Tech Safety Group

UreaKnowHow.com & Tech Safety Group

Capabilities Statement

Tech Safety Group

About us

UreaKnowHow.com and Tech Safety Group (UKH-TSG JV) joint venture provide

operational safety and reliability engineering expertise specifically to operators in the

nitrogen fertiliser industry.

Our services include, but not limited to:

Technical Safety and Risk Management,

Process Safety Documentation compliance with EU and International regulators,

Reliability, availability and maintainability studies (RAM),

Revamp support for Ammonia and Urea technologies,

Operation and Process support.

Introduction

UKH-TSG JV JV comprises a team of Ammonia and Urea specialists and process safety

specialists with experience of developing Safety Cases and associated studies for

nitrogen fertilizer companies to ensure compliance with local and international

legislative requirements (e.g. Seveso III, OHSAS 18001, ISO 31000, UK HSE).

We offer a flexible package of services, providing cost effective solutions to our client’s

needs acting as ongoing support for operation and process safety team during project

development or independent consultants for specific project deliverables.

Tech Safety Group

Technical Safety Services

UKH-TSG JV JV specialists work within projects to design and engineer the required

safety systems for an installation to meet the intent of codes, standards and legislation

and can provide support for all stages of a project from Concept through to Turnover

and ongoing support during Operation and Maintenance.

Services provided, as described in the later sections, include:

Failure modes, effects and criticality analysis (FMECA formal safety assessments)

Hazard identification and assessment (HAZID)

Fire and explosion analysis, mitigation and protection

Hazard and operability studies HAZOP (chairing, and conducting close-out)

ALARP assessment supported by Cost Benefit Analysis (CBA) and Fault Tree

Analysis (FTA)

Develop safety arguments, authoring, updating, reviewing and independent

auditing of Safety Cases

Carry out qualitative and quantitative assessment of risk from normal and

accident conditions

Hazard Registers and Risk Management using proprietary Risk Track platform

Inherent Safety and Design Optimisation

Regulatory and standards review and assistance

Development of project safety related engineering deliverables

Inclusion of safety legislation requirements for the operational facility

Development of additional process safety, reliability studies and technical notes

Development and maintenance of Safety Case and Security Reports

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Reliability, Availability and Maintainability studies

RAM modelling is used to predict asset performance and optimise the availability and

reliability of production systems to maximise Life Cycle Profit.

The modelling uses a sophisticated Monte Carlo simulation to study the effects of

resources, operational strategy, variable demand profile, partial operation, and system

configuration changes and/or equipment throughput variations.

UKH-TSG JV can guide you through the RAM process to help answer tough questions

including:

Identifying bottlenecks in the production

Detecting failures in the early part of design

Comparing different design options for production

Optimizing maintenance schedules

Increasing the effectiveness of logistics

Identifying equipment maintenance priorities on failure

Meeting contract production requirements

Tech Safety Group

Revamp support for Nitrogen Fertilizer technologies

Execution of revamps and brownfield modification projects is a complex task due to the

integration challenges with existing facilities and systems.

UKH-TSG JV multi-disciplinary engineering teams are therefore formed to meet the

needs of your project and develop technical definition at the appropriate level of detail.

Brownfield modification focus areas include:

Confirming existing facility as built data and specifications

Confirming capacity of existing systems (process, electrical, instruments, safety,

structural, mechanical)

Detailed constructability reviews to establish physical and logistical constraints

and drive design towards build simplicity

Identify and minimise requirement for partial / full production shutdowns

through design

Establish asset late life issues which may place additional constraints and / or

scope on the project (i.e. turndown, integrity, regulatory change)

Tech Safety Group

Operation and Process support

UKH-TSG JV offer services targeted towards fertilizer operators that support

compliance and licence to operate and increased production efficiency. Our offerings

range from day-to-day operations support, to heavy repair operations and project

execution.

The day-to-day UKH-TSG JV services are activities related to the safe and efficient

daily operations of a nitrogen fertilizer plant.

These activities are typically related to:

Contribute in daily operations and supervision of Ammonia, Urea and UAN

facilities

Planning and following up maintenance and inspection activities at the facilities

Troubleshooting and diagnostics in connection with operation and maintenance

challenges

Ensuring the plant technical integrity is maintained

Providing input into the framework conditions for the operation and

maintenance of the plant

Updating and correcting documentation for the relevant systems

Assisting projects with Ammonia, Urea and UAN expertise where relevant

Being the initiator for necessary modification projects on nitrogen fertilizer

plants

Tech Safety Group

A safety case is a written presentation of technical, management and operational information about

the hazards and risks that may lead to a major accident. In the safety case, the operator provides

justification for the measures the operator has taken or will take to ensure the safe operation. Safety

case is a live document that is required to be updated throughout the entire plant lifecycle in

accordance with specific regulations and corporate standards.

