Hazards Process Safety Conference

Programme

Tuesday 5 November

10:30–12:30 Workshops

  • Sphera Solutions
  • Wolters Kluwer
  • IChemE
  • IChemE Safety Centre

13:30–13:45 Opening session

Welcome, Eamon Chandler, Chair, Hazards 34 Technical Committee

13:45–14:30 Plenary presentation

Bhopal, 40 Years On
Fiona Macleod, Independent Consultant

In her presentation, Fiona will mark the 40th anniversary of the Bhopal disaster, the lessons learned and the ongoing issues at the site.

15:00–17:15 Parallel sessions

Hazards Studies

Introducing C3HazOp
Harvey Dearden, SISSuite, UK

‘Computer HazOp’ or CHazOp is a recognized method for assessing risks associated with system architectures, but the actual scope and methodology to be adopted is rather confused with different approaches urged by different practitioners. Common Cause Control HazOp (C3HazOp) provides a highly focused method that cuts down the workload and helps maintain participant engagement, without which the study can be very seriously weakened. This paper will outline the method and report on experience with pilot studies conducted on a user facility.

How Have Hazard Studies Changed Post Covid?
Alison McKay, TUV, UK

Before Covid-19 hazard studies were invariably conducted face-to-face with all the team present in one room. During the Covid-19 lockdowns we proved that we could continue to facilitate good quality hazard studies remotely. This paper discusses how conducting hazard studies has changed, maybe permanently, post Covid with many studies continuing to be carried out remotely, or as a hybrid (partly face-to-face, partly remote).

Effective HAZOP to LOPA Scenario Transition
Dave Green, RPS Group, UK

The question of when to progress scenarios from hazard studies (typically Hazard and Operability Studies) to further risk assessment deriving Safety Integrity Levels is a hot debated topic. This paper builds on hazard study facilitation experiences across many hundreds of hours determining the scenarios which should be transitioned/ reviewed in SIL determination. 

A Fault Tree Approach to Assessing the Effectiveness of Non-Physical Safety Measures to Protect Underground Pipelines
Michael Acton, DNV, UK

Underground pipelines undergo a variety of influences that threaten their integrity including external interference, external corrosion, ground movement and material and construction defects. This paper describes the development of the fault tree model to evaluate selected measures chosen by the participating companies as practical options, and the review and analysis of relevant information identified from the published literature and from previous research made available to the project by participating companies.

New Energies

Ensuring Safety and Confidence: Navigating the Transition to Net Zero
Max Walker, HSE, UK

Many of us have been raised in environments where we have been surrounded by, and even worked in, locations with significant hazard risks. While broader society acknowledges these risks as inherent to modern life, it does so with the expectation that independent regulatory bodies will advocate for and monitor businesses' adherence to relevant laws, intervening when standards and performance fall short. This paper will expand on the work HSE is focusing on to understand and analyse the demand for our resources, and how we can achieve the best regulatory outcomes.

Navigating the Hazards of Large-Scale Ammonia Terminals
Karina Almeida Lenero, Gexcon, UK

This paper will discuss the risk resulting from loss of containment scenarios at large ammonia import/ export terminals, focusing on the toxic hazards. It will explore the main scenarios contributing to the toxic risk, in particular releases from bunkering systems and large storage tanks.

Approach to Fusion Safety
Omar Afify, UK Atomic Energy Authority, UK

This presentation will aim to outline the approach adopted by UKAEA to conduct safety assessments and develop safety cases for future fusion power plants.

A Methane Emissions Management System Framework
Tiago Jacques, ANP, Brazil

Methane is considered an important cause in climate change. However, given its value as a viable energy resource, methane emissions from anthropogenic activities represent not only an environmental challenge but also a missed economic opportunity. This paper proposes a novel approach to methane emissions management, aiming to bridge the gap between environmental stewardship and financial benefit.

Digitalisation I

Process Safety Risk Reduction by Integrating Advanced Data Analytics and AI-Driven Safety Systems
Fayaz Abdul Lathif, Chola MS Risk Services, India

The incorporation of advanced analytics and AI-driven safety systems into process safety frameworks represents a paradigm shift towards more predictive, proactive, and preventative safety management. This paper aims to clarify these transformative technologies, demonstrating their critical role in advancing process safety and protecting lives, assets, and the environment.

Geometric Process Control Models for Abnormal Process Event Detection and Warning
Alan Mahoney, Process Plant Computing, UK

Geometric Process Control (GPC) models for process operation have been found to outperform other models for abnormal event detection. This paper reports the results obtained against fault-detection benchmarks of the Tennessee-Eastman challenge problem which shows the sensitivity of GPC models for change detection. It also presents industrial case studies including an ethylene cracker furnace.

Is AI the Answer?
Carolyn Nicholls, RAS, UK

Artificial intelligence is increasingly changing the way we live our lives. How does it fit with high hazard industry, particularly when it comes to process safety management? What are the advantages of AI for you and your site? Can it help you in mitigating your risks? Is it the panacea you’ve been looking for? This paper will explore the pros and cons of AI in HAZOPs, with a particular focus on the human factors.

