The document details the importance of adhering to terminal process safety standards, particularly in the context of major hazard facilities (MHF) to reduce risks to as low as reasonably practical (ALARP). It discusses the Buncefield disaster, highlighting its causes, consequences, and the necessity for robust safety systems like overfill prevention and hazardous condition detection. Additionally, it emphasizes necessary safety measures and solutions for various operational scenarios to mitigate risks associated with toxic substances and flammable materials.

1. Complying with Terminal Process Safety
Process Safety, Care & Maintenance.
Preeju Anirudhan (Instr. & Electronics Engineer)
Product & Application Manager – Chemical, Oil & Gas

2. Terminal Process Safety
Expectations & Standards
Government policies &
regulations, mandate all
operators of MHF must do
everything possible to reduce
risk to “as low as reasonably
practical” (ALARP)
.
.
.
.
MHF – Major Hazards Facility (OH&S Act 2007)

3. Terminal Process Safety
ALARP - Regions
Source – Guidance for MHF facilities (Work Safe / HSE UK)
License to operate does not mean you comply with ALARP

4. Terminal Process Safety
Tank Overfill & Ignition – Chronology

5. Loss of product containment
Explosion
• 40 minutes
undetected
• 300 tonnes of
petrol released
• Ignition source
Impacts of the Disaster (Potential at other sites)
• Explosion in one tank spreads to 20 others.
• Blast wave damaged structures up to 8 km away.
• Fire burnt for 3 days.
• 25 fire engines, 20 support vehicles and 180 fire fighters
• 43 reported injuries.
• Schools, transport were disrupted
• 92 businesses employing 9,500 people displaced
• 410 redundancies & 923 casual jobs lost.
• Extreme environmental impact from use of fire fighting
chemicals on soil & water bodies.
• £1 Billion including £750 M pay-up in claims. (Source - HSE)
Terminal Process Safety
Buncefield Disaster – Facts & Figures

6. Immediate Causes
• Failure of primary containment due to inoperability and/or malfunction of the
automatic tank gauging system (ATGS) and the independent high-level switch (IHLS)
• Insufficiently designed secondary (Bunds) and non-existent tertiary containment
Wider Underlying Causes
• Buncefield operators had little control over the two remotely operated UKOP
pipelines
• Inadequate shift handover
Terminal Process Safety
Buncefield Disaster – Causes

7. • Provides frameworks for risk assessment, SIL
calculation and equipment architecture
• Principles of Process Safety Management
 Clear understanding of risks and systems
as well as equipment in place
 Safety culture which allows for sufficient
time and resources allocated to process
safety issues
 Auditing systems
Terminal Process Safety
The PSLG Guidance

8. Terminal Process Safety
ALARP – Where do you want to be?
How to achieve?
Recommendation 3 – Prevention Layer
Operators of Buncefield-type sites should
protect against loss of containment of petrol
and other highly flammable liquids by fitting a
high integrity, automatic operating overfill
prevention system (or a number of such
systems, as appropriate) that is physically and
electrically separate and independent from the
tank gauging system.
•Such systems should meet the requirements of
Part 1 of IEC 61511 for the required safety
integrity level.

9. Terminal Process Safety
ALARP – Where do you want to be?
How to achieve?
Recommendation 13 – Mitigation Layer
Operators of Buncefield-type sites should
employ measures to detect hazardous
conditions arising from loss of primary
containment, including the presence of high
levels of flammable vapors in secondary
containment.
Detecting high levels of vapor in secondary
containment is an early indication of loss of
containment and so should initiate action, for
example through the overfill prevention system,
to limit the extent of any further loss.
Installing CCTV equipment that detects and
responds to changes in conditions and alerts
operators to these changes.

