KPIsRetail Design ManualDevelopment of OPProcess Safety Fundamentals Training Asset Integrity Management System2016Conduct PHA Process Safety for NGVDevelop business caseIdentify relevant process safety aspects Petroliam Nasional Berhad (PETRONAS) 2018Open Internal10
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) 2018Open11
Our challenges and journey in implementing PSM in retail business2019 &beyond2018 Technical safety in retailGroup PSM framework and initiativesITPM for retail business2017IPFs revalidationLeading KPIsRetail Design ManualDevelopment of OPProcess Safety Fundamentals TrainingAsset Integrity Management System2016Conduct PHA Process Safety for NGVDevelop business caseIdentify relevant process safety aspects Petroliam Nasional Berhad (PETRONAS) 2018Open12
Incorporating Inspection, Testing & Preventive Maintenanceactivities in our retail businessProduct pipe materialdeteriorationPipe MisalignmentWorn-out GasketCracked Sump Tank Petroliam Nasional Berhad (PETRONAS) 2018Open13
Our challenges and journey in implementing PSM in retail businessSustaining PSM in retail2019 &beyond2018 Technical safety in retail2017Group PSM framework and initiativesITPM for retail businessIPFs revalidationLeading KPIsRetail Design ManualDevelopment of OPProcess Safety Fundamentals Training Asset Integrity Management2016Conduct PHA Process Safety for NGV SystemDevelop business caseIdentify relevant process safety aspectsernal Petroliam Nasional Berhad (PETRONAS) 2018Open14
Creating a sustainable effort in managing process safetyrisk in retail business Specify process safety requirements for retail stations in GroupProcess Safety Management Framework. Include retail business in the Group Process Safety PerformanceMonitoring and Reporting monitoring. Incorporating process safety aspect in retail business auditingscope. Reviewing the capability and competency development program Petroliam Nasional Berhad (PETRONAS) 2018Open15
Thank you Petroliam Nasional Berhad (PETRONAS) 2018Open16
MECHANICAL INTEGRITY - Inspection of underground tank MECHANICAL INTEGRITY - Inspection of fittings and connection - Inspection of hose conditions OPERATING PROCEDURE - Loading and unloading activities Process Safety Information - P&ID Drawings - Isometric drawings - Safety Data Sheet (SDS) Open Applicable Process Safety Aspects at a Retail .