ADNOC Offshore – NASR Field Journey Towards Autonomous Operation
Arun Chandran, ADNOC, UAE

This paper outlines ADNOC Offshore - NASR Field's journey towards autonomous operations. Despite its initial design as a "Digital Oil Field" with advanced instrumentation, control and telecom systems, the asset still relies on human oversight. By leveraging its state-of-the-art infrastructure, NASR Field team aims to minimize human-system interaction, enhancing both Health, Safety, and Environment and operating efficiency through a technology-driven, people and process-oriented transformation.

Learning from Accidents

Preventing Serious Injuries and Fatalities – We Just Aren’t Getting Any Better
Daryl Wake, DEKRA, UK

This presentation calls for a paradigm shift in safety management. It advocates for a more nuanced, forward-thinking approach that transcends traditional models like the Heinrich Triangle. This new approach emphasises continuous improvement, predictive accuracy, and targeted interventions for high-risk activities.

What Is Your "Aha" Moment? Driving Curiosity to Improve Process Safety Culture
Douglas Eastaugh, Shell, UK

Learning from incidents and near misses is challenging, prompting organisations to invest heavily in improving their systems, which often remain complex and time-consuming to manage. Shell developed a two-stage plan to enhance process safety culture through the Major Accident Hazard Awareness (MAHA) Site, which shares impactful stories and monthly "MAHA Moments" to build awareness. This paper will show how this plan has been developed and early successes as it is rolled out and becomes more established within Shell. 

The Questions of Recurring Incidents; Why and How to Stop Them?
Ian Clarke, Swiss Re Corporate Solutions, UK

This presentation will focus on competency validation in the insurance industry, emphasising the importance of ensuring operators perform correctly in both standard and emergency situations. Through examples of preventable incidents, we will explore methods to improve and validate operator training, aiming to enhance decision-making and safety outcomes.

Identification of Drivers of Critical Safety by Leveraging Natural Language Processing
Mohammad Zaid Kamil, Dalhousie University, Canada

This paper introduces a data-driven methodology to assess drivers of critical safety (DCS) in the process industries using natural language processing to extract insights from incident reports. Developed by the US Chemical Safety and Hazard Identification Board, this approach enhances safety management by automating the identification of DCS and integrating lessons learned into a robust, proactive safety management system.

17:30–18:00 Trevor Kletz Lecture

The Challenges Facing the Process Industries
Marlene Kanga AO FTSE FREng FAICD, Rux Energy

18:30–19:15 Welcome reception in exhibition area


Wednesday 6 November

09:00–09:45 Plenary presentation

New Technologies, Developments and Energy Transition
Professor Andrew Curran, HSE

In his presentation, Andrew will talk about new technologies, developments and energy transition.

09:45–10:30 Plenary presentation

H2: The Risks and the Opportunities
Owen Quake, bp

In his presentation, Owen will give an overview of bp's H2 strategy, the key risks from the H2 value chain and managing these risks in a changing industry – encouraging delegates to consider how industry can support safe and sustainable transition to H2-CCS.

11:00–13:00 Parallel sessions

Hydrogen Safety 1

Dolphyn Hydrogen: Safety and Regulatory Challenges in the Offshore Production of Hydrogen from Wind
Laura Bond, ERM, UK

This presentation will cover the Dolphyn Hydrogen project, focusing on its innovative offshore hydrogen production, safety design aspects, and lessons learned during FEED. It will address hydrogen safety challenges, the operation of unmanned installations, electrolyser effectiveness in offshore environments, and the approach to compliance within an incomplete regulatory framework, concluding with key findings and next steps.

LTS Futures: Development of Safe Hydrogen Pipeline Operational Procedures
Max Koronka, SGN, UK

The LTS Futures programme is a pioneering £30 million project, jointly funded by OFGEM, SGN, and UK gas distribution networks, to repurpose a 30 km natural gas pipeline to hydrogen for a live demonstration. This presentation looks at practical aspects of a hydrogen pipeline operation, such as maintenance, public acceptance, and emergency response, including live welding and hot tapping trials, with significant offsite testing to inform safety and operational procedures for hydrogen service.

The Interpretation of IGEM/TD/1and IGEM/TD/13 Supplements for Hydrogen Service to Develop and Apply Repurposing Procedures to the National Transmission System
Gary Senior, Pipeline Integrity Engineers, UK

National Gas Transmission is preparing to transition the UK's 7,628 km National Transmission System from natural gas to hydrogen delivery, addressing challenges in material degradation, capacity assessment, and operational issues. This presentation will detail the comprehensive repurposing procedure developed in compliance with IGEM standards, focusing on technical assessments, modifications, and risk management necessary for pipeline adaptation to hydrogen and carbon dioxide transport.

Assessment of Risk and Reliability Challenges in Different Value Chain of Hydrogen Systems
Xueli Gao, Institute for Energy Technology, Norway

This paper reviews current risk and reliability assessment methods for hydrogen technologies across the value chain, from production to use, highlighting the importance of managing hydrogen's high flammability for safe deployment and public acceptance. It identifies research needs and gaps, including hazard identification, safety risk management, and human factors analysis, based on industry input and literature.

Risk Assessment & Management 1

Evolving the Hierarchy of Risk Control from Blunt Instrument to Precision Tool for Cutting Risk
Andrew Brazier, AB Risk, UK

This paper presents an expanded hierarchy of risk controls, incorporating inherent safety and emphasizing the role of human actions in managing process safety risks. Through detailed examples, it aims to facilitate a more productive discussion on inherent safety, human factors, and the ALARP (As Low As Reasonably Practicable) principle.

