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    Karen Haase - 1287621537

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    The document summarizes the key aspects of ANSI/API RP 755, which provides guidelines for developing and implementing Fatigue Risk Management Systems (FRMS) for personnel in the refining and petrochemical industries. It outlines the scope and framework of an FRMS, including components like staffing and workload balance, safety promotion through training, investigating fatigue-related incidents, and establishing hours of service guidelines. The goal is for companies to adopt comprehensive, science-based FRMS programs to systematically manage fatigue risks to process safety.

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    Karen Haase - 1287621537

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    rendy_perdana3
    86 views30 pages
    The document summarizes the key aspects of ANSI/API RP 755, which provides guidelines for developing and implementing Fatigue Risk Management Systems (FRMS) for personnel in the refining and petrochemical industries. It outlines the scope and framework of an FRMS, including components like staffing and workload balance, safety promotion through training, investigating fatigue-related incidents, and establishing hours of service guidelines. The goal is for companies to adopt comprehensive, science-based FRMS programs to systematically manage fatigue risks to process safety.

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    The document summarizes the key aspects of ANSI/API RP 755, which provides guidelines for developing and implementing Fatigue Risk Management Systems (FRMS) for personnel in the refining and petrochemical industries. It outlines the scope and framework of an FRMS, including components like staffing and workload balance, safety promotion through training, investigating fatigue-related incidents, and establishing hours of service guidelines. The goal is for companies to adopt comprehensive, science-based FRMS programs to systematically manage fatigue risks to process safety.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    86 views30 pages

    Karen Haase - 1287621537

    Uploaded by

    rendy_perdana3
    The document summarizes the key aspects of ANSI/API RP 755, which provides guidelines for developing and implementing Fatigue Risk Management Systems (FRMS) for personnel in the refining and petrochemical industries. It outlines the scope and framework of an FRMS, including components like staffing and workload balance, safety promotion through training, investigating fatigue-related incidents, and establishing hours of service guidelines. The goal is for companies to adopt comprehensive, science-based FRMS programs to systematically manage fatigue risks to process safety.

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    of 30

    Report on ANSI/API RP 754

    Process Safety Performance


    Indicators in the Refining &
    Petrochemical Industries
    Karen Haase
    API

    Mary Kay OConnor Process Safety Center


    International Symposium
    College Station, TX

    Process Safety Incidents


    Highest potential for multiple injuries/deaths
    Highest potential for significant environmental harm
    Highest potential for significant property damage
    Highest potential for significant business interruption
    Highest potential for damage to reputation

    VG - 2

    CSB Recommendation to API & USW


    Work together to develop two new consensus American
    National Standards Institute (ANSI) standards. In the first
    standard, create performance indicators for process
    safety in the refinery and petrochemical industries.
    Ensure that the standard identifies leading and lagging
    indicators for nationwide public reporting as well as
    indicators for use at individual facilities. Include methods
    for the development and use of the performance
    indicators.

    VG - 3

    RP 754 Committee Membership


    Academia (1)
    Associations (5)

    Owner/Operators
    Refiners (10)

    Engineering & Construction


    (1)

    Owner/Operator
    Chemicals (4)

    Government (1)
    Labor (3)withdrew 8/09

    Total Recordable Incident Rate vs. Calendar


    Year U.S. Refineries

    Expectation that RP-754 will


    aid in driving similar
    improvements in process
    safety performance

    VG - 5

    Process Safety Indicator Pyramid

    Broad Access [Nationwide]


    Public Reporting

    Tier 1
    LOPC Events of
    Greater Consequence

    Tier 2
    LOPC Events of Lesser
    Consequence

    Tier 3
    Challenges to Safety Systems

    Tier 4
    Operating Discipline & Management System
    Performance Indicators

    Tiers 1 & 2 are


    RP-754
    standardized
    definitions
    Tiers 3 & 4 are
    company
    defined
    performance
    indicators

    Tier 1 & 2 -- Process Safety Event


    An unplanned or uncontrolled release of any material,
    including non-toxic and non-flammable materials from a
    process that results in one or more of the consequences
    listed below:
    Harm to people; or
    Impact upon the community; or
    Damage to equipment; or
    A release of a threshold quantity
    PSE Rate = [Total PSE Count/Total Work Hours] x 200,000

    Tier 3 Challenge to Safety Systems


    Purpose
    Typically represent challenges to the barrier system that
    progressed along the path to harm, but were stopped short
    of a Tier 1 or Tier 2 PSE consequence
    Examples
    Safe Operating Limit Excursions
    Primary Containment Inspection or Testing Results Outside
    Acceptable Limits
    Demands on Safety Systems
    Other LOPC Events

    Tier 4 Operating Discipline & Management System


    Performance
    Purpose
    Typically represent the performance of individual
    components of the barrier system
    Indicative of process safety system weaknesses that may
    contribute to future Tier 1, 2 or 3 PSEs
    Examples
    Process Safety Action Item Closure
    Training Completed on Schedule
    Safety Critical Equipment Inspection
    Completion of Emergency Response Drills

