Implementing International Experience in Process Safety

From Personal to Process Safety: Evolution of Industry Approaches

Traditionally, HSE professionals have focused on the personal safety of employees. However, an analysis of major industrial incidents shows that a significant portion of accidents is related specifically to process safety violations. Implementing a systematic approach to managing process risks is becoming a natural stage in the development of a safety culture at modern enterprises.

During the webinar, Alexander Remeyko and Vladislav Smolin, representing Salym Petroleum Development, share their practical experience in adapting and implementing international process safety principles at Russian production facilities.

Prerequisites for Implementation: Analysis of Global Statistics and Local Incidents

The speakers note that the decision to implement process safety principles was based on an analysis of accumulated statistics from partner enterprises. Data shows that about 30% of all incidents in the oil and gas industry are associated with process safety violations.

The presentation details a real case from the company's practice: an incident during the tie-in of a new pipeline section using Stopple technology. Unplanned changes to the work procedure (equipment steaming) led to a loss of sealing in the locking device and a gas release. This case clearly demonstrated the need for strict control over process discipline and change management.

10 Process Safety Fundamentals

The foundation of the new system is 10 Process Safety Fundamentals, each formulated based on the analysis of real man-made events. The speaker demonstrates with examples how these rules work in practice:

• Using double block and bleed on hydrocarbon drainage lines to prevent uncontrolled leaks.
• Prohibition of leaving open drains and critical transfers unattended, minimizing the risk of overflows.
• Strict adherence to procedures during high-risk work with step-by-step confirmation (signature) of each stage's completion.
• Leak testing after maintenance and before putting equipment into operation.
• Management of Change (MoC) for any deviations from standard procedures or when connecting auxiliary equipment.

Phased Implementation and Effectiveness Evaluation

Given the scale of the task, the company chose a phased implementation strategy, starting with the five most critical principles for its production. To successfully implement the project, a cross-functional working group was created, and leaders were identified at the production facilities.

To evaluate the effectiveness of the implementation, a radar chart (spider chart) is used, covering 15 areas: from personnel competencies to conducting audits. This approach allows identifying areas for improvement and promptly adjusting the action plan, for example, by integrating new requirements into the initial induction program.

What you will learn from this webinar:

• How to adapt international Process Safety principles to Russian realities?
• Which visualization and communication tools are most effective for engaging personnel?
• How to organize a daily monitoring system for process safety incidents?
• How to use a radar chart to assess the maturity of the process safety culture?
• What role do local leaders play in implementing new safety standards?