Risk Appetite in Heavy Industries, an Insurance Prospective
Soondus Moorhead, CNA Hardy, UK

This presentation will introduce attendees to the fundamentals of specialty insurance in heavy industries, focusing on the role of insurance in promoting process safety and best practices. Key topics include risk transfer, insurable risks, risk appetite, and the importance of applying current industry practices to new sustainable technologies, with insights from CNA Hardy's expertise in the Lloyd’s of London market.

Visualising Risk Reduction: Utilising Weighted Bowtie Diagrams for Enhanced Risk Assessment, Management and Communication
Colin Chambers, HSE, UK

This paper explores the application of Weighted BowTie Diagrams (WBTDs) for risk assessment and effective communication, demonstrating their utility through a case study on preventing overfilling in a bulk fuel storage tank. The study highlights how WBTDs enhance traditional bowtie diagrams by visualizing cumulative risk reduction and barrier effectiveness, improving decision-making and risk management.

Update to the UK Pipeline Quantitative Risk Assessment Guidelines IGEM/TD/2
Michael Acton, DNV, UK

Learn about the key updates in Edition 3 of IGEM/TD/2, which provides refined guidance for Quantitative Risk Assessments of high-pressure natural gas pipelines, incorporating new developments such as the introduction of "Type H" high-density areas and revised failure models. This presentation will cover the expanded guidance for complex locations, updated risk reduction measures, and the latest UK best practices for managing pipeline safety.

Digitalisation II

Remote Operations – Cybersecurity Risk?
Matt Vickers, Abbott Risk Consulting (ARC), UK

This presentation will explore the shift towards remote operations in offshore installations, discussing benefits such as reduced risk profiles and decreased need for helicopter transfers through Integrated Onshore Command (IOC). It will also address logistical and security challenges, particularly cybersecurity risks, and propose a pragmatic approach to ensure reliable and safe remote operations in the oil and gas industry.

Acceleration Adoption of PHA AI Tools
Angus Keddie, Process Safety Matters, UK

Exploring the transformative potential of AI in High Hazard Process Risk Assessment, this presentation examines the historical adoption of technology in safety processes and investigates how AI can enhance HAZOP efficiency. By analysing past technological failures and successes, the session aims to identify strategies for the rapid adoption of AI-enhanced HAZOP tools, ensuring they move from "stranger on the horizon" to integral safety components.

Can We Use AI to Turn Observations into Leading Indicators of Safety Culture and Plant Integrity?
Sian Richards, Empirisys, UK

Boost is an AI-driven solution enhancing safety observation impact by simplifying submission, analysis, and action planning through automated hazard identification and risk prediction. This presentation will introduce the research and development of Boost from a process safety and technical perspective, finishing with a demonstration of the tool in action.

Digital Coating Inspection Portal - AI Driven
Shaheen Al Beshr, ADNOC, UAE

This abstract outlines ADNOC Offshore's implementation of an AI-driven solution using Virtual Tour Laser scan data and 3D processing to create a precise inventory of external corrosion through machine learning. The solution significantly reduces visual inspections, enhances asset visibility, and supports proactive maintenance strategies, ultimately reducing risks and operational costs associated with corrosion management.

Human Factors 1

The Integration of Qualitative Human Factors Safety Critical Task Analysis with Wider Engineering Risk Assessments
Jamie Henderson, Human Reliability Associates, UK

This paper discusses the integration challenges between Safety Critical Task Analysis (SCTA) and engineering risk assessments within UK COMAH regulations. It highlights the recent CIEHF guidance's impact on SCTA practice, proposing a framework for improving dialogue between qualitative SCTAs and quantitative MAH risk assessments to enhance overall risk management effectiveness.

Safety Critical Task Analysis – Lessons from Industry
Derek Porter, Risktec Solutions, UK

This presentation will explore the regulatory expectations and practical challenges of Safety Critical Task Analysis (SCTA), drawing on real-life projects across oil & gas, chemical, nuclear, and manufacturing sectors. It will provide insights into screening procedures, prioritization strategies, and effective implementation measures to mitigate human failures in operational environments.

Safety Psychology and the Design of Critical Control Systems
Rachel Bennett, RMB Integrity Consulting, UK

This presentation will explore safety psychology's role in enhancing engineering design and hazard management, bridging disciplines to improve decision-making and safety outcomes. Led by experienced practitioners, it will offer practical insights and case studies highlighting the critical integration of psychological principles into engineering practices for optimal safety performance.

Storm Preparedness for Mobile Offshore Drilling Units: An Example of Decision Making Under Uncertainty
Simon Dunford, HSE, UK

This presentation discusses recent HSE investigations into mooring failures on MODUs in the North Sea during storms, highlighting challenges such as uncertain weather forecasts and conflicting production goals. It emphasizes the application of Human Factors insights to enhance decision-making under uncertainty, advocating for proactive preparations and supportive organizational arrangements to mitigate risks and maintain situational awareness in hazardous environments.