10. Terminal Process Safety
How to Design a Plant Safety System (PSLG)
Tank Gauging
Safety control
BPCS and Recommendation 3 & 13 - Concept

11. ZZZZZZ
Recommendation 13- Detection of Flammable vapours
SIL2 Including communication
approval covers hardware, software
and wireless communication
No Calibration evert
ensuring lifetime detection
stability, with no need for re-
calibration
60~80% savings on
total project cost due to
reduced engineering;
wiring, installation and
documentation demand
Truly wireless, no cables:
Ultra-low power consumption
of 5 mW on average allows
for typical battery life of 24
months
Fast Response (5S)
Reliable IR Technology
Intrinsic safety
approval with field-
replaceable battery
packs
Terminal Process Safety
Mitigation using Wireless GasSecure GS01

12. Major successes in ANZ region (8 sites)
140 GS01 installed at seven sites (Australia)
11 GS01 installed at NZOSL Napier (NZ)
Terminal Process Safety
Mitigation using Wireless GasSecure GS01

13.  Detectors
 Access-Points
 Gateways
 Controllers
& Logic Control
Terminal Process Safety
Wireless Solution – What does it consist of?

14. Level
Gas
CCTV
Independent
safety control
Real-time video
Shutdown
Terminal Process Safety
Plant Safety Solutions for Non-Fuel Storage (PSLG)

15. Terminal Safety
Care & Maintenance

16. Explosions, e.g. ignited during
work by sparks or high
temperatures
Explosions due to the inherently
unstable character of some
chemicals (e.g. explosives)
Serious effects from toxic gases,
vapors, or liquids via skin contact,
ingestion, or inhalation
Exposure to corrosive/
caustic substances
Serious effects (carcinogenic,
genetic, mutagenic) from long
term exposure
to certain toxins
Reaction of substances coming
in contact with catalytic materials
becoming dangerous
Potential dangers due to ...
ZZZZZZ
Risks
Flammable gases
and vapors
Toxic liquids and gases
(Chlorine (Cl2), Ammonia (NH3 ),
Hydrogen chloride (HCl)
Toxic organic substances
(e.g. Benzene, Methanol,
Ethylene, Butadiene)
Particles (e.g. dust and
combustible particulates)
Many more HAZMATs
in different processes
Terminal Safety – Care & Maintenance
Confined Space Entry - Risks

17. Pre-entry check and
personal air monitoring
Area monitoring
Head & body protection Training & services
Breathing protection
Escape equipment
ZZZZZZ
Terminal Safety – Care & Maintenance
Confined Space Entry - Solutions

18. Particles
(e.g. dust and combustible
particulates)
High risk of explosions,
e.g. ignited during hot work by
sparks or high temperatures
High risk of explosions due
to the inherently unstable character
of some chemicals (e.g. explosives)
Risk of serious effects from toxic
gases, vapors or liquids via skin
contact, ingestion or inhalation
Risk of exposure to corrosive/
caustic substances
Risk of serious effects (carcinogenic,
genetic, mutagenic) from long-term
exposure to certain toxins
Reaction of substances coming
in contact with catalytic materials
becoming dangerous
Potential dangers due to ...
ZZZZZZ
Risks
Flammable gases
and vapors
Toxic liquids and gases
 Chlorine (Cl2)
 Ammonia (NH3 )
 Hydrogen chloride (HCl)
Many more HAZMATs
in different processes
 Organic substances
(e.g. Benzene,
Methanol, Ethylene,
Butadiene)
Terminal Safety – Care & Maintenance
Shutdowns and Turnarounds - Risks

19. Personal Air Monitoring
Head & Body
Protection
Area Monitoring
& Access Control
Rental Shop, Gas
Testers, Training &
Safety Services
Breathing Protection
Escape & Rescue
Equipment
ZZZZZZ
Terminal Safety – Care & Maintenance
Shutdowns and Turnarounds - Solutions

20. Particulate
matter
High risk of explosion
vapors
High risk of explosion
caused by vapors
Hazardous substances
Dust
Powder
Potential dangers due to ...
ZZZZZZ
Risks
VOC (volatile organic compounds)
such as these solvents:
 Hydrocarbons
 Esters
 Ketones
 Alcohol
Terminal Safety – Care & Maintenance
Painting & Coating - Risks

21. Personal
Air Monitoring
Head & Body Protection
Area Monitoring Training & services
Breathing protection
Escape equipment
ZZZZZZ
Terminal Safety – Care & Maintenance
Painting & Coating - Solutions

22. Any Questions? – Visit us @ Booth 15
• Detection
• Protection
• Service & Training.
• Shutdown & Rental
• Total Care Solutions