Implementation of an Integrated Safety Barrier System

Integrated Safety Barrier System: From Theory to Practice

Implementing an effective risk management and industrial safety system is a task that requires a comprehensive approach. During the webinar, Artem Kaniseev, Lead HSE Engineer at Tomskneftekhim LLC, shares practical experience in implementing an integrated safety barrier system at a large petrochemical enterprise. The speaker explains how various components of the barrier model interact with each other and what tools help improve the safety culture level.

Risk Management and Practice-Oriented Training

The first key barrier is the risk management system. The enterprise has implemented a vertically integrated approach: risk questionnaires are formed at the structural division level and escalated to the enterprise risk register. This allows focusing on the most significant threats and considering them during business planning.

The second important element is personnel training. The speaker emphasizes the importance of a practice-oriented approach. Using real cases and simulating emergency situations (for example, equipment depressurization) allows workers to analyze mistakes and better understand the consequences of violations. Expanding the target audience of such trainings to include contractor supervisors further strengthens this barrier.

Communication, Audits, and Safety Culture

Effective communication is another critical barrier. The practice of "Hazard Conversations" and regular HSE shift meetings create conditions for an open dialogue between management and workers. This helps identify hidden threats and take prompt action.

The presentation details the approach to audits. In addition to standard inspections, targeted audits of lagging processes (e.g., work permits) and regular line walkdowns involving top management have been introduced. This demonstrates a commitment to safety leadership.

Safety culture is maintained through a system of rewards and penalties. On the one hand, there is a strict policy for violating key rules (up to removal from the site). On the other hand, safety championships are held where departments compete in the quality of behavioral audits and identifying hazardous conditions. This stimulates personnel engagement and the practice of safe intervention.

Innovation and Control Automation

The speaker demonstrates by example how modern technologies strengthen safety barriers. Using mobile walkdowns to monitor equipment condition allows for prompt defect identification and their integration into the ERP system for maintenance planning.

Special attention is given to a pilot project implementing intelligent video surveillance (IVS) at loading and unloading racks. To monitor the use of safety harnesses, cameras were installed at the entrances to the rack. To increase recognition accuracy (up to 95%), special bright covers for the harnesses were developed. Implementing the "black screen" concept reduced the information load on operators, displaying only violation cases on the monitor.

What you will learn from this webinar:

• How to build a vertically integrated risk management system?
• Which practical training formats are most effective for incident prevention?
• How to engage personnel in hazard identification through safety championships?
• How to organize targeted process audits and management line walkdowns?
• How to implement an intelligent video surveillance system to monitor PPE usage when working at heights?