Inherent Safety Thinking Applied to Construction and Fabrication of Deepwater Facilities

Abstract

In 2013-2014 the projects organization set a goal to look at personal safety through a process safety lens (inherent safety principles) to reduce hot spots in personal safety risks through improved construction planning (both pre and during construction). This paper presents a suite of innovative techniques that were developed to identify opportunities for construction risk reduction. The techniques focus on the identification of construction hazards and development of design alternatives, fabrication sequence and yard layout changes to eliminate the source of the hazard. The paper presents the approach and techniques developed; case studies where the approach was applied; and where significant risk reduction and fabrication efficiency improvements were achieved. The techniques developed have been applied at three primary project phases: Construction Engineering – High-level review to identify and eliminate hazards through (construction / design) engineering changes or construction related changes.30-60-90 Day Planning Reviews – Mid level reviews using a modified HAZID type approach to eliminate hazards through detailed work scope identification, work activity sequence, engineering controls, construction assembly sequence, and coordination of simultaneous task.Construction Execution Reviews – Simplified Bowties and Audits to review the number and quality of barriers to each threat line to verify that sufficient controls are in place and effective for the key top events. The techniques have been primarily applied to the higher risk hazards, based on work activities from previous fabrication experiences that occurred at similar facilities. In particular, the work has focused on: –Eliminating working at height: by moving work to ground level (engineering and fabrication sequence changes)–Reducing the amount of working in confined spaces: changing the work sequence to complete as much activity as possible prior to confining the work face area, and providing additional access and ventilation–Reducing dropped object exposure: moving work to ground level, and reducing the simultaneous working at multiple levels of a structure–Eliminating and reducing the number and complexity of lifts: changes to the fabrication sequence and construction engineering–Reducing traffic and transportation risks: elimination of people – heavy vehicle interactions through yard layout The quantifiable benefits of the approach have been: Reduction in the exposure of personnel to HSSE hazards by eliminating and reducing exposures during construction activities, through inherent safety thinkingImprovements and optimization of construction efficiency and sequence by reducing exposures associated with higher risk activities.