This document discusses process safety and introduces the bowtie methodology. It defines process safety as identifying and preventing releases of hazardous substances and energy. Process safety is ensured by maintaining safety barriers and equipment, following operating procedures, and knowing emergency response procedures. The bowtie methodology graphically illustrates how hazards are controlled through preventative and recovery controls. It links hazards, safety critical elements (SCEs), and performance standards to ensure effective risk management. The document emphasizes the importance of assuring critical controls such as identifying and testing SCEs, emergency response systems, and inspection regimes.

1. Process Safety: Innovating New Operation Horizons
Glimpse
of
Process Safety
By:
TAJAMMAL HUSSAIN
Loss Prevention Expert
tajammal.hussain@live.com

2. 2 . TAJAMMAL HUSSAIN
WHAT is PROCESS SAFETY!
Process Safety is about identifying and preventing the releases of hazardous
substances and energy.
Process Safety is ensured by:
 Maintaining Process Safety Barriers and safety critical equipment in a
proper condition
 Managing plant operations as designed
 Following operating procedures and avoiding shortcuts and workarounds
 Operate plant within Safe Operating Limits
 Knowing exactly what to do in case of loss of containment or emergency

3. 3 . TAJAMMAL HUSSAIN
WHAT is PROCESS SAFETY!...
Examples of Process Safety Incidents could include:
 Flammable or toxic gas release: Risk of fire, explosion, poisoning
 Pipeline leak: Risk of fire, environmental damage, intoxication
 Oil spillage
 Electrical systems failures
 Dropped objects, collisions, structural collapse threatening process
containment
These have the potential to cause
 Injuries or Fatalities & Environmental damage
 Total loss or severe damage to the facility
 Damage to the reputation of the company

4. 4 . TAJAMMAL HUSSAIN
INTRODUCTIONTO BOWTIE METHEDOLOGY
 Bowties are developed for MAEs identified during HAZID Workshop
 SCEs are identified during Bow Tie development
 Unlike traditional risk evaluation tools, the bow-tie method makes the link
between preventive controls of causes and recovery controls of
consequences;

5. 5 . TAJAMMAL HUSSAIN
INTRODUCTIONTO BOWTIE METHEDOLOGY..

6. 6 . TAJAMMAL HUSSAIN
INTRODUCTIONTO BOWTIE METHEDOLOGY…
 The Bow-tie Diagram is a user-friendly, graphical illustration of how hazards
are controlled
 Effective risk management is only possible if people are assigned
responsibilities for controls via HSE-Critical Tasks
 Visible links are made to HSE-critical systems and competencies and
auditing
 The total methodology demonstrates not only what controls are in place
today, but why they will still be there tomorrow

7. 7 . TAJAMMAL HUSSAIN
CONCEPTS OF SCEs and PERFORMANCE
STANDARD
Safety Critical Element
 A SCE is classified as an equipment, structure or system whose failure could
cause or contribute to a major accident, or whose purpose is to prevent or
mitigate the effect of a major accident e.g. ESDVs & PSVs.
Performance Standards
 When SCEs are identified, Performance Standards (PS) for each SCE needs
to be defined. A PS is basically the performance required by the SCE for
managing hazard in terms of:
 Functionality, Availability, Reliability, Survivability and
Interaction/Dependency
 Assurance and verification activities ensures that SCE meet their PS

8. 8 . TAJAMMAL HUSSAIN
KEY DIMENSIONS of PROCESS SAFETY
ASSURANCE OF CRITICIAL CONTROLS
Includes but not limited to;
 SCEs identification as per Guide lines and its traceability in CMMS
 SCEs performance standards & its link to CMMS
 SCEs PM/ functional testing etc. ( actual vs planned)
 Function testing of critical control loops including ESD and F&G system
 Implementation of written scheme of examination and verification
 Set point Register and safe operating envelopes including alarm
Management
 Emergency response system including spill management
 Override/ bypass/ inhibited SCE and critical controls trend analysis

9. 9 . TAJAMMAL HUSSAIN
KEY DIMENSIONS of PROCESS SAFETY
ASSURANCE OF CRITICIAL CONTROLS…
 Inspection regime verification (actual vs plan, suitability, effectiveness of
 inspection plans, NDT testing, corrosion inhibition, Cathodic Protection,
 erosion/ corrosion probe data analysis, structures & pipe racks inspection
 and PSV management

10. 10 . TAJAMMAL HUSSAIN
Thank You