    Primary Modes of Implementation


    Report everything . . . Database sorts it out
    Train personnel to identify and report Tier 1 & 2 events

    VG - 10

    RP 754 Adoption Plans


    API, NPRA, OGP, and CONCAWE have committed to 2010
    data collection
    CCPS is reviewing the future of its document
    ACC plans to pilot
    IPIECA is vetting the reporting requirements with their
    stakeholders
    UK HSE provided positive comments during the ballot period

    Benefits of Participation
    Consequence analysis
    No. & % DAFWC / Fatalities
    No. & % Fires
    No. & % Explosions
    No. & % Acute Releases
    Industry benchmarking
    Event analysis
    Type of process
    Mode of operation
    Point of release
    Type of material

    Broad Access [Nationwide] Public Reporting


    Annually, each Company publicly reports Tier 1 and Tier 2
    PSE information

    2010 Implementation
    2011 Data validation
    2012 Industry aggregated result
    2013 Industry and Company blinded results
    2014 Industry and Company transparent results
    Tier 2 reporting may lag Tier 1 by one year

    Local [Site] Public Reporting


    Each site determines the appropriate methods to
    communicate PSE information
    Annual report of site-specific Tier 1, 2, 3 and 4 PSE
    information to employees and employee representatives
    Annually, each Company makes available a summary of
    site-specific Tier 1 and 2 PSE information and may report
    site-specific Tier 3 and 4 PSE information to the local
    community and emergency management officials

    Performance Targets
    Process safety performance is dynamic and complex,
    and must be managed over the entire life cycle of a
    facility
    Due to the long wave length, performance targets
    should be multi-year
    For example, a 25% reduction in total Tier 1 PSEs over 5
    years is a more appropriate target than a 5% reduction
    year over year

    VG - 15

    Conclusions
    Process safety incidents result in devastating
    consequences
    Adopting RP-754 provides a significant opportunity for
    industry to improve process safety performance
    Similar success has been demonstrated in occupational
    safety performance

    VG - 16

    Report on ANSI/API RP 755


    Fatigue Risk Management Systems
    For Personnel in the Refining &
    Petrochemical Industries
    Ron Chittim
    API
    Mary Kay OConner Process Safety Center
    International Symposium
    College Station, TX

    RP 755 Committee Membership


    Owner/Operators
    Refiners (8)

    Owner/Operator
    Chemicals (4)
    Academia (1)

    Engineering & Construction


    (2)

    Associations (3)

    General Interest (2)

    Government (0)

    Labor (2) Withdrew 8/09

    VG - 18

    Fatigue Risk Management System: RP 755


    Finding:
    It has not been possible for the Investigation Team to directly attribute
    actions or inactions of the operators and supervisors to fatigue.
    However, this extended working period clearly has the potential to
    contribute to a lack of attentiveness, and slowness to identify and
    respond to process upsets.

    Recommendation:
    ...API and the United Steel Workers union work together to develop
    fatigue prevention guidelines that would, at a minimum, limit hours and
    days of work and address shift work ... developed in conformance with
    ANSI principles and the composition of the working group developing
    the guidelines should be diverse

    Overview of Key Concepts


    Committee recognized that addressing fatigue goes well beyond hours of
    service and days of work

    Comprehensive Fatigue Risk Management System (FRMS) approach adopted

    FRMS to be integrated with other safety management systems


    FRMS should be informed by sound science and recognize operational issues
    Key stakeholders shall be consulted in developing and implementing the local
    application of the FRMS

    Culture of fatigue risk management should be created in which the shared


    responsibility of mitigating risk is recognized
    Scope of work excluded matters subject to collective bargaining like overtime

    Scope & Positions Covered


    Refineries, petrochemical and chemical operations, natural gas liquids
    extraction plants, and other facilities such as those covered by the OSHA
    Process Safety Management Standard, 29 CFR 1910.119
    Applies to locations where employees commute to work
    Does not apply to locations where employees are housed on-site
    On-site contractors expected to have equivalent programs

    Employees working night shifts, rotating shifts, extended hours/days or call


    outs involved in process safety sensitive actions

    RP 755 - FRMS Framework


    Staff-Workload Balance
    Safety Promotion: Training, Education & Communication
    Work Environment

    Incident/Near Miss Investigation


    Hours of Service Guidelines
    8, 10 & 12 hour shifts
    Normal Operations, Outages & Extended Shifts
    Call-outs
    Exception Process
    Periodic Review of FRMS to Achieve Continuous Improvement

    Staff Workload Balance & Work Environment


    Assess staffing levels and workload balance initially and periodically,
    including consideration of:
    Workload variability incl. start-ups, shutdowns, unplanned events and
    emergency management situations
    Turnover, absenteeism & workforce demographics

    FRMS should consider type of work being performed


    Where possible, the work environment should be designed to enhance
    alertness
    Brightly lit utilizing indirect lighting to avoid glare and eye strain
    Indoor temperature and humidity should be in a comfortable range
    Workstations should be designed utilizing ergonomic principles

