(8a) Dynamic Process Safety Barrier Management System Based on Risk Hierarchy

Process safety is a critical concern for all industries, as they are consistently engaged in efforts to reduce and manage operational risks. In complex segments, such as Oil and Gas, the efficient management of safety barriers is crucial yet challenging, requiring innovative solutions. This paper proposes a dynamic process safety barrier management system for key assets in a midstream facility.

Based on the Bowtie (BT) method integrated with corporate and automation data, the system was developed to continuously monitor, in real-time, the integrity and effectiveness of safety barriers, both preventive and mitigative. It provides a semi-quantitative assessment and comprehensive view of the operational safety status. Unlike traditional static systems, this dynamic model adapts to changes in operating conditions and identified emerging, enabling a rapid and effective response.

The methodology is based on the barrier hierarchy principles outlined in ANSI Z10, ISO 45001, and ISO 45002 standards. By mapping hazards on a 5x5 risk matrix, a 1-25 score is assigned to quantify the initial risk level. This score is then reduced based on the protection factor of existing controls, following the hierarchy of their corresponding barriers. Finally, the BT diagram presents a structured and hierarchical overview of the asset safety status.

In order to make this model dynamic, a computational system was developed using the Python-based Django framework. The platform features an interactive front-end where users can build BT diagrams for the required scenarios and assets. It also guides users through layer of protection/mitigation analysis (LOPA/LOMA) based on a predefined set of hazards, consequences, and barriers mapped by the process safety team.

The system back-end, on the other hand, periodically runs an algorithm that collects real-time corporate and automation data related to controls, such as critical alarms, performance indicators, and operational checklists If any controls fail to meet the required conformity criteria, the corresponding protection factor is impaired, increasing the 1-25 risk score of the related hazard/consequence.

By collecting control-related data from various areas of the midstream facility, from plant instrumentation to HR training programs, the system provides a robust framework for continuously analyzing the status and trends of these controls. This ensures proactive and continuous risk management aligned with international process safety standards.

Moreover, the Bowtie tool provides a clear and structured visualization of risk analysis, linking the root causes of potential incidents with their respective consequences and associated control barriers. By combining BTs from different assets, the platform also provides a comprehensive view of the overall plant's risk level. This facilitates understanding and communication of risks within the organization, as well as simplifying strategic decision-making.

The results indicate that the proposed system contributes to enhance operational safety by efficiently tracking control barrier weaknesses and providing objective information for managers to prioritize and allocate resources. The implementation of this dynamic system not only strengthens the safety culture within organizations but also contributes to incident reduction and continuous improvements in process safety.