Safety Case has become the tool of choice for Major Hazard Operators to demonstrate that all

measures necessary for the prevention and mitigation of major accidents have been taken.

UKH-TSG JV has the capabilities to assist in the Safety Case preparation including various supporting

studies such as Major Accident Hazard (MAH) Analysis, Fire and Explosion Analysis (FEA), Escape

Muster Evacuation and Rescue Analysis (EMERA), Emergency System Survivability Analysis (ESSA),

Quantitative Risk Analysis (QRA) etc.

As requested by project development further specific safety studies can be developed. These specific

studies include, but not limited to, Hazard Identification (HAZID), Hazard and Operability (HAZOP) and

Safety Integrity Level (SIL), Fault Tree Analysis (FTA), Event Tree Analysis (ETA), Dispersion and

Radiation Study, Non-flammable Hazard Analysis (NFHA) etc.

Currently we support a range of engineering companies and operators in the fertilizer industry the

Middle East and Europe. We can work as part of the project team supporting the Process Safety

department during the project lifecycle, or independently providing consultancy for specific scope of

services.

UKH-TSG JV is able to call upon a team of qualified and motivated specialists with experience in various

sites worldwide who provide technical safety consultancy services over entire project lifecycle from

Concept, FEED, and Detailed Design to Commissioning and Operation. The emphasis is placed firmly

on the provision of clear and concise guidance and solutions that add value to our clients businesses

and ensure compliance with the local and international safety regulations.

Services offered by UKH-TSG JV in support of safety case development / management include:

Engineering support and development of new safety case

Existing safety case update and management

Qualitative Risk Assessment

Formal Safety Assessment

Probabilistic Risk Assessment

Safety and Reliability Services

Tech Safety Group

Qualitative risk assessment can be based on informed judgement and reference to appropriate

guidance. A qualitative risk assessment, in general, is a systematic process to brainstorm and examine

potential hazards and whether existing precautions or safety measures are adequate or if further

measures are needed to prevent the unwanted consequences. Hazards where the risks are obvious

can be addressed directly through qualitative process.

UKH-TSG JV offers the following qualitative risk assessments.

Hazard Identification (HAZID) Study

HAZID workshop is a qualitative exercise

based primarily on expert judgement from a

study team. The objectives of a HAZID are to:

identify all potential major hazards and

hazard scenarios;

develop all credible consequences associated

with the identified hazards;

risk rank all credible consequences using an

agreed risk matrix; and

pending on the risk ranking provide safety

measures into design and operations to

reduce risks to ALARP.

Hazard and Operability (HAZOP) Study

HAZOP workshop is a technique used to

identify hazards that might affect safety and

operability, using systematic critical group

review structured by the use of guidewords,

usually applied to a process design.

The objectives of a HAZOP are to scrutinise all

aspects of the process design in detail to

ensure that it is inherently safe and to confirm

that all hazard and operability issues have

been considered appropriately.

Identify Potential Hazards

Select Hazard

What ifs brainstorming

Identify causes, consequences & safeguards

Risk Ranking

Provide Recommendations to eliminate / reduce risk to

ALARPMore what ifs? More Hazard?

Yes

No

Yes

Tech Safety Group

Human Factor Engineering (HFE)

HFE is a multidisciplinary approach to

engineering that focuses on the integration of

people, work, organisation, equipment and

environment. The objectives of a HFE are to:

Reduce risk to health, personal and

process safety and the environment;

Eliminate, reduce likelihood or mitigate

consequences of human error;

Improve human efficiency and productivity,

thereby enhancing operational performance;

and

Improve user acceptance of new facilities.

Simultaneous Operations (SIMOPS) Study

SIMOPS study is similar to HAZID study, where

the workshop is conducted using the HAZID

study process. SIMOPS is defined as

occurrence of two or more potential

conflicting activities or activities being

coordinated in the same location at the same

time within a process operations envelope.

The objectives of a SIMOPS study are to:

identify all potential hazards and risks

introduced by SIMOPS;

develop all credible consequences associated

with the identified hazards;

risk rank all credible consequences using an

agreed risk matrix; and

pending on the risk ranking provide safety

measures into design and operations to

reduce risks to ALARP.