    VG - 23

    Training, Education & Communication


    Employees & Family Members: Initial and recurring training that
    includes:

    Basic sleep, circadian & fatigue physiology

    Strategies for achieving good quality, restorative sleep

    Healthy lifestyle choices in 24/7 operations

    Risks & signs of fatigue impairment in their work environment and


    work duties and effective ways of mitigating them

    Supervisors: Initial and recurring training that includes:

    The scientific basis, structure and management of the corporate FRMS

    Influence of staffing levels on employee fatigue

    Effects of work and rest scheduling on employee fatigue

    Managing a team of employees to minimize fatigue risk


    VG - 24

    Incident/Near Miss Investigation


    Investigations of incidents should consider role of fatigue
    Fatigue-related information collected should include:

    time of incident
    shift pattern incl. number of consecutive shifts worked
    number of hours awake
    number of hours slept in last 24 hours for individuals involved

    For some incidents, concluding a definitive role of fatigue may not be


    possible
    Aggregate analysis of incidents may reveal patterns suggestive of the role of
    fatigue that may not be apparent when evaluating individual incidents

    Hours of Service Guidelines


    Hours of Service Guidelines have been developed:

    In the context of the existence of a comprehensive FRMS

    Recommendations for 8, 10 & 12 hour shifts

    Will address normal operations, outages and extended shifts

    Guidelines will identify the upper limits for hours of service

    Consistently working at the upper limits is not sustainable and may


    lead to chronic sleep debt

    In addition to the upper limits, the FRMS should provide target hours
    of service for normal operations

    Objective of limits is to establish triggers at which additional fatigue


    risk evaluations need to be performed

    12 Hour Shifts
    Normal Operations

    Work sets shall not exceed 7 consecutive day or night shifts


    To permit 2 consecutive nights sleep after a work set:
    + There shall be 36 hours off after a work set or
    + Minimum of 48 hours off after a work set containing 4 or more night shifts or
    + Minimum of 48 hours off after a total of 84 hours worked regardless of day or night shift

    Outages

    Work sets shall not exceed 14 consecutive day or night shifts


    There shall be a minimum of 36 hours off after a work set
    Time off beyond 36 hours shall be addressed at the plant level

    Extended Shifts (i.e., shifts greater than 14 hours)

    Shall occur only when necessary to avoid an unplanned open safety critical position or
    accomplish an unplanned safety critical task
    Shall be managed by an established management process
    After shifts of 14 -16 hours, a minimum of 8 hours off shall be provided before returning for
    next shift
    After shifts greater than 16 hours, a minimum of 10 hours off shall be provided before
    returning for next shift
    Extended shifts shall not exceed 18 hours
    No more than 1 extended shift longer than 14 hours should occur in a work set

    Periodic Review of FRMS Continuous Improvement


    FRMS should undergo periodic assessments of its effectiveness and identify
    opportunities for continuous improvement
    Targets should be set for key parameters of FRMS such as:

    Percentage overtime

    Number of open shifts

    Number of extended shifts

    Number of exceptions

    Metrics gathered to determine if targets are being met

    Plans should be developed to close gaps between targets and actual FRMS
    performance

    Questions?
    Contact Information

    Ron Chittim
    API
    202/682-8176
    [email protected]

    Karen Haase
    API
    202/682-8478
    [email protected]

    Electronic download of RP 754 and RP 755


    http://api.org/standards/psstandards/

    VG - 29

    Hours of Service Guidelines


    Operational Situation

    12-Hour Shift

    10-Hour Shift

    8-Hour Shift

    Maximum Consecutive Shifts (Day or


    Night) In a Workset
    a) Normal Operations
    b) Outages

    7 shifts
    14 shifts

    9 shifts
    14 shifts

    10 shifts
    19 shifts

    Minimum time off after a workset


    a) Normal Operations
    Workset of 4 or more night shifts

    36 hours
    48 hours

    36 hours
    48 hours

    36 hours
    48 hours

    48 hours

    48 hours

    48 hours

    36 hours

    36 hours

    36 hours

    18 hours

    16 hours

    16 hours

    N/A
    N/A
    8 hours
    10 hours

    N/A
    8 hours
    8 hours
    N/A

    8 hours
    N/A
    N/A
    N/A

    1 14 hour shift or
    2 12 hour shifts or
    for 3 or more 12 hour
    shifts, follow 12 hour
    normal operations
    guidelines above

    2 if greater than12
    hours in duration;
    extended shifts must
    be non-consecutive
    If >2, follow 12 hour
    normal operations
    above

    After 84 hours or more regardless of day or night

    b) Outages
    Extended Shifts
    a) Unscheduled maximum shift
    b) Time off after shift
    10 16 hour shift
    12 16 hour shift
    14 16 hour shift
    >16 18 hour shift

    Maximum Number of Extended Shifts per Workset

    VG - 30

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