Experience with developing Process Safety KPIs within ScottishPower
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- Valerie Atkinson
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1 Experience with developing Process Safety KPIs within ScottishPower Process safety management for power and steam generation Energy Institute, London Martin Sedgwick Head of Asset Management Steven Stewart Process Safety Design Authority 8th July 2010
2 Agenda Overview of ScottishPower s journey implementing PSPIs... Brief introduction to ScottishPower Approach To Developing Process Safety Leading and Lagging Indicators Current Status Of Indicators Enduring Process Safety Solution Management / Board Reporting Process Safety Key Learning Points 2
3 Company Overview 3
4 Iberdrola Group ScottishPower part of Iberdrola Group, a worldwide leader in energy Presence in 40 countries worldwide 4
5 ScottishPower Overview ScottishPower is a major integrated power company... REGULATED COMPETITIVE UK ENERGY NETWORKS 3.4m customers #3 UK distribution network operator ENERGY RETAIL 5.3m customers ENERGY WHOLESALE ~6GW flexible generation Energy Management Gas Storage 5
6 Longannet Power Station Carbon Capture Pilot Plant Approach To Developing Process Safety Leading and Lagging Indicators 8th July 2010 ScottishPower 2010 Energy Institute Seminar 6
7 Overview Of Approach Based on HSG254 recognised as best practice Tested through benchmarking - HSE and Oil & Gas sector Common KPIs for all sites, but different targets applied Incremental approach trials using prototype dashboard Buy in and sign off from the top KPI Lifecycle developed: 7
8 Application Of HSG Step 1 - Hazards 90 GENSIP Hazards Plant Process People 8
9 Application Of HSG Step 2 Risk Control Systems 42 Risk Control Systems 90 GENSIP Hazards Plant Process People 9
10 Risk Control Areas Risk Control Systems Grouped Into 8 Risk Control Areas... Operation & Compliance Audit 10
11 Application Of HSG Step 2 Risk Control Systems 42 Risk Control Systems 90 GENSIP Hazards Plant Process People 11
12 Application Of HSG Step 3 Define Leading Indicators 42 Risk Control Systems 90 GENSIP Hazards Plant Process People 100 Leading Indicators 8th July 2010 ScottishPower 2010 Energy Institute Seminar 12
13 KPI Definition Documents Crib sheets used to specify each KPI in detail Provides definition of KPI: Objective Definition Data Source Data Aggregation / Calculation Targets Data Recording Guidelines Formal sign off by senior managers 13
14 Application Of HSG Step 3 Define Leading Indicators 42 Risk Control Systems 90 GENSIP Hazards Plant Process People 100 Leading Indicators 8th July 2010 ScottishPower 2010 Energy Institute Seminar 14
15 Application Of HSG Step 4 Classify Lagging Indicators 42 Risk Control Systems 3 Classifications Of Lagging Indicators 90 GENSIP Hazards Plant Process People 100 Leading Indicators 8th July 2010 ScottishPower 2010 Energy Institute Seminar 15
16 Application Of Latest Thinking Approach to classification of lagging indicators... Classification of Process Safety Incidents based on benchmarking with HSE and API guidance: Major Process Safety Incident: Equipment damage > 100k Loss of Production > 24 hours Injuries / fatalities (RIDDOR) Major environmental impact Significant Process Safety Incident: Equipment damage > 20k but < 100k Significant release of energy or hazardous matter Fire and explosions Minor Process Safety Incident: Demand on safety system Process upset control loops out of control, equipment in manual Breaches of plant limiting conditions 16
17 Application Of HSG Step 4 Classify Lagging Indicators 42 Risk Control Systems 3 Classifications Of Lagging Indicators 90 GENSIP Hazards Plant Process People 100 Leading Indicators 17
18 Application Of HSG Incident Management key to understanding lagging indicators Risk Control Systems 3 Classifications Of Lagging Indicators 90 GENSIP Hazards Plant New Incident Reporting Process People Process 100 Leading Indicators 8th July 2010 ScottishPower 2010 Energy Institute Seminar 18