Carbon Capture 1

Design Considerations for Pressurised Flare and Vent Systems for Efficient CO2 Management
Hugo Manuel Dias Rodrigues, Siemens, Portugal

This presentation discusses safety challenges in Carbon Capture and Storage (CCS) projects, focusing on high CO2 gas field exploitation and the design complexities of disposal systems like flares and vents due to low temperatures and solid CO2 formation during depressurisation. It introduces an innovative approach of segregating high CO2 systems into a pressurised flare header to mitigate blockage risks, with potential applications in Floating Production Storage Offloading facilities and CCS projects.

Process Safety Assurance Studies for CCS Projects
Zuriyaty Md Yusoff, Petronas, Malaysia

This paper explores critical process safety assessments unique to Carbon Capture and Storage (CCS), focussing on the challenges and risks associated with each stage of the CCS value chain—capture, transportation via subsea pipelines, and storage. Key considerations include CO2 phase behaviour, safety systems like CO2 detection, and mitigation strategies such as inherently safer designs and low temperature studies to manage risks effectively.

Lessons Learned from Process and Technical Safety in CCUS Projects
Hugo Siddle, WSP, UK

This paper examines the critical role of Carbon Capture, Utilisation, and Storage (CCUS) in achieving net zero emissions, emphasising the significant safety challenges associated with large-scale CO2 management. It explores lessons from early-stage CCUS project design, focussing on adapting established oil and gas safety practices to mitigate the unique hazards posed by CO2, including physical effects modelling, risk assessment methodologies, and emergency response strategies.

An Updated Release Model for High-pressure CO2 Pipelines: Validation of Discharge and Dispersion Predictions Against CO2PIPETRANS Experiments
Jan Stene, DNV, UK

This presentation looks at advances in safety for carbon capture and storage (CCS), focusing on the transportation of high-pressure CO2 through long pipelines. Key topics include the development and validation of the extended pipebreak model, addressing initial source term accuracy and its integration with the unified dispersion model (UDM) for assessing CO2 dispersion in the atmosphere, as demonstrated through comprehensive validation against CO2PIPETRANS experiments.

14:00–15:45 Parallel sessions

Processes & Procedures

It’s OK, We Have a Back-up
Roger Stokes, BakerRisk, UK

The presentation addresses the critical need for reliable backup systems in facilities dependent on electrical power and other services for safe operation. It explores historical reliance on emergency pre-plans and highlights real-world case studies, including incidents such as the MV Dali bridge collapse and the Fukushima Daiichi nuclear disaster, underscoring the devastating consequences of multiple system failures during emergencies.

How Safe Are Your Isolations? Lessons and Improvements to Isolation Management from an Operator’s Perspective
Matt Hastings, Ithaca Energy, UK

This presentation discusses the ongoing challenges and improvements in managing isolation practices, focusing on the broader context beyond equipment to include safety critical components. It explores a risk-based approach for identifying and managing isolation risks, highlighting the role of human factors and the importance of workforce engagement in achieving safer practices, despite initial resistance to change. Examples illustrate how data-driven insights and audit feedback are leveraged to enhance compliance with industry standards like HSG 253 and ensure continual safety improvements.

Perplexing Persistence of Poor Procedures
Andrew Brazier, AB Risk, UK

The paper explores longstanding challenges with procedures in industries like offshore oil and gas, emphasizing persistent issues such as inadequate coverage of foreseeable circumstances and disconnects between written procedures and actual practices. It critiques bureaucratic approaches that prioritize paperwork over effective risk management, proposing practical solutions to improve procedure usability and relevance in managing operational risks effectively.

Risk Assessment & Management II

Seeing the Invisible
Trish Kerin, IChemE Safety Centre, Australia

This paper examines the difficulty in identifying weak signals before incidents and proposes leveraging priming bias to enhance detection. It introduces a workshop approach combining failure mode assessment and incident learnings to train participants in recognising potential weak signals more effectively.

Are You Confident of the Status of the Safety Critical Systems? Can You Demonstrate Whether it is Fully Operational, Degraded, or Impaired?
Edwin Bailey, Ithaca Energy, UK

This paper explores ensuring the reliability of safety-critical systems in offshore installations, focussing on the gas detection system as a case study. It highlights the application of advanced risk-based techniques to objectively assess and classify the system's operational status (fully operational, degraded, or impaired), emphasising the importance of informed safety management decisions based on quantitative performance metrics and barrier modelling methodologies.

Facilitated discussion

Lithium Ion Batteries

Safety Considerations for Hydrometallurgical Metal Recovery from Lithium-ion Batteries
Sakshi Jain, University of Sheffield, UK

This presentation explores the critical safety considerations of hydrometallurgical metal recovery in lithium-ion battery (LiB) recycling, emphasising the hazards associated with processes like leaching and extraction. It aims to guide LiB recyclers and researchers in identifying and mitigating risks through best available techniques and regulatory insights, stressing the importance of early integration of safety measures to manage hazards effectively as the industry scales up.

Lithium-ion Battery Storage – New Technology, Same Old Process Safety Principles?
Ben Smith, Arup, Australia

This paper explores the intersection of traditional process safety principles with emerging lithium-ion battery technology, using case studies of incidents to highlight commonalities and lessons for safety design and operation. It argues that integrating established process safety knowledge into new energy technologies like grid-scale batteries is crucial for ensuring safe implementation and supporting the energy transition effectively.