Human Performance

People

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Calculation or estimation of numerical values or graphical representations that describe the physical

outcomes of hazardous events associated to flammable, explosive and toxic materials with respect to

potential impact on human, asset and the environment.

UKH-TSG JV offers the following consequence modelling.

Flare / Vent Radiation & Dispersion Modelling

Results from the modelling could be applied to

determination of:

stack height;

sterile radius; and/or

hazardous area and exclusion zone.

Proprietary software employed to the

modelling are either Softbits Flaresim and/or

DNV GL PHAST.

Gas Dispersion Modelling

The models studies releases scenarios involving

toxic and/or unignited flammable gas. The study

is carried out with the following main objectives:

Assess the consequences of the identified

credible dispersion events; and

Assess potential impact on personnel /

facilities.

Fire / Explosion Consequence Modelling

To ensure safe and efficient operation of the

proposed facilities, it is necessary to assess

and mitigate the consequences arising due to

accidental releases resulting in potential fire

and explosion events. The modelling provides

a detailed assessment of all potential fire and

explosion events for facility siting, fire and gas

detection system arrangement, fire-fighting

system requirements, etc.

Vessel Fire Survivability Analysis

The models studies the impairment time of a

jet fire impinged vessel / pipe to ensure that

all hazardous inventories are removed before

escalation offers.

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Formal Safety Assessment (FSA) focuses on major accident hazards. Providing a well-considered,

detailed description of a suitable and sufficient FSA within safety case will enable operators to provide

evidence of:

an understanding of the risk and the controls that are critical to managing risk;

the magnitude and severity of the consequences arising from potential major accidents;

the likelihood of potential major accidents;

clear linkages between hazards, the major accidents, control measures and the associated

consequences and risk; and

a prioritised list of actions that reduce risks to a level that is ALARP.

UKH-TSG JV carried out FSA for fertilizer plants as part of design projects undertaken by various EPCM

companies. Depending upon the facility the FSA may consist of a number of separate studies including,

but not limited to, the following:

Fire & Explosion Analysis (FEA)

FEA is used for the development of facility

design and layout, and in assessment of

potential incidents that could lead to major

accidents. It is applied by understanding the

fundamentals of release, dispersion, fire and

explosion physical phenomena to derive a

measure of effect, in terms of loading, on

people, the environment and facilities.

Quantitative Risk Analysis (QRA)

QRA uses a systematic method to quantify

risks associated with the activities involved in

the production and processing of hazardous

chemicals. FEA identifies the hazards and

analyses the consequences, and QRA

estimates the hazardous event frequencies

and combines them with the results from the

FEA to assess and manage the risk. The key

objectives of any QRA are to identify the major

hazards, quantify the overall risk, optimise the

risk reduction measures to be implemented

and to help the decision making process with

regard to acceptable risk criteria.

Tech Safety Group

Non-Flammable Hazard Analysis (NFHA)

QRA has two important parts to it: the process

hydrocarbon part and the non process

hydrocarbon part. NFHA considers and

assesses the risks of ship collision, personnel

transfer, occupational, dropped object and/or

structural failure.

Temporary Refuge Integrity Analysis (TRIA)

TRIA is conducted to determine the

performance criteria that have to be achieved

for a Temporary Refuge (TR) to meet its safety

goals. The analysis examines the effects on

personnel in TR from smoke and gas ingress,

temperature rise and carbon dioxide

accumulation.

Emergency System Survivability Analysis (ESSA)

ESSA systematically reviews the emergency

systems installed against major accidents to

ensure each system can withstand an initial

major accident and/or survive long enough to

achieve its goals.

Escape, Temporary Refuge, Evacuation &

Rescue Analysis (ETRERA) / Escape, Muster,

Evacuation & Rescue Analysis (EMERA)

The analysis focuses on the performance of

the ETRER / EMER facilities during a major

accident where all control measures have

failed. The goals are to ensure personnel can

be promptly made aware of the accident and

can safely egress and be evacuated and

rescued.

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Bowtie & Safety Critical Element Development

The bowties provide detailed way of

visualising the role of barriers and clearly

demonstrate the links between the causes

and consequences for each major accident

and the associated barriers.

Safety Critical Elements are barrier elements

whose failure could cause or contribute

substantially to a major accident. As these

barrier elements are particularly important to

manage risk it is necessary to ensure they are

appropriately specified and implemented.

