Petrochemical Corporation of Singapore (Private) Limited No Reason for Not Learning Lessons – There are Many Valuable Resources Out There! Er. Lucas NG Hong Kiang General Manager of Plant, PCS & Resorts World Chairman, SCIC – GSPS Organising Committee Sentosa, Singapore Welcome to Singapore Source: website 2 No Reason for Not Learning Lessons – There are Many Valuable Resources Out There! 1. Introduction to PCS 2. Numerous Process Safety Wake-up Calls 3. Valuable Resources Out There! 4. Ownership 5. Be Learning Organisation 6. Conclusion and Takeaway Source: websites 3 No Reason for Not Learning Lessons – There are Many Valuable Resources Out There! 1. Introduction to PCS 2. Numerous Process Safety Wake-up Calls 3. Valuable Resources Out There! 4. Ownership 5. Be Learning Organisation 6. Conclusion and Takeaway Source: PCS 4 1. Introduction – PCS PCS operates its petrochemical plants for past 35 Years Jurong Island Singapore Petrochemical Corporation of Singapore Jurong Island (Private) Limited, PCS Source: websites 5 1. Introduction – PCS Upstream company of Singapore Petrochemical Complex on Jurong Island supply high quality ethylene, 1977 – incorporation (10 August) propylene, acetylene, butadiene, 1- butene, MTBE and benzene to companies within Island 1984 – first ethylene plant (cracker) in Southeast Asia on stream (18 February) 1997 – second cracker unit on stream (9 April) Source: www.pcs.com.sg 6 Incorporation of PCS – 10 August 1977 T Fukuda Lee Kuan Yew T Hijikata Japanese PM Hon Sui Sen PM President, SC FM Chairman, JSPC Reception on Incorporation of PCS Vice-chairman, - 14 August 1977 PCS Source: PCS 7 PCS 1st Ethylene Plant Start-up – 18 February 1984 Start-up of PCS , TPC, PPSC, and DSPL plants Source: PCS 8 First PM Mr Lee Kuan Yew visited PCS – 13 January 2001 Welcome Mr & Mrs Lee Mr & Mrs Lee visited PCS Central Control Updating Mr Lee Centre accompanied by government officials Source: PCS 9 No Reason for Not Learning Lessons – There are Many Valuable Resources Out There! 1. Introduction to PCS 2. Numerous Process Safety Wake-up Calls 3. Valuable Resources Out There! 4. Ownership 5. Be Learning Organisation 6. Conclusion and Takeaway Source: websites 10 2. Numerous Process Safety Wake-up Calls Many wake-up calls in the past decades to century right from the early industrialised Europe… Seveso Disaster : the Dioxin Crisis… …the creation of the 10 July 1976 - the ICMESA factory at European Community's Meda near Milan, Italy Seveso Directive Source: websites 11 2. Numerous Process Safety Wake-up Calls , 12 October Greek tanker Spyros exploded at Jurong Shipyard, Singapore Source: websites 12 2. Numerous Process Safety Wake-up Calls …Bhopal gas tragedy, the world worst industrial disaster …release 40 tons of methyl isocyanate (MIC) and other chemicals into the air …the creation of the Center for Chemical Process Safety, Responsible Care, ® Union Carbide pesticide plant in Process Safety Management , amended Bhopal, India… after 30 years Seveso-II (Directive 96/82/EC)… Source: websites 13 2. Numerous Process Safety Wake-up Calls …killing 15 workers, injuring 180 others 23 March 2005 and severely damaging the refinery … hydrocarbon vapor cloud was ignited and violently exploded at the ISOM isomerization process …addressed the asset integrity and reliability, operators competency and fatigue, safety, siting of temporary facilities etc.… Source: websites 14 No Reason for Not Learning Lessons – There are Many Valuable Resources Out There! 1. Introduction to PCS 2. Numerous Process Safety Wake-up Calls 3. Valuable Resources Out There! 4. Ownership 5. Be Learning Organisation 6. Conclusion and Takeaway Source: websites 15 3. Valuable Resources Out There! Health & Safety Executive, HSE European Process Chemical Safety Centre, Safety EPSC Board, CSB Process Safety Singapore Center for Chemical Chemical Industry Process Safety, Council, SCIC CCPS Major Hazard Department, MHD Source: websites 16 3. Valuable Resources Out There! Source: websites 17 No Reason for Not Learning Lessons – There are Many Valuable Resources Out There! 1. Introduction to PCS 2. Numerous Process Safety Wake-up Calls 3. Valuable Resources Out There! 