ts1 - taruli sibuea

7/30/2019 TS1 - Taruli Sibuea

1/18

Safety Improvement

Implementation Program atPertamina Refineries

BY Taruli Sibuea

HSSE REFINING

J uni 2011


2/18

PERTAMINA1

Topic of Presentation

Summary4

Introduction1

SIIP Program Design2

Implementation3


3/18

PERTAMINA

PT PERTAMINA (Persero) REFINERIES1. Introduction

RU II :

- P. Brandan- Dumai- Sei. Pakning RU III Plaju

RU IV Cilacap

RU V :

- Balikpapan- Methanol Bunyu- Kasim

RU VI Balongan

2


4/18PERTAMINA

How We Accelerate Pertaminas Transformation

Safety

Culture

Refining :

Deliver safe, top quart ile operation, expend to meet national demand

3


5/18PERTAMINA

The case for change

No Harm to People, Asset, Environment

and Reputation Pertamina vision is to transform to a

company w ith Excellent Safety

Performance by 2015

Many HSE Role models from linemanagement

Compliance to HSE Golden Rules andown safety procedures

Leadership commitment tolerance of unsafepractices.

Standards of safety performance tolerance oflow standards for implementing cri tical tasks.

Contractor safety contractors not following basic

safety rules. Knowledge and competencies in HSE are low. Safety is driven by HSE Department.

From (Result o f DuPont Safety Assessment 2006)

To / Future State

4


6/18PERTAMINA

2. SIIP Program Design

Al ignment WorkshopsFour workshop to manage thechanges and ensure succesfulimplementation.

Strengthen Safety BasicsHazard Awareness and RAMSafe Walk and TalkSafety Supervision.

Technical SafetyTechnical /Process SafetyPrimer

2008

2010

2012

2014

Close the Gaps in SafetyCritical ProcessesReview safety critical process

Gap closure Workshop (PtW,J SA)

Technical SafetyHEMP AwarenessTraining

Integrated HSEManagement SystemHSE MS TrainingHSE MS Review

Enhancing HSE CultureHeart and Minds ToolsLaunch of Behavior Based

SafetyTechnical Safety

HEMP Implementation

Sustain the ProcessReview the progress ofimplementation

A Step wise Journey to Excel lence in Safety

5


7/18PERTAMINA

Deployment for Safety Improvement Implementation Program (SIIP)

Program Design Implementation

1. Preparation

a. Establish task groupb. Establish unit to be evaluated

2. Implementationa. Evaluate the present statusb. Identified Deviationsc. Do Correction

PIC HSE Personal competencies

Process Eng.ProductionME

Metric

Measurement

0

5

10

w1 w2 w3

Audit (Health Check, MWT)

% Compliance to definedoperating windows setting

% Compliance to defined alarmsetting

% Compliance to defined safeguarding setting

Verify

performance

Leadership Commitment1 2

3

4

6


8/18

PERTAMINA

Chairman

(Refining Director)

Steering

Committee-2Steering

Committee-3

Executor

Chairman

(GM RU)

Refine

ryUnit

Ce

ntral

SteeringCommittee

Secretary (Man. HSE Ref.)

Line Organization

Secretary (Man. HSE RU)

ExecutorSteering

Committee

Line Organization

Standards,

Procedures, Incident

Investigation

Steering

Committee-2Steering

Committee-3

Manager

SVP

Organization & Responsibilit ies (Organization Of Safety Committee Meeting)

SMOM

Manager

Standards,

Procedures, Incident

Investigation

7


9/18

PERTAMINA

Lagging Indicator:

Leading Indicator

KPI

HSE KPIs For Pertaminas Refineries

1. Number of Safety Walk & Talk (SWAT)2. Number of Management Walk Through (MWT)3. % Follow up on Incident Investigation Recommendation4. % Compliance to Management of Change (MOC) Personal, Facility & Technical5. % Fire Protection Readiness6. % Compliance to Setting of Operating Windows, Alarm and Safeguarding.7. % Compliance to Schedule Testing of Alarm & Safeguarding8. % Overdue Inspection for Tank, Vessel, Piping, Pressure Safety Valve (PSV),

Compressors, Pumps, Column, Boiler & Furnace

1. Total Recordable Incident Rate (TRIR)2. Number of Incident

3. Implementation

8


10/18

PERTAMINA

IssuesEquipmentProcess

People

Safety

Some Safeguard system are not working or by pass

Some monitoring equipments are not working ( TI,FI )

Some operating windows are exceeded

Some Supervisors and Operators competencies needto upskill regarding Safe operations .