Approaches for Li-Ion Battery Consequence Assessments
Christopher Gold, Gexcon, UK

This paper will present an analysis of the safety challenges posed by Lithium-Ion (Li-Ion) batteries, focusing on thermal runaway risks and associated hazards like fires and explosions. It will discuss modelling methodologies for risk assessment and mitigation measures, aiming to inform decision-making in battery system design and layout, particularly for Battery Energy Storage Systems (BESS).

Human Factors II

A Model to Assess the Risk of Organisational Change
Lorraine Braben, Braben Consulting, UK

This paper outlines a practical model for developing a Management of Organisational Change (MoOC) system to meet COMAH requirements, addressing gaps in existing literature by providing clear guidance and categorisation of change types. It aims to assist Hazards delegates in understanding and implementing robust risk assessment processes tailored to high hazard process sites, thereby enhancing safety and compliance with HSE expectations.

Experience in the Application of Functional Mapping as a Human-centred Design Technique for High Hazard Industry
Iain Stuart, LQE+, UK

This paper will explore human centred design (HCD) and functional mapping as transformative tools for integrating new technologies and optimising human-technology interactions in high hazard industries. Learn from Iain Stuart's extensive experience in applying these methodologies to enhance safety, efficiency, and operational effectiveness across diverse sectors including oil & gas, marine, construction, and energy.

Facilitated discussion

Modelling 1

The Rarefaction Balancing Method in HSE’s PiRRaM Model
Andrew Newton, HSE, UK

This paper introduces PiRRaM, a model developed by HSE for predicting transient characteristics of accidental releases from pipelines carrying pressure-liquefied substances like ammonia and propane. It integrates DNV's PipeBreak model with additional physics, including rarefaction waves, to smoothly transition from saturated choked flow to incompressible liquid outflow, addressing challenges in modelling small hole limits and ensuring accuracy in mass flow rate predictions.

Digital Platform for Leakage Analytics
Kieran McDade, Cadent Gas, UK

The UK gas sector currently relies on the Shrinkage Leakage Model (SLM) for estimating emissions, but its limitations are increasingly apparent due to static emission factors and lack of granularity, hindering effective leak detection and mitigation. Cadent Gas is pioneering the Digital Platform for Leakage Analytics (DPLA), utilizing advanced technologies like methane detection and machine learning to transition to observed emissions, aiming for accurate, proactive leak detection and substantial environmental benefits, transforming the gas sector's approach to emissions management.

Exploratory Numerical Simulations of Unignited and Ignited Ammonia Releases
Jennifer Wen, University of Surrey

The study investigates large-scale ammonia releases, both unignited and ignited, using modified OpenFOAM code originally designed for hydrogen dispersion simulations. It explores scenarios of pressurised ammonia releases on land, analysing dispersion patterns and ignition potential under varying ambient conditions, including the presence of hydrogen. Results aim to inform safety considerations for ammonia bunkering operations, crucial as ammonia becomes a prominent alternative fuel in marine transport and power generation.

16:00–17:15 Parallel sessions

Modelling II

SAFEN Loss of Containment Frequency Models
Ingar Fossan, Safetec, Norway

The SAFEN initiative addresses the need for accurate loss of containment frequencies in facilities handling hydrogen, ammonia, and carbon dioxide, pivotal in the energy transition. This session  presents SAFEN's new models for leak frequencies, based on comprehensive incident data and failure mechanisms, enhancing quantitative risk assessments for safer operations with hazardous fluids in the low-carbon industry.​

PolyPiRRaM: An Analytical Solution to the One-dimensional Transient Compressible Pipe-flow Equations
Andrew Newton, HSE, UK

The PolyPiRRaM model, derived for full-bore ruptures in compressible fluid pipelines, offers a simple yet robust analytical solution applicable across various fluids. It identifies universal decompression behaviour and is validated against experimental data, demonstrating its utility for safety assessments and regulatory compliance in diverse pipeline scenarios.

Experimental Characterisation and Modelling for Improved Safety of Purging Operations
Kevin Gault, GRTgaz, France

GRTgaz collaborated with RICE to enhance purging guidelines for their extensive gas pipeline network through experimental evaluation and simulation using SYMMETRY software. Findings highlighted that while complete filling purging was more effective in displacing air, configurations with dead ends posed significant challenges, influencing safety and operational efficiency. These insights informed updated technical documentation, improving purging practices to bolster reliability and safety across GRTgaz’s infrastructure.

Water

Investigation of Hazardous Area Zone Extents for Biogas in the Water Industry Including a Comparison to IGEM SR25
Tim Jones, RPS Group, UK

This paper explores the suitability of IGEM SR25 guidelines, originally designed for natural gas, in the context of biogas systems in the water industry. It compares the zone extents for vent terminations and outdoor releases between typical biogas compositions and natural gas, highlighting potential discrepancies and considerations for safety modelling.

Understanding Major Hazard Area Classification Implications of Emerging Net Zero Technologies Implemented in the Water Industry
Adriana Reyes Cordoba, AtkinsRealis, UK

This paper examines the integration of innovative technologies in wastewater treatment to achieve Net Zero carbon footprints, focusing on resource recovery and alternative energy production. It highlights challenges in adapting safety regulations, particularly under DSEAR, to address new risks associated with retrofitting these technologies into existing facilities, and presents findings from a case study on updating Hazardous Area Classification documents.

