The Baker Panel Report - ABSA

BP PROCESS AND PERSONAL SAFETY BOOKLETSBP has developed and issued a series of booklets designed to identify potential hazards in refineries and petrochemical plants. 45 Thesebooklets supplement operator training courses, operating manuals, and operating procedures. 46 BP intends for these booklets to assist itsemployees and contractors to better understand the “why” of safe operating practices and procedures. 47 Topics within the series include thesafe operation and control of process heaters, the safe shutdown and start-up of process units, the hazards associated with steam and processsystems, and the safe handling and storage of the hydrocarbons. These booklets cover approximately 14 topics and are publicly available.C. Refining-Specific Process Safety Minimum ExpectationsAs discussed above, BP business segments and strategic performance units may establish minimum expectations related to their health andsafety performance operations in recognition of the unique risks in these operations. Process safety minimum expectations define the minimumexpectations for operation of process units and major equipment at all BP refineries worldwide. They provide minimum requirements forsignificant aspects of process operation, such as start-up, shutdown, normal operation, and maintenance. In many instances, these minimumexpectations do not require specific actions or practices, but instead require the refinery to develop its own procedures or define an operatingwindow to address a safety risk identified in the minimum expectations. The minimum expectations also contain pertinent references alongwith sections listing process hazards and safe operating conditions for the process or equipment that is subject to the minimum expectation.Framed as minimum expectations, BP encourages the refineries to regularly exceed these requirements.Development of these minimum expectations, which began in 2000, was intended to standardize process safety requirements across BP’sglobal portfolio of refineries. BP subsequently rebranded the process safety standards as minimum expectations in 2004, and new minimumexpectations have continued to be developed since the rebranding. BP originally identified 15 subjects for process safety standarddevelopment, and these 15 subjects have provided the basic framework for the development of process safety minimum expectations to thepresent day.As of June 2006, BP refining had issued 13 process safety minimum expectations in addition to minimum expectations relating to inspectionsand control of work: PSME No. 3: Hydrogen Sulfide Processing and Handling (First issued March 26, 2001, Rebranded April 28, 2004); PSME No. 4: Sulfuric Acid Alkylation Process Operations (First issued October 29, 2001, Rebranded April 28, 2004); PSME No. 5: Fluid Catalytic Cracking (First issued October 1, 2001, Rebranded April 28, 2004); PSME No. 6: Hydrofluoric Acid Alkylation Process Operations (First issued February 19, 2002, Rebranded April 28, 2004); PSME No. 7: Crude and Vacuum Distillation (First issued October 23, 2002, Rebranded April 28, 2004); PSME No. 8: Delayed Coking (First issued December 26, 2002, Rebranded April 28, 2004); PSME No. 10: Hydrotreating/Hydrocracking (First issued June 2, 2003, Rebranded April 28, 2004); PSME No. 11: Sulphur Recovery Process Operations (First issued December 15, 2005); PSME No. 12: Cyclic Reforming (Ultraforming) Process (First issued August 11, 2003, Rebranded April 28, 2004); PSME No. 13: Semi-Regen Reforming Process (First issued November 23, 2004); PSME No. 14: Continuous (CCR) Reforming Process (First issued November 23, 2004); PSME No. 16: LPG (Light Ends) Handling (First issued May 6, 2005); and PSME No. 18: Safe Use of Nitrogen (First issued February 25, 2004, Rebranded April 28, 2004).BP has advised the Panel that additional process safety minimum expectations are in development or are under consideration for development.BP’s HSSE Management Framework and Process Safety Related Standards C 54