Barrier Management over

the Lifecycle
David McDade
Training Consultant
Risktec Solutions Limited

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David McDade

David is a Risk Management and Training Consultant based in Risktec’s

Glasgow office (having also been previously based in Warrington and
Dubai).
He has over 16 years of risk management and technical safety engineering
experience in multiple high-hazard industries including oil and gas, clean
energy and civil nuclear.
David's key experience includes leading Hazard Identification (HAZID) and
bowtie analysis studies, safety/HSE case production, and the development
and delivery of training, including at MSc level.

[email protected]

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Longford, Australia gas explosion of 1998

Trouble brewing

“prior to any disaster there will always be information

somewhere within an organisation that trouble is
brewing”
“critical information must not be allowed to lie around
unrecognised, ignored or buried like some landmine
waiting to be triggered.” 1

Professor Andrew Hopkins

Fairfaxmedia/THE AGE/ RAY KENNEDY. - https://www.icheme.org/knowledge-networks/safety-

centre/news/the-long-view-on-longford/

1 Lessons from Longford: The Esso Gas Plant Explosion, Hopkins, 2000

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Agenda
 So what do we need to know?
o Risk identification and assessment
o Bowties

 How are we managing risk?

o Confidence in the barriers now
o Confidence into the future

 Understanding and communicating barrier health and responsible parties

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So what do we need to know?
1. What could cause us harm?
 What are our major hazards that could lead to a potential incident?

2. What will protect us?

 What are the critical barriers (safeguards) we rely upon to control these risks?

3. How do we know?
 Are we confident the barriers will function as designed when required?
 What is the minimum level of performance required?
 Are these critical barriers available and effective throughout the life of our asset?

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Risk identification and assessment process
Identify Assess Manage

Record in Hazard
Register

Identify Assess Demonstrate control

Hazards Risks using Bowtie or
Major similar method
Hazard Checklist Risk Assessment Matrix
Medium
Risk Record in Hazard
Register

Demonstrate control
Low Risk through HSE
Management System

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Bowtie structure

Hazard

Consequences
Threats

Preventive Top Mitigative

barriers Event barriers

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Bowtie example

Prevention Mitigation

Hazard

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How controls are made effective in bowties
Hazard

• Check accuracy
and currency
• Verify
performance
• Ensure
awareness

HSE Critical Activities  Job descriptions

 Competency

 Performance standards
Safety and Env. Critical Element  Performance criteria

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How this looks on a bowtie

 Safety and Environmental Critical Elements (SECE)

 Hardware barriers
 Managed by Performance Standards (which define inspection,
testing, maintenance requirements)

 HSE Critical Tasks / Activities

 Human barriers
 Group or set of tasks/actions necessary for the development,
implementation, operation or maintenance of a barrier

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Bowtie Barriers Example

Hydrocarbons in
pipeline

Loss of
containment
Corrosion

Pipeline design (fully Inspection or

Corrosion inhibitor
rated, appropriate for monitoring of pipeline
automatically injected
contents) condition

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Bowtie Barriers Example

Hydrocarbons in
pipeline

Loss of
containment
Corrosion

Pipeline design (fully Inspection or

Corrosion inhibitor
rated, appropriate for monitoring of pipeline
automatically injected
contents) condition

SECE Safety SECE Safety HSE Critical Task

Environmental Environmental
Critical Element Critical Element

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SECEs & bowties

Hazard

Engineered systems as
barriers on major
accident hazard bowtie
diagrams are SECEs

Safety and Env. Critical Element  Performance standards

 Performance criteria

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SECEs

Bowties will identify SECEs - each barrier that is

dependent on a Critical system or equipment

…to ensure each risk

control works…
SECE

Performance Standard Maintenance and Inspection Requirements

Maintenance
Assess Integrity Mgmt System
SECE performance may be independently verified against requirements
through independent Technical Integrity Management
Scheme…
Technical Integrity Verification Plan

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How can we communicate this?
 A Key Performance Indicator (KPI) is a measure / evaluate trends or success at reaching specific
defined targets

 Can be described as ‘Leading Indicators’ or ‘Lagging Indicators’

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KPI dashboard

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HSE Critical Activities and bowties

Hazard

Personnel who
undertake SCE
performance
assurance activities
are in safety-critical
roles, as well as those
who carry out “human
intervention actions”

HSE Critical Activities

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Who’s responsible & what must they do?

Torch, pool
or flash fire
Gas detection Detect leak & Muster & Fireproof
10% LEL >> alarm via account for supports
alarm, 40% >> operator rounds personnel Mech. Eng
plant ESD feed or CCTV. Plant Training Coord
trip & isolation S/D at local
ESD buttons or
C/R Muster areas
impaired
Instr. Tech Operator
Multiple muster
areas on site,
People are required plus offsite
to ensure plant point
functions as intended Safety Eng

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Link between bowties and training & competence

Competent people provide

resilience against major risks

…to ensure each risk

control works…
Critical activity Critical activity catalogue

Critical role Accountability packs

…use
Activity competencies Competency
Mgmt System
Assess people
against
Training requirements
requirements

20 Personal T&D plans

HSE Critical Tasks

 By taking each HSE Critical Task in turn, we can group them by Job Role

= Asset Manager = Shift Supervisor

= Operations Manager = Laundry Attendant

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HSE Critical Tasks by Job Role

Asset Manager Operations Manager Shift Supervisor Laundry Attendant

 1. Ensure competency of  1. Ensure ongoing  1. Conduct appropriate  1. Remove fluff from the
personnel hired for HSE competency of supervision of personnel tumble dryers
Critical Positions personnel in HSE  2. Monitor process
 2. Manage HSE MS Critical Positions conditions
Interface/Bridging  2. Schedule  3. Respond to alarms in
Documentation housekeeping audits accordance with alarm
 4. Ensure appropriate  4. Implement and management guidelines
Emergency Response manage PTW system  4. Maintain headcount
Plan in place  5. Implement and inventory for personnel on
 5. Approve override of maintain ERP and site
safety features on any implement training and  5. Update permit register
equipment. emergency response  6……..
 6…… drills
 6…….

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The Laundry Attendant example

Laundry Attendant Responsibilities:

 Sort, wash, dry, press, and fold clothing and other textile items
 Remove stains from items using the appropriate procedures
 Perform minor sewing duties
 Track which items belong to whom
 Keep an updated inventory of laundry detergents and sewing kits
 Remove fluff from the tumble dryers
 Ensuring that the facility remains clean at all times
 Respond to user queries, concerns, and complaints

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How can we communicate the HSE Critical Tasks

 Job descriptions which clearly identify HSE Critical Tasks

 Presentations
 Posters
 Information available on intranet

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Handbooks for all personnel

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Software showing barrier status

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Conclusion
 The barrier management approach using bowties defines:
o SECEs
o HSE Critical Activities
 These are managed through MMS and Competency Management System

 Further communication and management is beneficial:

o KPI dashboards
o Critical roles booklets
o Software showing barrier status

 This wholistic approach enables risks to be better understood and hence proactively managed,
not only today but through-life

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Thank you

Have a safe and secure day!

[email protected]
risktec.tuv.com
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