Facilitated discussion

Climate Change

NaTech Hazards – Wild Weather
Aimee Russell, RAS, UK

This paper explores natural hazards affecting high-risk sites in the UK, building on previous discussions about NaTech risks and climate change adaptation. It focuses on identifying and screening natural hazards, emphasising their potential interactions and direct impacts on industrial infrastructure, essential for comprehensive risk assessment and management.

Integration of Climate Risk Management in a Pre-existing Risk Matrix in the Engineering Sector
Paula Vieira Salomão, Hatch, Brazil

This study explores integrating climate-specific categorisation into an engineering company's risk matrix to enhance awareness and mitigation of climate-related risks during technical assessments. By distinguishing between physical and transition risks, based on ISSB standards, the modified matrix aims to improve risk identification and mitigation effectiveness, as demonstrated in a case study on an alumina refinery accident in Brazil.

Facilitated discussion

Process Safety Management

Is it Time Process Safety Embraced Biological Hazards?
Patrick Swords, PM Group, Ireland

The paper addresses the origins and risks associated with biological agents, categorising them into four groups based on their potential for harm and spread. It emphasises the unique challenges in applying process safety principles to biotech facilities, particularly in ensuring effective protection measures against releases, distinct from traditional hazard analyses like fire and explosion modeling.

Sailing the Supertanker - Improving Process Safety Management Control and Reporting Systems
Ashley Hynds and Leanne Potter, DNV, UK

This presentation explores parallels between managing a supertanker and a major accident hazard business, highlighting the critical need for effective management, control, and reporting systems (MCRS) to ensure safety and operational success. Drawing on case studies from oil and gas exploration and multisite operations under COMAH regulations, it outlines a structured approach to enhancing MCRS, aiming to improve process safety management and leadership across organisations.​

Facilitated discussion

17:30–17:45 Flash poster sessions

18:00–18:45 Networking reception in exhibition area


Thursday 7 November

09:15–10:00 Plenary presention

Natech Events, the Risks to Process Safety and the Environment
Mike Nicholas

In his presentation, Mike will talk about Natech events, the risks to process safety and the environment due to climate change and the work being undertaken by the Chemical and Downstream Oil Industries Forum (CDOIF) to address these issues.

10:30–12:30 Parallel sessions

Hydrogen Safety II

Failure of the Vacuum in a Vacuum Insulated Hose while Transporting Liquid Hydrogen
Richard Goff, HSE, UK

This presentation details HSE's experiments with liquid hydrogen for the ZEST programme, focusing on a vacuum failure in a transfer hose caused by a cryogenic leak from a mass flow measurement system, discussing the implications on safety and potential mitigations.

A Methodology for Hydrogen Vents Overpressure Assessments
Josue Melguizo Gavilanes, Shell, Netherlands

This session addresses the critical need for safe venting guidelines for hydrogen, given its unique explosion hazards and rising use in various sectors. By revisiting Dorofeev's work and applying it to realistic scenarios, the presentation offers a methodology to estimate overpressures from hydrogen gas explosions, using standard consequence modelling software and experimental evidence.

Repurposing Pressure Equipment for Hydrogen Service
Philip Garner, Axiom, UK

This presentation explores the challenges of decarbonising industry sectors using hydrogen as an alternative fuel, focusing on the complexities of repurposing existing pressure equipment. Attendees will gain insights into hydrogen embrittlement, material interactions, and safety considerations, supported by a practical feasibility study and fracture mechanics assessment.

Hazard Study 0 Case Study: Retrofitting an Industrial Burner for Hydrogen Fuel
Oyinda Gunn, Axiom, UK

This paper explores the application of Hazard Study 0 (HS0) in retrofitting industrial burners for hydrogen fuel to support decarbonisation in the chemical industry. It presents safety challenges, lessons learnt, and compares different hydrogen-ready burners available on the market.​

Engineering & Design 1

Equipment Design in an Unregulated Environment: Welcome to the Wild West
Faye Litherland, Fluor, UK

This presentation addresses the critical need for updated guidance in the design of large-scale equipment for biological containment facilities, given the rise in biological drug approvals and industries using genetically modified cells. Combining over 50 years of industry data and government-backed risk levels, we present a framework to inform equipment design, ensuring appropriate containment for biological hazards and enhancing biosecurity measures.

Impact of Creeping Change on Pressure Relief Devices
Robert Fitch, Axiom, UK

This presentation examines the critical role of pressure relief devices in high hazard process industries, highlighting the importance of ensuring their suitability as processes and equipment change. Drawing on experience and case studies, it provides insights on managing risks and enhancing safety through rigorous management of change procedures.

Protecting against Runaway Reactions in Semi-Batch Alkoxylation Processes
Stephen Rowe, DEKRA, UK

This paper examines the significant safety risks in alkoxylation reactions, particularly the exothermic nature and risk of runaway reactions from ethylene or propylene oxides. Through a case study and incident statistics, it explores worst-case scenario definitions for emergency relief systems, potential simulation errors, and the importance of temperature control and agitation, concluding with a review of protection layers to mitigate runaway risks.

Building Design and Selection for Protection of Critical Assets
Karen Vilas, FORTRESS Protective Buildings, USA

This presentation explores the design of Multi-hazard Resistant Buildings (MRBs) to protect critical assets in industrial processing facilities from various hazards, such as explosions, fires, and toxic events. Key concepts of protective building design will be introduced, illustrated through full-scale testing videos, to demonstrate how materials like concrete and steel respond to such hazards, enhancing the delegate's understanding of current MCB design best practices.

