Safety And Environmental Standards For Fuel Storage Sites: Final Report

Health and Safety Executive Safety and environmental standards for fuel storage sites Process Safety Leadership Group Final report Health and Safety Executive Safety and environmental standards for fuel storage sites Process Safety Leadership Group Final report HSE Books Safety and environmental standards for fuel storage sites Final report © Crown copyright 2009 First published 2009 ISBN 978 0 7176 6386 6 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the copyright owner. Applications for reproduction should be made in writing to: The Office of Public Sector Information, Information Policy Team, Kew, Richmond, Surrey TW9 4DU or e-mail: [email protected] 4 Safety and environmental standards for fuel storage sites Final report Contents Foreword 7 Introduction 9 Scope and application 11 Summary of actions required 14 Part 1 Systematic assessment of safety integrity level requirements 22 Part 2 Protecting against loss of primary containment using high integrity systems Part 3 Engineering against escalation of loss of primary containment 37 Part 4 Engineering against loss of secondary and tertiary containment Part 5 Operating with high reliability organisations 42 62 Part 6 Delivering high performance through culture and leadership Conclusion 25 64 66 Appendices Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix 1 2 3 4 5 6 7 8 9 10 Mechanisms and potential substances involved in vapour cloud formation Guidance on the application of layer of protection analysis (LOPA) to the overflow of an atmospheric storage tank 82 Guidance on defining tank capacity 125 Guidance on automatic overfill protection systems for bulk gasoline storage tanks 129 Guidance for the management of operations and human factors 142 Emergency planning guidance 197 Principles of process safety leadership 244 Process Safety Forum: Governance and terms of reference 247 BSTG report cross reference 249 Acknowledgements 252 References Abbreviations 67 256 264 Further information 267 5 Safety and environmental standards for fuel storage sites Final report 6 Safety and environmental standards for fuel storage sites Final report Foreword The recent Texas City and Buncefield incidents have moved industry and regulators beyond the pure science and engineering responses to develop ways to prevent a recurrence. They have caused us to also critically examine the leadership issues associated with delivering what has to be excellent operation and maintenance of high-hazard processes. The responses by industry and regulators to these incidents, and the recommendations arising from their investigations, are essential to ensuring they never happen again. Such responses need to be effective and measured, requiring a dialogue between industry and the community to determine the balance between risk prevention, the viability of the operations and their value to society. In this regard the regulators are the effective representatives and arbiters for society. The formation of the Process Safety Leadership Group (PSLG) in September 2007 was designed to meet the need for an effective framework for interaction between industry, trade unions and the COMAH Competent Authority (CA); a frame