Performance Standard Development

A performance standard is a statement of the

performance of a safety critical element,

which cab ne applied to persons and

procedures as well as hardware systems and

equipment items.

ALARP Demonstration Study

This study is carried out to review the risk level

and identify existing measures installed,

identify potential additional reasonably

practicable measures to reduce risk further,

and to demonstrate that all risks are ALARP

with weighing risk against the sacrifice, in

money, time or trouble, needed to control it.

Tech Safety Group

Probabilistic risk assessment involves obtaining numerical estimate of the risk from a quantitative

consideration of event likelihoods and consequence effects. Specific quantitative tools and techniques

are used to estimate the severity of the consequences and the likelihood of realisation of the hazardous

effects.

UKH-TSG JV offers the following quantitative risk assessments.

Fault Tree Analysis (FTA)

FTA is a top down deductive methodology

that uses graphical tree model to present the

various logical combinations of failures that

could result in an undesired state or incident.

The failure combinations include equipment

failure, human errors and management

system failures. The tree starts with a top

event which is a specific undesired state or

incident that is broken down into a series of

contributory events that are structured

according to certain rules and logics. This

process of breaking down the events to

identify contributory causes and their

interaction continues until the root causes are

identified.

Event Tree Analysis (ETA)

ETA is a left to right binary deductive

methodology that uses graphical tree model to

identify and quantify possible outcomes

following an initiating event. The event tree

provides systematic coverage of the time

sequence of event propagation, either through

a series of protective system actions, or normal

plant functions, or operator interventions and

incident consequences.

Risk Based Cost Benefit Analysis (CBA)

Risk based CBA is a decision making tool for

comparing the costs and benefits of additional

risk reduction measure in terms of cost of

implementing the measure and the benefit of

the measure, in terms of Implied Cost of

Averting a statistical Fatality (ICAF).

CBA provides an important guide to

demonstrate whether the benefits of a

measure outweigh its costs, and thus indicate

whether it is appropriate to implement the

measure.

Quantitative Risk Analysis (QRA)

As previously defined, the key objectives of a QRA are to identify the major hazards, quantify the

overall risk, optimise the risk reduction measures to be implemented and to help the decision

making process with regard to acceptable risk criteria.

RISK

Q=0.0E+0 w=2.8E-4

LOC and ignitionleading toFatality

LOC

Q=0.0E+0 w=3.0E-3

Gas release atthe grade due to

pipe rupture

IGNITION

IgnitionProbability

Q=0.16

MANNING

ManningProbability

Q=1

FATALITY

FatalityProbability

Q=0.59

INITIATING EVENT

Q=0.0E+0 w=1.4E+2

Initiating Event

FCV FAIL CASE

Q=2.2E-2 w=4.4E-2

FCV003 FailureCase

SKID BLOCKAGE

Q=1.0E-3 w=4.4E-3

Closure /blockage of

valves within wellpad

DEPACK

137 wellworkover /start-up per

operator per year

w=137

HIGH PRESSURE

Probability ofhigh pressure

build-up

Q=1

FCV FAIL

Q=1.0E-5 w=2.0E-5

FCV003 fails opendetected in DCSbut un-notice by

operator

FCV FAIL (BODY)

FCV body failsopen

FR=0.0345 Tau=1

FCV FAIL (UNDET)

FCV actuatorfails open

undetected inDCS

FR=0.01015 Tau=1

FCV FAIL (DET)

FCV actuatorfails open

detected in DCS

FR=0.02036 Tau=1

OP ERROR (FCV)

FCV003accidentally left

open

Q=0.001

MANUAL VALVE

Closure ofgathering tie-inmanual valve

Q=0.001

NRV BLOCKAGE

NRV blockageleading to

pressure build-upwithin skid

w=0.00438

Valve Closes Gas Release is Contained

0.01 0.000001 per year

Gas Release Venting Starts Vent to Safe Location

0.0001 per year Valve Fails Open 0.80 0.0000792 per year

0.99 Venting Fails to Start Uncontrolled Gas Release

0.20 0.0000198 per year

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Safety Integrity Level (SIL) Study /

Layers of Protection Analysis (LOPA)

LOPA is a technique defined in IEC 61511-1 used

for evaluating the effectiveness of protection

layers in reducing the likelihoods and

consequences of identified hazardous events,

which in term can be further assessed to

determine the required Safety Instrumented

Functions (SIFs) and the SIL requirements.

