Hazards XXProcess safety and environmental protection Harnessing knowledge Challenging complacency

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Copyright 2008Institution of Chemical EngineersA Registered CharityOffices in Rugby (UK), London (UK), Melbourne (Australia) and Kuala Lumpur (Malaysia)

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Hazards XXProcess safety and environmental protectionHarnessing knowledge Challenging complacencyA three-day symposium organized by the Institution of Chemical Engineers (North West Branch) and held at the Weston Building, Manchester Conference Centre, UK, 14 17 April, 2008.This book contains the papers and poster papers presented at Hazard XX.There is also an accompanying CD-ROM.Organizing Committee M.F. Pantony (Chairman) Consultant M.J. Adams Symposium organizer/secretary G.R. Astbury Consultant C.J. Beale Ciba Speciality Chemicals plc S.R. Beattie Syngenta plc A. Boyd AstraZeneca G.A. Chamberlain Shell Global Solutions T. Clayton Environment Agency H. Conlin RPS Risk Management H.R. Cripps HRC Consultants Ltd K. Dixon-Jackson Ciba Specialty Chemicals plc M.I. Essa Health and Safety Executive R.F. Evans Health and Safety Executive B. Fulham Health and Safety Executive N. Gibson Burgoyne Consultants Ltd S. Hawksworth Health and Safety Laboratory P. Hooker NPIL Pharmaceuticals (UK) Ltd M. Hoyle AstraZeneca I. Kempsell Sellafield Ltd T.A. Kletz Loughborough University I.F. McConvey AstraZeneca G.S. Melville Phoenix Loss Prevention Ltd M.J. Pitt Sheffield University A. Saimbi Morgan Professional Services R.C. Santon Consultant G. Sellers Consultant

Corresponding members of the committee M.S. Mannan Mary Kay OConnor Process Safety Centre,

Texas A&M University System R.L. Rogers Inburex GmbH

INSTITUTION OF CHEMICAL ENGINEERSSYMPOSIUM SERIES No. 154ISBN 978 0 85295 523 9

Preface

It gives me great pleasure in writing this preface for Hazards XX. This is the twentieth symposium since the first was held in March 1960, nearly half a century ago. Hazards success and its growing popularity help bring about global recognition from process safety and environ-recognition from process safety and environ- process safety and environ-ment professionals, experts and practitioners worldwide. This is so that we may share, harness and adopt knowledge, experience and expertise for the benefit of us all. I passionately believe that, through those who lead, manage and train others, Hazards will help catalyse acatalyse a a dynamic safety culture with a view to reducing risk and harm, help develop harmony in societies and a much cleaner environment, not to mention sustainable and profitable businesses.

Hazards XX offered the opportunity to be involved with two workshops entitled Recent advances in Safety Training presented by IOSH and Health and Safety Update presented by NEBOSH, held on Monday the 14th April 2008. The Symposium and Exhibition stretched over the three subsequent days offered the opportunity to engage in a whole host of high quality technical papers, covering aspects and issues such as: Safety Management, Environmental Protection, Safe Process Design, Compliance and Standards, Transport and Storage, Human Factors and Behaviour etc. The aforementioned themes were covered in several parallel sessions run over the three days. This year the organising committee made special effort to weave into the programme 15-minute slots for those presenting Poster Papers in session 5 on the afternoon of day 1 of the Symposium and Exhibition.

The Plenary Session 1, on Day 1 of the Symposium Tuesday 15th April 2008, covered Keynote Papers. This session kicked off with The Burgoyne Memorial Lecture from Mr Peter Webb of Basell Polyolefins UK Ltd on Performance Indicators a tool to help senior managers show process safety leadership. In this session we also bene-fited from a paper from Mr G. Visscher of the US Chemical Safety and Hazard Investigation Board on Expecting the Unexpected: Lessons from CSB accidents investigations. A joint paper from Dr D. Edwards of Granherne, Moscow and Mr C. Brandon on Challenging the SHE culture in the Russian Federation and a paper from Mr P. Bratt

and Ms C. Henney of Hammonds, Trinity Court, Manchester on Buncefield Legal Impacts proved to be interesting. Above all a paper by Professor Trevor Kletz on Accidents of the Next 15 years? helped us address and challenge complacency.

The plenary session (Session 16) on the final day of the Symposium included a paper and DVD presentation involving Centrica Rough 47/3 Bravo Offshore Platform incident of 16th February 2006, covering the catastrophic vessel failure and subsequent hydrocarbon fire. Furthermore, an HSE paper from J. Carter, I. Travers and V. Beckett on the use of process safety performance indicators to ensure the effective management of major accident hazard risk. This paper is timely in the wake of high profile incidents such as the BPs Texas City Refinery incident of October 2005 and Buncefield incident of December 2005.

Sadly, during the organisation of this conference a member of the Hazards Committee, Dr Richard Rogers, died unexpectedly. For some thirty years, Richard has made a significant contribution to the development of process safety technology, its application in industry to produce safe processes, and in the preparation of European standards. Initially Richard was a member and then manager of the UK ICI/AstraZeneca Hazards and Process Studies Group and more recently a consultant with Inburex GmbH, Germany. His personality and contribu-tion to process safety will be missed

Finally, I hope you found your attendance at Hazards XX fruitful, informative and inspiring. The success of Hazards is largely due to dedicated efforts of its committee members who put together the whole symposium programme including the organisation of the Symposium Dinner with excellent steer from the Chairman, Dr Martin Pantony. Regrettably, Martin, after many years of service to hazards, both as the Chairman and as a Committee Member is stepping down as the Chair of the Hazards Committee. I am sure you will all join me in thanking Martin for his outstanding contribution to Hazards and in wishing him well in the future.

M Iqbal EssaChairman NW IChemE Branch

(HM Principal Specialist Inspector HSE)

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