“Improve process safety analysis

and culture at TATA Steel with

BowTie Server

Tata Steel Slide

Tata Steel Group

One of the world’s most geographically-diversified steel producers

▪ 11th largest global steel producer

▪ Annual crude steel capacity of more than 27.5 million tonnes

▪ Around 74,000 employees

▪ Manufacturing operations in 26 countries across five continents

-------------------

▪ Agreement for the formation of a joint venture with the European steel activities of Thyssenkrupp.

Tata Steel Group

2Introducing Tata Steel

Tata Steel Slide

Tata Steel Group

A global network serving demanding markets worldwide

Western Europe

Steel making operations

Distribution and

downstream assets

North America

WesternEurope

Scandinavia

CIS

WesternAfrica

South Africa

Latin America

ChinaJapan

IndiaHong Kong

New ZealandSales offices

SE Asia

Key

Turkey

CEE

3Introducing Tata Steel

SlideTata Steel 4

Tata Steel in IJmuiden

Introducing Tata Steel

Raw materials - Pig iron - Steelmaking - Casting - Rolling - Coating

SlideTata Steel 6But there are also hazards….

World

Industry

Steel

Industry

Tata Steel

Tata Steel

local

Piper Alpha (167†) Macondo Well (11†) Texas City (15†)Bophal (20.000+ †)

China steel ladle(32†)

PT ladle drop

Furnace explosion(4†) Ternium Steel (10†)

BF hot blast line

Coke Gas heating alley

GH explosion (1†)BF 5 explosion (3†)

BF bleeder valve Pickling line fire

CSN, Brazil 2006

Drivers for Process Safety

SlideTata Steel

What is Process Safety?

7

In essence: keeping control of identified Safety

and environmental Major Hazard scenarios - low

frequency of occurrence / major consequences.

It’s a tough subject :

• Difficult to predict;

• Hard to imagine;

• Difficult to keep the overview. (e.g. Macondo incident *)

* Prof. Andrew Hopkins; ”Disastrous Decisions”, may’12.

ISBN 978 1 921948 77 0

Tata Steel Slide

* REGULATOR’S REACTION TO BUNCEFIELD

Companies must ask 3 questions*:

Do we know what can go wrong?

Do we know what barriers we have to ensure that it

doesn’t go wrong?

Do we know that our barriers are effective and

working properly?

What’s process safety? 8

1

2

3

Tata Steel Slide

Mission , Vision and Strategy

9

Mission:

Eliminate all major process safety events by controlling all Major Hazard scenario’s within Tata Steel

Europe, through the thorough application of our process safety management framework.

Vision:

This will be achieved, among other things, by :

The thorough application of Barrier Management to manage Process Safety Critical Equipment and

Process Safety Tasks (PSCE & PSCT)

Strategy:

• BowTie Server - improve risk communication / encourage to learn from each other;

• BowtieXP template - keep high standard to identify PSCE and PSCT / speak the same language.

• AuditXP framework - Develop standards to report on the barrier health status.

Tata Steel Slide

Implementing the strategy

Back to the primary process:

“The art of steelmaking starts with conversation”

Process Safety Management Foundations L3 10

Tata Steel Slide

Challenges

Language:

How to relate the phasesof process safety andalign the approaches:

SIMPLIFIED

11

Barrier investigation :

HSE - scenarios with

consequence ≥ 4 on Risk Grid with BowTie.

PROCESS HAZARD ANALYSIS :

PHR2 (minimum), HAZOP or FMECA.

Delivers barrier identification

LOPA : delivers reliability

requirements for SCE and SCT.

Server in ‘rekencentrum’ IJmuiden :

A BowTie / HAZID / AUDIT tool to execute barrier Management.

DELIVERS HAZARD CONTROL : APPROACHABLE TO ALL ORGANIZATIONAL LEVELS

Delivers Process Safety Critical Equipment

overview and SCT regarding to maintenance

Delivers overview of Process Safety

Critical Task (SCT) for operations.

Bo

wT

ie

PS + AMD + HHI

SCE performance setting : SCE management process of AMD. HHI-

engineer implement maintenance plan for

SCE into SAP.

HAZARD IDENTIFICATION :

PHR0 : Delivers HHF and HHI indentification

SCT performance setting :

Set requirements for Operating

procedures.

DELIVERS ASSET INTEGRITY

Regimes and drawings (P&ID)

AMD + HHI PS + HHI

PS : Process Safety

team IJmuiden

HHI : operators and

engineers from

High Hazard

Installation

PS toolbox : several PSGs

Link to local managementsystem Link to SAP PM

DELIVERS OPERATIONAL CONTROL

PS-toolbox. Process Safety

Code of Practice PSC-03.1

PS-toolbox. Process Safety

Code of Practice PSC-03.2

PS-toolbox. Process Safety

Code of Practice PSC-06.1

Tata Steel Slide

The 3 level barrier approach of Tata Steel

Process Safety Management Foundations L3 12

1 Barrier: Passive, Active, Procedural or Mix

2 Barrier component:detect | decide | final (act)

3 SMS Element:Performance Standard Operation or -Equipment

Execution of maintenance, instructions, Assurance of Safety Instrumented Functions or -Operational Interventions

Tata Steel Slide

Change in practice

Cokes Factory 1 Pilot

Current situation:

• HAZOPs are performed

• There is an with the first Process Hazard studies, preparing for the barriermanagement approach.

Pilot Goals:

• Enabling ownership of the analysis proces to the factory assisted by the localPS experts.

• Enabling the plant to use their bowties in operator involvement AND management involvement for risk reducing actions.

• Preparing for barrier health checks

Intermediary results:

• Old data is reused and imported in BowTieServer

• Crews are involved and enthusiastic

• Ramping up for the improvement cycle

Process Safety Management Foundations L3 13

Tata Steel Slide

Culture and strategy

What do we learn from marketing

Process Safety Management Foundations L3 14

Tata Steel Slide

Learning points | the way forward

Influencers for success:

• Interaction between individuals

• Culture | Politics

• Changes

• Management commitment

• Compliance pressure

• User acceptance of and onboarding of the tools

Next steps in closing the circle:

• Barrier health checks (focus on the elements and components)

• Incident learning – what scenario’s did we miss, what control mechanisms did work and which didn’t?

• Focus on what works – bringing it back to simple.

Process Safety Management Foundations L3 15

Tata Steel Slide

Topics to tackle in the next steps of risk ownership

Tata Steel barrier approach:

• The model is a choice and has up- and downsides.

Ownership of hazards

• Defining the best approach.

Implementing risk reducing actions

• Defining good practices combining other action tools.

• Defining good practices combining other improvement actions protocolsconsidering e.g. CAPEX and OPEX decisions.

Process Safety Management Foundations L3 16