Fire and Explosion Hazard Management (FEHM): An Overview

Transcription

1 Fire and Explosion Hazard Management (FEHM): An Overview Overview of Fire and Explosion Hazard Management Figures Figure 1. Accident Investigation and Causal Analysis Figure 2. Fire and Explosion Incidents: Relationship of Key FEHM Components Figure 3. Understanding Fire and Explosion Mechanics: Fault- Tree-Analysis Diagram based on Ball Energy Model Figure 4. Preventing Fires and Explosions: Understanding the Expanded Fire Triangle Figure 5. Fire and Explosion Hazard Management (FEHM) Process Figure 6. Stages of a Fire and Explosion Hazard Management Process Figure 7. Potential Fire and Explosion Figure 8. Fire and Explosions Overview of System Dynamics

2 Overview of Fire and Explosion Hazard Management Figures The purpose of the document is to provide a printable version and brief explanation of the diagrams used to develop Industry Recommended Practice IRP 18 Fire and Explosion Hazard Management. These diagrams were created as part of the work of a Canadian Oil and Gas Industry Committee looking into fires and explosions in the upstream industry. Enform has issued an Industry Recommended Practice prepared by the IRP18 Committee. Further information about this IRP can be found on the Enform website These diagrams were created by Walter Tersmette, P. Eng., as part of his role as the Co-chairman of this industry committee. Figure Discussion 1 Accident Investigation and Causal Analysis One focus of the IRP18 Committee s work was to identify and analyze relevant fire and explosion case studies. To complete the analysis, two accident theory models used by the safety industry were applied: 1) James Reason s Swiss Cheese model and 2) Edward Adam s Organizational Responsibility Model. Reason s Swiss Cheese model sets out the basic relationships between hazards, defenses and losses. The model identifies three basic levels of defenses based on organizational, local workplace and human factors and the potential holes in those defenses. Adam s Organizational Responsibility Model looks more closely at the activities of managers, supervisors and workers, the key people in every management system. 2 Fire and Explosion Incidents: Relationship of Key FEHM Components This diagram illustrates the relationship between the key components of fire and explosion management relative to the sequential events in an accident. What was the fire and explosion hazard management process? (FEHM - This is described by Figures 5, 6 and 7) Were the potential hazards fully recognized: fuel, oxygen-air and ignitionenergy sources? (Figure 4) What were the preventive barriers and controls? What plans and procedures were established to manage the potential job hazards? How did they or could they fail? Could these have been anticipated and addressed in the job planning stages? What events occurred that may have escalated the severity of events? What protective measures did or could have altered the outcome?

3 Figure Discussion 3 Understanding Fire and Explosion Mechanics: A Simplified Fault- Tree Analysis This is a simplified fault-tree-analysis diagram based on the Ball Energy Model. One important addition resulting from the analysis of fire and explosion case studies was the recognition that dealing with a closed system, there is a need to assess how oxygen may enter that system and the potential consequences should this occur. 4 Preventing Fires and Explosions - Understanding the Fire Triangle Based on the case studies reviewed, the committee ascertained that many of the incidents were the result of failure to recognize potential fire and explosion hazards. Figure 4 shows a more complete range of potential hazards related to fuel, oxygen and ignition sources. 5 Fire and Explosion Hazard Management (FEHM) Process This diagram depicts the relationship between an employer s philosophy, fire and explosion hazard management process and prevention plans and controls. 6 Stages of a Fire and Explosion Hazard Management Process This diagram depicts the five stages of an effective FEHM process. The figure includes reduced images of a number of the other figures to help clarify the relationships between the figures in this document. 7 Potential Fire and Explosion This diagram shows a list of potential controls that should be considered to prevent or reduce the risk of fires and explosions. 8 Fire and Explosions Overview of System Dynamics This diagram shows the complex interrelations between the three components of the fire triangle and the factors affecting the probability of ignition.

