Presentation on theme: "HSE’s Ageing and Life Extension Key Programme (KP4) and Human Factors"— Presentation transcript:
1 HSE’s Ageing and Life Extension Key Programme (KP4) and Human Factors Peter Fearnley, Energy Division - OffshoreKP4 website:
2 ……..Covering……. Why? Ageing and Life Extension Equipment, Systems and PeopleWhat can I do, what can I ask
3 UKCS operates a Safety Case Regime Why?UKCS operates a Safety Case RegimeThe Safety Case describes measures in place reducing major accident risks to people to the lowest reasonable level*There are proper arrangements in place for an independent audit of the systems (?)*The systems are complex and need all our attention to remain effective
4 Why? To be safe all 3 have to work well, together Facilities People FitnessCompetenceMorale/TrustPerceptionBehaviourFacilities& EquipmentDesignWork EnvironmentMaintenanceReliabilityDemandTo be safe all 3 have to work well, togetherSystemsHazard identificationRisk assessmentManagement CommitmentProcedures, TrainingIncident investigationMonitoringChangeLearning
5 Why? Ageing and Life Extension History of Development Systems People Facilities & EquipmentDesignWork EnvironmentMaintenanceReliabilityDemandSystemsHazard identificationRisk assessmentManagement CommitmentProcedures, TrainingIncident investigationMonitoringChangeLearningPeopleFitnessCompetenceMorale/TrustPerceptionBehaviourHistory of Development
6 WHAT ARE AGEING & LIFE EXTENSION? “Ageing is not about how old your equipment is; it’s about what you know about its condition, and how that’s changing over time”Condition Management is the keyLIFE EXTENSIONWhen assets exceed design life = Life Extension phaseHalf UKCS production platforms in LE phaseSome platforms anticipate years productionPlus 5-10 years to removal from sea bedAcross the European Union’s hazardous industries ageing is implicated in:30% of incidents28% of loss of containment
7 What Is ALE? It’s All About Managing Ageing Forth Rail Bridge Opened 4th March 1890 (~123 years old)Robust structure200 trains per dayContinuous painting programme
8 What Is ALE? It’s All About Managing Ageing Forth Road Bridge Opened 4th September 1964 (~48 years old)Highly engineered structurevehicles per dayIM programme didn’t identify cable corrosion risk2003: numerous wire strands in suspension cables found to be corroded and failedWeight restrictions appliedNeeds replacing ~£1.4 Billion
9 *MAINTAINING AND IMPROVING SAFETY* WHAT IS KP4?Raising awareness of consequences of ALEUnderstanding & forecasting degradation mechanisms & rates of Safety Critical ElementsObsolescence managementSharing ALE knowledge for the benefit of allWorking with industry for a common goalReducing Hydrocarbon Releases*MAINTAINING AND IMPROVING SAFETY*
10 WHAT HAS KP4 COVERED? Process Safety, Fire and Explosion Structures MarineMechanical and CorrosionElectrical, Control and InstrumentationPipelinesHuman and Organisational Factors
11 HYDROCARBON LEAKS: EQUIPMENT, SYSTEMS, PEOPLE Norwegian study found:60% of leaks due to human interventions;key issues:failure to check pre and post-work isolations and integrity;Technical degradation caused ~21% of HC leaksNo relationship between age and leak frequency – condition management!100% management system failure?Equipment, Systems, People
12 EQUIPMENT, PEOPLE AND SYSTEM ISSUES When equipment doesn’t work as designed (ALE), carry out risk assessmentRisk Perception & AssessmentHSE still finding problems with Operational Risk Assessments (ORA) – risk assessment can be too difficultFailures identifying and addressing MAH risks, see ORA guidance rolled out by OGUKClear procedures guiding correct thought process, e.g. ORA default should be shut-down unless there are good reasons to continue operations
13 WORKFORCE INVOLVEMENT IN ALE Need to equip people at all levels of the organisation with the right skills to recognise and respond to riskHazard awareness, assessment & anticipationNeed to understand and actively manage the factors that influence human performance, e.g. operating wrong valve, not following a procedureDistractions, badly written procedures, poor communication, lack of feedbackNeed to develop a culture where ‘speaking up about concerns’ is managed appropriatelyacceptable for ‘bad news’ to travel up the line
14 What Can I Do, What Can I Ask? Getting ALE and People (HF) issues right requires a focus – where is it in your organisation?Does your organisation have an ALE policy?How well are they doing?What are they planning to improve?Are you clear what your part is in this?
15 What Can I Do, What Can I Ask? Does your organisation have a clear approach to dealing with people issues/human factors?Do you see it worked out in incident and near-miss investigations?Are the reasons for mistakes understood and does this make a difference to the way jobs/tasks are planned and carried out?Are audits, monitoring and other learning seen as vital to stopping incidents before they happen?