4. Ownership 5. Be Learning Organisation 6. Conclusion and Always be Anticipate Resolve Issues Takeaway Prepared Risks Source: websites 18 4. Ownership Strengthen WSH Ownership Make WSH more salient in business decisions Align company directors and top management to WSH ownership Strengthen WSH ownership of workers Source: websites, WSH 2028 19 4. Ownership Senior Management Commitment and Ownership Management Responsible Advisory Care® Board Committee (Chair: MD / CEO) (5 HSE HSE personnel) Function HSE Safety & Health Contractors HSE Promotion Function HSE Management Working HSE Committee Committees Committee Committee Committee (Chair: GM of Plant) (Regulatory Requirement) Petrochemical Complex Contractors PCCA contractors’ representative as a Association (PCCA) member of RC Committee since 2004 Source: websites, PCS 20 4. Ownership Workplace Safety and Health (Major Hazard Installations) Regulations came into operation from 1 September 2017 Safety Case Written Presentations Descriptive information of Major Hazard Installations (MHIs) Major accident prevention policy (MAPP) & safety and health management system (SHMS) Predictive aspects (risk assessment) Technical aspects (preventive & mitigation measures) Senior Management Management Senior Emergency response aspects Commitment and Ownership ALARP (As Low As Reasonably Practicable) demonstration 21 No Reason for Not Learning Lessons – There are Many Valuable Resources Out There! 1. Introduction to PCS 2. Numerous Process Safety Wake-up Calls 3. Valuable Resources Out There! 4. Ownership 5. Be Learning Organisation 6. Conclusion and Takeaway Source: websites 22 5. Be Learning Organisation Incident reports review for gaps closure Form Taskforce Review Gaps Recommend / TOR Improvements Source: PCS, websites 23 5. Be Learning Organisation Management must have a vibrant process safety system that is beyond regulatory requirement, learning lessons of past incidents Review report for gaps closure… Source: PCS 24 5. Be Learning Organisation BP Texas City Refinery Explosion – 23 March 2005 . Budget for infrastructure and process equipment maintenance . Budget for employees training, including specialised training . Competency and experience level of inspectors . Carry out inspections according to plan; enforce safety rules . Fatigue during shift work; fatigue management system – guidelines for work on rotating shifts Source: websites; CSB 25 5. Be Learning Organisation Buncefield Oil Storage Depot Fire – 11 December 2005 Before After . “Clear and positive process safety leadership is at the core of a major hazard business and is vital to ensure that risks are effectively managed. It requires board- level involvement and competence” . “Board-level visibility and promotion of process safety leadership is also essential to set a positive safety culture throughout an organisation” Source: COMAH, Control of Major Accident Hazards 26 5. Be Learning Organisation Forms of Lesson – Competency Development Video Presentation Suggestion Scheme Presentation Process Safety Boot Camp Incidents Sharing session Source: PCS, websites 27 5. Be Learning Organisation 1st Process Safety Competency Development – Boot Camp John Murphy & Louisa Nara John Murphy & Byron Sun 4th 2nd session – July 2014 3rd session – June 2015 4th session – Sept 2016 th 5 session – July 2017 th Byron Sun & Jim Conner 5 http://onlinelibrary.wiley.com/doi/10.1002/prs.11879/pdf Source: PCS 28 5. Be Learning Organisation Internal lessons – process safety near-misses, minor incidents Various in-house sharing and training sessions Source: PCS 29 5. Be Learning Organisation Sharing of lessons learnt – monthly incidents sharing, staff meeting… Monthly incidents sharing… staff and contractors …Staff meeting with incidents sharing Source: PCS 30 5. Be Learning Organisation …Sharing of lessons learnt – daily day-and-shift staff operations meeting, shift-begin meeting etc. Shift-begin meeting with incidents sharing Always maintain a sense of vulnerability, create environment and seize every opportunity to share past incidents for learning valuable lessons… Source: PCS 31 5. Be Learning Organisation Process Safety Book (e.g. CCPS) reading and sharing… Source: PCS, website 32 5. Be Learning Organisation CCPS Asia Pacific Regional Technical Steering Committee Meeting in Singapore 2 October 2018 Collaboration between CCPS and SCIC Emphasized Process Safety Management Strong support from Asia Pacific Region Source: PCS 33 5. Be Learning Organisation CCPS Asia Pacific Regional Technical Steering Committee Meeting in Singapore 2 October 2018 Fruitful discussion and sharing of ideas to further secure the safety and health of the industry Source: PCS 34 5. Be Learning Organisation CPCIF (中国石油和化学工业联合会) visited PCS – 5 June 2017 Responsible Care® Process Safety Code of Management Practices . supplement existing process safety requirements . leadership, accountability and culture… . …information and experience sharing for continuous improvement Source: PCS 35 5. Be Learning Organisation Zibo City CIA (山东淄博市化学工业协会) visited PCS – 11 August 2017 PCS shared… Always be Anticipate Resolve Prepared Risks Issues …covering various areas ranging from safety, security, operations and reliability management, and sharing excellent insights on process safety and reliability Source: PCS 36 No Reason for Not Learning Lessons – There