Safety Leadership

Lifting the Veil: Honest Talk and Leadership Challenges from the Sharp End
Rachael Cowin, Legitimate Leadership, UK

This presentation will explore the unspoken challenges in process safety through anonymous interviews, revealing insights often overlooked by traditional safety audits. It aims to foster candid dialogue among delegates, offering practical leadership strategies to address shared industry concerns and enhance safety culture collaboratively.

Corporate Governance for Safety
Nick Shaw, Office for Nuclear Regulation, UK

This presentation will discuss ONR’s oversight of corporate governance for safety at nuclear licensed sites in the UK, emphasising the role of boards in ensuring effective hazard control and continuous safety improvement. It will highlight best practices and challenges observed in governance arrangements, offering insights relevant to board members, senior leaders, legal counsels, company secretaries, and audit professionals interested in enhancing safety governance within their organisations.

The Platypus Philosophy and Long Term Hazard Management
Neil Blundell, Office for Nuclear Regulation, UK

This paper introduces the Platypus philosophy as a framework for identifying and managing weak signals of potential hazards in the nuclear industry, particularly during long-term decommissioning, storage, and management of nuclear facilities and materials. It advocates adapting this framework to extend hazard horizon viewpoints to intergenerational timescales, ensuring effective knowledge retention and management amidst evolving personnel and operational changes.

Major Hazards Agenda and Strategy 28: An IChemE Update
Steve Flynn

Fire & Explosion Hazards and Assessment

Process Safety Incidents Prevention through Gas Monitoring Enhancement in Confined Spaces
Muhammad Huzaimi bin Tahir, Petronas, Malaysia

Discover best practices in gas monitoring for confined spaces, focusing on comprehensive safety guidelines, standardised gas detector protocols, and digital tools to streamline processes and ensure regulatory compliance. Learn how these measures, implemented by a multidisciplinary team, have led to significant safety improvements, cost savings, and industry-wide knowledge sharing.

What is the Impact of Dynamic Flare System Design on Cost, Safety, and Environment?
Hugo Manuel Dias Rodrigues, Siemens, Portugal

This presentation explores the impact of dynamic flare analysis on project capital cost, safety, and environmental impact in process safety equipment design. By critically examining traditional flare system design methods and introducing dynamic analysis, the study highlights significant advantages in cost reduction, enhanced safety, and minimized environmental impact.

Lagging Fires, their Implications for the Process Industry, Test Methods, and Mitigative Actions
Sixten Dahlbom, Research Institutes of Sweden, Sweden

This presentation will explore the persistent threat of lagging fires, emphasising the need for incorporating risk assessments in new plant construction. It will also introduce a novel testing method based on isothermal calorimetry and modelling techniques, offering insights from case studies, statistical analyses, and collaborative research findings to improve plant safety and reduce fire incidents.

13:30–15:30 Parallel sessions

Hydrogen Safety III

A Large Scale Experimental Programme to Improve Understanding of Liquid Hydrogen Dispersion
Steven Betteridge, Shell, UK

This presentation will explore the critical role of liquid hydrogen in the energy transition, focusing on its use as a fuel alternative and energy vector, as well as the importance of quantifying hazards associated with LH2 releases. It will detail Shell's commissioned experiments at the DNV test site to gather dispersion data for validating and improving consequence models, thereby ensuring safer LH2 storage and transfer operations.

Thermal Heat Flux Measurements During a Hydrogen Flaring Operation
Kevin Gault, GRTgaz, Franch

This presentation looks at the work GRTgaz is doing to develop MosaHYc, a 90km hydrogen pipeline between France and Germany, and converting its experimental benches from natural gas to hydrogen at its Research and Innovation Centre for Energy (RICE) facility. An experimental campaign at Fos-sur-Mer tested a hydrogen flare under high wind conditions, measuring thermal heat flux with radiometers and a thermal imaging camera, validating results with the PERSEE+ modelling software.

Comparison of the Heat Load from Hydrogen Jet Fires Impacting on a Target Using Different Computational Fluid Dynamics Modelling Techniques
John Evans, Thornton Tomasetti, UK

As the world transitions to net zero, hydrogen is emerging as a versatile energy source to replace traditional hydrocarbon fuels. This paper compares the heat load on a target from hydrogen jet fires to hydrocarbon jet fires, using large-scale experiments and CFD modelling techniques, highlighting key differences in radiative and convective heat fluxes.

Advancing Hydrogen Safety: Integrating Computational Fluid Dynamics for Risk Assessment in Hydrogen Production via Water Electrolysis
Alexandre Lebas, MES International, UK

This paper explores the production of hydrogen via alkaline water electrolysis at a pilot plant, highlighting its advantages for the clean energy transition. It employs advanced Computational Fluid Dynamics (CFD) to perform detailed safety assessments, addressing the risks associated with hydrogen's high flammability and explosion potential, and provides valuable insights for asset protection and personnel safety.

Engineering & Design II

DSEAR – It’s Not All Glamour
Steve Sherwen, RPS Consulting, UK

This presentation will demystify the practical aspects of DSEAR assessments, focusing on common scenarios and pragmatic approaches to compliance. Delegates will gain insights into effective risk management across various industries, ensuring safety and regulatory adherence without excessive documentation.