Management consequences needs to be stronglyimplemented

Need improvement to Permit To Work implementation.

Risk Containment Acitivities (Accelarated Preventive Response, APR)

APR to identify gap and mitigate in the area of critical process safety. Involvement more people / teamfor the program.

Related to PSM Element :

Process Safety Information Process Hazard Analysis Operating Procedure Training Mechanical Integrity Management of change Compliance Audit

Key Learning from Balikpapan and Cilacap Furnace incident

APR For : Boiler & Furnace Storage Tank Fire Protection Facility Pressure Vessel and Piping

9


11/18

PERTAMINA

50

60

70

80

90

100

2008 2009 2010 2011

50

60

70

80

90

100

2008 2009 2010 2011

50

60

70

8090

100

2008 2009 2010 2011

PPE Contractor

(% Safe)

100%

Week

Scaffolding

(% Safe)

Gap Gap Closure Remark

1. Unstandard Blind formaintenance work (workpermit).

2. Unsafe Scaffolding use by small

Contractor (no bracing, baseplate, stair, toe).

1. Intervention

2. Review to improve

scaffolding standard.

Week

50

60

70

8090

100

2008 2009 2010 2011

Week

100%

90% Target

85% - 90% Target

< 85% Target

Electrical Tools & Distribut ion

(% Safe)

Work Permit

(% Safe)

Week

Sample Results of SIIP in Refinery

100%100%

Before After

Before After

10


12/18

PERTAMINA

Lock and tags System to manage Bypass

Avai labil it y of Good Fire Fighting Equipment Avai labil it y of informat ion during emergency

KPIs on display

Sample Impact of Safety Leadership in Refinery

11


13/18

PERTAMINA

Good House-keeping, Painting & Insulation

Good Scaffolding Material Good Plant Housekeeping

Good Chemical Handling

12


14/18

PERTAMINA

Safety Golden Rules deal with Compliance issues on Key Safety Rules

There has to be investigation and appropriatemaximum consequence for those breaking rules..

If you choose to break the rules,

You Choose not to work for Pertamina

13


15/18

PERTAMINA

Overall Safety Effort : Reduce and Eliminate Hazard to Prevent Incident

People risks

Observable behaviour

Man-Machine Risks

Unseen behaviour

Integrity Risks

Understanding assets

Reactive

Catastrophic

Incident

Multiple fatality

Near Miss

Major Incident

Loss Incident

Fatality

Serious Injury

First-aid Incident

Unsafe Acts and Conditions

Process Safety

Preventative

Assess the effort

to eliminate both

behavioural and

process safety

hazards

Behavior

? ?

??

?

?

??

14


16/18

PERTAMINA

Key Learning For Continues Improment

Maintain The Processes(Safety Committee Structure, Safety moment in every meeting, Safety board and leading

indicators)

Do More(Incident Investigation, Safety Observation and Intervention, Safety Action Plans)

Change the Process(Involve Contractor in Safety Culture development, Improve operating discipline)

Introduce the Process(Develop a matrix of knowledge and competency for capabil ity development, develop

system to maintain the mechanical integrity safety critical equipment)

15


17/18

PERTAMINA

4. Summary

- We have got some improvements by implementing SIIP.

- We learnt f rom incident in Pertamina and other refineries and conducted RiskContainment (Accelerated Preventive Response) for cri tical process safety.

- We have to cont inuously identify the gap and follow up to achieve SafetyExcellent.

Achieving Safety Excellence is a Long Journey

16


18/18

PERTAMINA |17

ts1 - taruli sibuea

Documents