In May we invited Sapref, Engen and Sasol to tell us about their safety measures and whether a Bhopal-like disaster could happen in SA. Last month we published Engen's response. Now Sapref responds.
Critical control safety systems
Sapref originally adopted the Shell-recommended Instrumented Protective Function (IPF) methodology in 1995 based on the German standard, DIN V 19250 and the draft IEC 61508. This methodology refers specifically to automated responses to abnormal situations as detected by instrumentation (typically alarm and trip functions). The process entails the execution of a risk assessment for each protective function by a multidisciplinary team. This is accomplished by consideration of the instrument failure probability and the associated consequences. The result of the classification enables specification of the most appropriate implementation and maintenance strategies for the IPF.
All instrumented protective functions within the Refinery were subjected to this process over a 2-year period. This strategy has resulted in comprehensive documentation and confirmation of the suitability of each function to meet its desired intent.
The later finalisation of IEC 61508 had replaced 'IPF' classification levels with 'Safety Integrity' levels (SIL). The methodology and implementation requirements between the two versions remain compatible thereby ensuring a simple migration from IPF to SIL.
Arguably, Sapref has been the forerunner of the IPF methodology within the Shell group. Clear documentation, appropriate maintenance strategies, and objective analysis of each instrumented protective function are immediate outputs of the process. This, in turn, allows us a vastly improved level of confidence in our ability to minimise environmental impacts, and prevent potentially harmful incidents from affecting Sapref's people and neighbours.
Shareholder support
Sapref regards health, safety and environmental (HSE) performance as critical key performance area and this is fully supported by both our shareholders. We have a commitment to becoming world class and we adopt the best of both Shell and BP practices. We have invested more than R480 million on environmental improvements since 1993. Also, we have invested R160 million in upgrading our underground product transfer pipelines, which run from the refinery to our storage facilities at the Island View harbour. We have also committed to investing a further R300-R400 million to further enhance the integrity of these pipelines following an independent review of these pipelines.
Programmes and targets to improve safety
We have a number of safety awareness programmes aimed at both Sapref people and contractors. Safety induction and competency programmes have been extended to contractors. Contractor skills levels are evaluated and any shortcomings identified in order to improve contractor performance. Our training programmes include Hearts and Minds, a programme aimed at bringing about personal behavioural change and improving the safety culture at Sapref. Regular 'HSE stops' are conducted where all work stops and work teams discuss topical HSE issues to improve learning and awareness.
We also have an electronic incident reporting and follow-up system called CIS (continuous improvement system), which is used by Sapref people and contractors to report actual and near miss incidents and to track follow-up/remedial actions. There are also HSE structures in place involving the refinery leadership team, which analyse specific incidents, the root causes and identify measures for improvement. The CIS system has proved to be a great learning tool.
Sapref conducts emergency response drills regularly to ensure preparedness for any emergency event. We invest significant effort to ensure that our fire crews are well trained. Our fire department is a respected authority in our industry and provides training not only to Sapref people and contractors, but to other companies and to the eThekwini (Durban) fire department.
An example of our safety focus is evident in our current maintenance shutdown where we will have up to 2500 contract workers on site (almost five times the normal volume of people). These contract workers have to undergo up to three levels of HSE induction, medical fitness testing, and competency assessment before coming on site. Our systems for controlling contractor work activities have also been evaluated and improved and ongoing training programmes are also being offered.
Sapref reports annually on its HSE and social performance and this report is available on its website.
For more information contact Phumi Nhlapo, Sapref Communications Department, 031 480 1303, [email protected], www.sapref.com
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