Innovative Retrofitting of Crude Oil Storage Tanks with Aluminum Geodesic Dome and Vapor Recovery System
Bijoy Jose Verghese, ADNOC, UAE

ADNOC Offshore faces challenges with vapour emissions from its open top floating roof storage tanks, despite adherence to industry standards. This paper looks at how they are exploring a joint innovation with HMT Tanks for dome roof Internal floating with emission capture to mitigate environmental impacts and reduce emissions significantly.

Proof Testing – A Holistic Approach to Ensuring Effective Test Methods Utilising Human Factors and Technical Functional Safety evaluation
Dave Green, RPS Group. UK

This paper explores a novel approach combining Human Factors (HF) analysis and Functional Safety (FS) review in proof testing Safety Instrumented Functions (SIFs), aiming to provide a comprehensive evaluation of testing methodologies. It addresses the challenge of ensuring SIFs perform as required, offering delegates insights into reducing human errors and enhancing safety through integrated HF and FS assessments, thus benefiting professionals reliant on SIFs across various industries.

Facilitated discussion

Safety Culture

Measuring Process Safety Culture through PSM Element Focused Interviews
Mohammad Kazmi, Aramco, Saudi Arabia

This presentation will explore the meticulous process of conducting a comprehensive process safety culture assessment, emphasising the use of guided interviews over surveys to pinpoint nuanced cultural gaps. It will highlight insights from assessments conducted across 40 global plants, focusing on key phases and deliverables essential for improving safety management systems and organisational culture.

Using Cultural “Warning Flags” within the Office for Nuclear Regulation
Caroline Sugden, Office for Nucler Regulation, UK

The Office for Nuclear Regulation (ONR) has introduced a novel approach to identify and monitor weak signals of organisational culture across nuclear dutyholders, encapsulated in nine empirically derived "warning flags." These flags aim to enhance regulatory insights and decision-making by systematically capturing cultural indicators during routine engagements and investigations, thereby supporting targeted interventions and improving overall industry safety and compliance.

Rescuing Emergency Planning and Preparedness from the 'Tick Box
Nigel Cann, Arup, Australia

Arup, an Approved Assessor of Safety Cases for Australia, outlines compliance with Work Health and Safety Regulations Regulations for major hazard facilities under Comcare, akin to the UK's COMAH Regulations. They highlight gaps in emergency plans and advocate for effective community dialogue, emphasising the need for tailored emergency response plans, training, and debriefs to enhance readiness and safety outcomes. This presentation will cover specific examples of setting up an initial response strategy for onsite personnel at a PVC resin manufacturing facility and run through the events of an actual exercise and the important lessons learned from that exercise.

Facilitated discussion

Aging Plant

Safety Investment Methods in High Hazard Industries for Projects with Declining Profitability and Finite Lifespan – the Case of Oil & Gas Upstream
Tiago Jacques, ANP, Brazil

This paper explores regulatory challenges and improvements in Brazil's high-risk oil and gas industry, advocating for integrating risk aversion into investment decisions to manage major accidents. It highlights the complexities of decision-making and operational risk management, emphasising the need for balanced regulatory frameworks and effective safety measures.

The Alternatives to Revive Safety and Integrity af Aging Oil & Gas Wells
Muhammad Abou Amad, ADNOC, UAE

This paper presents innovative zero-emission technologies for maintaining Down Hole Safety Valves (DHSVs) in offshore wells, including capillary line DHSVs, unconventional methods for control line de-plugging, and swellstack technology for severe damage repair. Successfully trialled in UAE offshore fields, these solutions have not only saved over $100 million in workover costs across 16 wells but also prevented 20,700 tonnes of CO2 emissions, marking a significant shift towards sustainable practices in the oil & gas sector.

A New Approach to PHA and SIL Re-validation: Lessons from Ageing Oil and Gas Facilities
Tom Ridout, ERM, UK

This paper addresses the challenges faced by ageing operational assets in maintaining up-to-date process hazard studies and functional safety data amidst under-resourcing and cost pressures, exacerbated by recent events like Covid-19. It proposes a structured approach to revalidate Process Hazard Analysis (PHA) and Safety Integrity Level (SIL) across oil and gas facilities, emphasizing prioritization of high-risk hazards, data streamlining, and interdisciplinary collaboration to bridge information gaps and ensure alignment with current standards.

Managing Chloride Stress Corrosion Cracking in LNG Fractionation Columns
Birinengi Harry, Nigeria LNG Ltd, Nigeria

This presentation discusses the risk-based approach used over two decades to manage chloride stress corrosion cracking (Cl-SCC) in LNG de-ethaniser columns, the discovery of extensive Cl-SCC, and the mitigation strategies, including composite wraps, implemented to prevent catastrophic failures and maintain process safety. Detailed assessments and repair methodologies for affected columns will also be covered, highlighting the successful return to service while awaiting replacement.

15:30–15:45 Closing remarks

Eamon Chandler, Chair, Hazards 34 Technical Committee

"The talks are a good mix of theoretical and practical. They give you the background and the theory but it's very focused on the applicability of it. I can take what's applicable back to my company and implement it there and then."

Teri Zdrojewski, AWE

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"I've learnt techniques and tools that we can use to improve our processes but also softer things around culture."

Tomas Davies, Sellafield Fuels