19 Incident Investigation Application of Swiss Cheese model to drive out lagging indicators... High temperature steam pipes and oil systems in close proximity Operational and Compliance Audits Technical Risk Management Operations Management Maintenance Management Critical Systems Management Staff Competence Local Procedures not well known for first contact with Fire Services Alarm / Instrumentation Management Emergency Preparedness Turbine Pedestal Fire Fire hydrants defects unknown Resetting governor creates oil hammer Strainer drain line weld defective from installation Deluge system manually operated Delays in applying Deluge system causes damage to system reducing efficacy No Turbine/ Major Incident Fire Procedure No Plant Modification history giving detail of design rational Vacuum Breakers fail, extending run down time Strainer east drain line left open pressurising drain line Various oil leaks Strainer drain line restraints failed, pipe movement Deluge valves located in Turbine Hall, delaying access Missing persons did not follow evacuation procedure Decision to not use the Deluge system for fear of plant damage and exacerbating fire Delay as Fire Brigade procedures require BA bottle replacement 19
20 Application Of HSG Outcomes documented in PSMS 42 Risk Control Systems 3 Classifications Of Lagging Indicators 90 GENSIP Hazards Plant New Incident Reporting Process People Process 100 Leading Indicators 20
21 Current Status Of Indicators 21
22 Process Safety Dashboard Matrix shows worst case KPI across all RCAs at each site 22
23 Process Safety Dashboard KPI Details shows status of individual KPIs 23
24 Process Safety Dashboard Trends show the positive impact that KPIs have had on performance 24
25 Process Safety Dashboard Drill Down enables the source of issues to identified and tackled 25
26 Process Safety Dashboard Summary Charts provide view of risk profile 26
27 Process Safety Dashboard Monthly Reports support Operational Risk Governance meetings 27
28 Enduring Dashboard Solution Preview of next generation of software in development... 28
29 Further HSE Guidance Three categories of indicators 29
30 Further HSE Guidance Shift Logging 30
31 Further HSE Guidance Shift Logging 31
32 Further HSE Guidance Alarm Management 32
33 Further HSE Guidance Alarm Management 33
34 Further HSE Guidance Reliability Engineering 34
35 Further HSE Guidance Reliability Engineering 35
36 Further HSE Guidance Maintenance Management 36
37 Further HSE Guidance Maintenance Management 37
38 Further HSE Guidance Incident Management 38
39 Further HSE Guidance Incident Management 39
40 Further HSE Guidance Technical Risks 40
41 Further HSE Guidance Technical Risks 41
42 KPI Dashboard Architecture An enterprise scale solution... Scheduling Maximo (CMMS) EXP (Reliability Engineering) PSR (Technical Risks) Cintellate (Incident Management) PAS (Alarm Management) Opralog (Shift Logging) Dashboard Ad Hoc Analysis (Business Objects) 42
43 Process Safety Dashboard Leading and lagging KPIs listed separately... 43
44 Process Safety Dashboard Concept of Leading and Lagging indicators embedded... 44
45 Process Safety Dashboard Donut charts used to report leading and lagging statistics separately... 45
46 Status Of KPIs 46
47 Weighted KPIs Application of risk based weightings to KPIs... 47
48 Top 10 KPI Report Proposed approach to ranking KPIs... Calculate Score Between 0 and 4 For Each KPI Apply Offset To Each KPI Based on Category Operational Control Indicators
49 Top 10 KPI Reporting Operational Control Indicators Generic Indicators Programme Indicators 49
50 KPI Weight Approach Enables individual KPI scores to be aggregated up to RCA level... Calculate Score Between 0 and 4 For Each KPI Apply Static Weightings To All KPIs Within Each Risk Control Area KPI RCA Weighting Maintenance Management Backlog Size In Months 20% Corrective Maintenance Compliance 10% Work Prioritisation Work Identification, Routine Plant Inspections Outage Defects Backlog Size In Months Percentage of WOC With Failure Information Percentage of WOC With Hours Captured Percentage of WOC With Log Completed 5% 2% 2% 2% Work Planning, Scheduling Work Execution Percentage of WOC With Re-Work Percentage of WOC With Risk Assessment 1% 10% Safety Defects Backlog Size 3% Percentage of PM to CM 30% Personal Risk Assessment Preventative Maintenance Compliance 15% 50
51 RCA Adjusted For Weighting 51
52 Management / Board Reporting 52
53 Group Governance Process Cascade up approach... All Sites 53
54 Operational Risk Group (ORG) Governance of Process Safety established across business... Monthly meeting Dedicated to reviewing technical risks Agenda Review Process Safety Incidents Process Safety KPIs Performance Review Technical Risks Benchmarking Regulatory Changes 54
55 Process Safety Key Learning Points 8th July 2010 ScottishPower 2010 Energy Institute Seminar 55
56 Key Learning Points From ScottishPower s journey to date... 56
57 End Of Presentation 57
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