4 Figure 1 Investigation and Analysis of Fire and Explosion Incidents Incident Causation Model Management Supervisor Worker Fire & Explosion Hazard - Defenses Fire Explosion Incident Organizational Workplace Human Engineering Administrative Protective Determining the Nature of Incident Dynamics Understanding the Physical Operations Being Completed Identifying Site Layout, and Protection Assessing the Ability of People to Avoid Errors

5 What a company believes, their approach to hazard management, and what risk they are willing to accept. How and when a company plans to execute their philosophies. Inherently safe design Risk assessment Process safety management Emergency response Project design reviews Fire protection Safety management Explosion protection Practical procedures that are the nuts and bolts of a company s operations and FEHM. These procedures describe how to implement their strategies. System & Design Layout and Spacing Inspection & Maintenance Operating Procedures Gas and Fire Detection Emergency and Shutdowns Emergency Response and Procedures Fire Protection Systems Alarms and Detection / Suppression Systems Emergency Emergency Procedures Fuel Hydrocarbon Energy Ignition and Design Detection and Suppression Systems Operating Plans and Emergency Figure 2 Fire and Explosion Incidents: Relationship of Key FEHM Components Hazard Identification Risk Assessment Consequences Fire & Explosion Hazard Management Process (FEHM) Expanded Fire Triangle Fuel - HC - Gases - Liquids - Vapours - Chemical - Solids Oxygen - Air Energy Ignition Develop Fire & Explosion Prevention Plans - Implement Control Measures Preventive Barriers & Fire Explosion Incident Escalation Events Protective & Emergency Worker Injuries Fatalities Well Control Public Safety Environmental Impacts Damage Fire and Explosion. Strategy / Protocol A fire and explosion strategy is a systematic approach to identifying, reducing and managing hazards. A fire and explosion protocol is concise and FEHMH documents the company s approach on how it plans Philosophy to meet the overall hazard management philosophy of the company. Strategy / Protocol Procedures Procedures Procedures describing how strategy / protocol is implemented. What Can Go Wrong? Hazardous Material Oxygen s Ignition s STAGE 1 STAGE 2 Assessment of the Fire Evaluation of Alternative and Explosion Risk for Preventive & Protective the Planned Operations Control Measures Incident Experience Planned Operations Requirements What Are You Doing? Preventive Design Standards Operating Plans and Procedures Worker Training STAGE 3 STAGE Development of a Fire Implementa and Explosion Hazard Protective Management Strategy Preventive C Protective Heat (Ignition) FEHM Strategy Procedures Fuels [6] Oxygen (Air) Oxygen Air Control Figure XX Potential Control Methods Barriers Fuel Barriers Oxygen Fire Explosion InciSolvent d Barriers Ignition

6 Figure 3 Understanding Fire and Explosion Mechanics Fault-Tree-Analysis Diagram based on Ball Energy Model Hazard Barriers / Hazard Barriers / Hazard Barriers / Ignition Fuel Oxygen Heat (Ignition) FEHM Strategy Procedures Fuels [6] Oxygen (Air) Fire and Explosion Incident Must be considered for those operations where oxygen may be introduced into a closed system. For hydrocarbon releases into atmosphere, there is no opportunity to affect this dimension of the fire triangle.

7 Figure 4 Preventing Fires and Explosions: Understanding the Fire Triangle Heat / Ignition s [5] 1. Hot Work 2. Vehicles (Inluding engines and 3. Other Open Flames (i.e. Flare Stacks, Burners, Torches) 4. Electric Arcs and Sparks (i.e. non-explosion proof equipment) 5. Static Electricity 6. Hot Surfaces 7. Friction and Mechanical Sparks 8. Chemical Reactions and Sparks (i.e. fuel - oxidizer reactions) 9. Spontaneous Combustion 10. Pyrophors (i.e. Iron Sulphide) 11. Pressure / Compression Ignition (Dieseling) 12. Sudden Decompression 13. Catalytic Reactions Ignition / E FEHM Strategy Procedure Fuels [6] Oxygen / Air Oxygen s Planned Introduction of Air o Air-based operations o Air Purging Unplanned Introduction of Air o Underbalanced operations o Swabbing & other operations that create a vacuum o Pockets of air created during the installation and servicing of o Oxidized (Weathered) Hydrocarbons o Oxidizers o Chemical Reactions o On-Site Generated Nitrogen o Tank Drawdown Release of Hydrocarbons into Air Gases o Natural Gas o Hydrogen Sulphide o LPG Gases (Including propane and butane) o Other hazardous gases (i.e. hydrogen, acetylene, carbon monoxide) Liquids / Vapours o Crude oil / Condensate o NGL liquids o Hydrocarbon based frac fluids o Gasoline, Diesel & other fuels o Methanol Chemicals o Solvents and cleaning agents o Special compounded hydraulic fluids & lubricants o Chemicals used for well servicing and stimulations Solids o Lubricants o Sealants, o Packings, O rings, diaphragms and valve seats o Paints and Coatings

8 Figure 5 Fire and Explosion Hazard Management (FEHM) Process FEHM Philosophy What a company believes. Its approach to hazard management and what risk it is willing to accept. Fire and Explosion Management Process The overall strategic approach the company establishes for managing fire and explosion hazards. Hazard / Risk Assessment Assigned Responsibilities Education & Training Site-Specific Prevention Planning Inherently Safe Design Process Safety Management Safety Management Systems Communication (Worksite & Industry) Prevention Plans The specific measures that determine how the FEHM process is implemented. Preventive Barriers and FEHM Process System & Design This is the company s overall, systematic approach to identifying, reducing and managing hazards. It defines how and when a company plans to execute its philosophies. Fire and Explosion Prevention Plans These concise plans document the protocols required for specific operations. They show how the FEHM philosophy and program will be applied to a specific job and work site. Layout and Spacing Inspection & Maintenance Operating Procedures Protective & Emergency Gas and Fire Detection Emergency and Shutdowns Emergency Response and Procedures Fire Protection Systems

9 Figure 6 Stages of a Fire and Explosion Hazard Management Process What Can Go Wrong? Fuel Oxygen s Ignition s Preventive Design and Barriers Operating Plans and Procedures Worker Training STAGE 1 Assess Fire and Explosion Hazards for Planned Operations STAGE 2 Identify Need for Site- Specific Fire & Explosion Prevention Plan STAGE 3 Evaluate and Choose Fire and Explosion Control Measures STAGE 4 Develop & Implement Fire & Explosion Prevention Plan STAGE 5 Monitor Effectiveness & Revise Process as Needed Incident Experience Alarms and Planned Operations Requirements What Are You Doing? Detection / Suppression Systems Emergency Emergency Procedures Protective

10 Fuel Hydrocarbon Purge Out of Service (Clean or Clear) Isolate - Blank and Blind. (Lock-out / Tag Out) and Design Design Specifications Lease / Layout Vehicle Access Control Operating Plans and Practices Inspection & Maintenance Site-Specific Operating Procedures Codes of Practice & Related IRPs Material Inventory Control Material Substitution Emergency Shutdowns & Worker Training & Education Safe Work Permit System Oxygen Air Control Purging Into Service Seals & Gaskets Ventilation Inert Gas Blanket Figure 7 Potential Fire and Explosion Pre-Startup Safety Review Management of Change Evacuation Plans First Aid Area Classifications Grounding and Bonding Gas and/or Fire Detection Fire Control Spill Containment / Control Elimination of Open Flames O 2 / LEL sensors Escape & Routes Pressure / Temperature Control Warning & Alarm Systems Emergency Transporation Plans Explosion Proof Electrical Energy Ignition Fixed Fire Protection Systems Detection and Suppression Systems Emergency Response Plans (ERP) Emergency

11 Figure 8 Fire and Explosions Overview of System Dynamics What are the potential energy or ignition sources? What controls are in place to ensure worker and equipment safety? What are the oxygen or air sources? Can work activities introduce additional ignition sources? Energy Ignition Oxygen Air Ignition Delays: Is there enough time for the required heat transfer to take place? Are work activities causing oxygen/air to be added into the system? Is it possible for fuels to be released into the workspace? What are the potential fuel hydrocarbon sources? Fuel Hydrocarbon How are work activities affecting fuel quantity and quality? There are 3 key points that must be remembered: 1. Anytime all three sides of the fire triangle can co-exist, there is real potential for a fire or explosion. 2. There are 8 critical risk factors that increase the probability of a fire and explosion significantly. 3. The system is dynamic and circumstances change over time. As a result, safe situations may become unsafe.