High Level SIL Verification

High Level SIL Verification is conducted to determine the Probability of Failure on Demand (PFD)

of a SIF at its required SIL. The calculation process splits a SIF into three subsystems (i.e. sensor,

logic solver, and final element), which are evaluated using historical failure data, proof test

interval, common cause factor, and other factors, if applicable.

The verification determines whether a particular SIL have been met, based on hardware fault,

program error, and human error.

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UKH-TSG JV offers the following safety and reliability services.

Hazard Register Implementation

A hazard register records all the hazards that

have been identified by the various

identification of hazard tools and techniques,

and demonstrates that all potentially

significant hazards and consequences have

been identified, the risks associated are

evaluated and understood, and that

safeguards are in place to manage the risks.

The information to be captured within a risk

register should contain the following:

System / Area;

Hazard;

Cause;

Consequences;

Safeguards; and

MAH potential.

Reliability, Availability and Maintainability

(RAM) Modelling

RAM modelling is used to predict asset

performance and optimise the availability and

reliability of production systems to maximise

Life Cycle Profit.

The modelling uses a sophisticated Monte

Carlo simulation to study the effects of

resources, operational strategy, variable

demand profile, partial operation, and system

configuration changes and/or equipment

throughput variations.

100% Storage Tank A

50% Pump B

50% Pump C

50% Pump A

100% Heat Exchanger

100% Storage Tank B

Tech Safety Group

Industries and technologies UKH-TSG JV specialists have experience with the following technologies:

Ammonia Urea Syngas Technologies

KBR Stamicarbon Reforming

ThyssenKrupp Uhde Saipem Auto Thermal Reforming

Haldor Topsoe Toyo Engineering Ethylene

Casale Group Casale Group Gas Separation

Linde / Lurgi NIIK Gas Liquefaction

Tech Safety Group

Projects UKH-TSG JV specialists were involved in the following projects:

Ammonia Technology

Client Location Scope of Service

ThyssenKrupp Uhde

Abu Qir Algeria Revamp case study and energy efficiency program

Haldor Topsoe PVFCCo Vietnam Training, operation and production optimisation

ThyssenKrupp Uhde

EAgrium Egypt Process engineering and design services

ThyssenKrupp Uhde

Maaden Saudi Arabia Process engineering and design services

ThyssenKrupp Uhde

Maaden Saudi Arabia Commissioning support

KBR / Casale Amonil SA Romania Operation support and production optimisation

ThyssenKrupp Uhde

SAFCO Saudi Arabia Operation and production optimisation for world largest ammonia plant;

ThyssenKrupp Uhde

FERTIL UAE Preparing process documentation for formal proposal and bidding process;

ThyssenKrupp Uhde

Petrovietnam Fertilizer Company

Vietnam Preparing process documentation for formal proposal and bidding process;

ThyssenKrupp Uhde

Duslo Sala Slovak

Republic On site inspection and assessment

KBR / Casale Azomures SA Development of risk register and ALARP Demonstration methodology

Tech Safety Group

Urea Technology Client Location Scope of Service

Stamicarbon Stamicarbon Netherlands Marketing, sales, contract negotiations for all revamp projects

Stamicarbon SAFCO Saudi Arabia Guidance & Control Basic & Detailed Engineering for revamp projects

Stamicarbon Fertil UAE Revamp project

Stamicarbon Yara Canada Commissioning and Start up, Corrosion Inspection

Stamicarbon El Delta Egypt Corrosion Inspection

Stamicarbon Yuntianhua China Commissioning and Start up

Stamicarbon Various Various Visited more than hundred urea plants during twelve years

Stamicarbon Acron Russia Participation in revamp studies

Stamicarbon Salavat Russia Participation in revamp studies

Stamicarbon Nitrogenmuvek Hungary Participation in revamp studies

Stamicarbon Stamicarbon CIS Countries Licensing Management services for Urea Revamps

Stamicarbon Stamicarbon China Licensing Management services for Urea Revamps

Stamicarbon Stamicarbon Iran Licensing Management services for Urea Revamps

Stamicarbon Stamicarbon Saudi Arabia Licensing Management services for Urea Revamps

UreaKnowHow.com SAFCO / SABIC Saudi Arabia Providing training services regarding urea technology and urea market

UreaKnowHow.com Pequiven Venezuela Providing training services regarding urea technology and urea market

UreaKnowHow.com SKW Piesteritz Germany Providing training services regarding urea technology and urea market

UreaKnowHow.com Agrium Canada Providing training services regarding urea technology and urea market

UreaKnowHow.com Sandvik Process

Systems Sweden Technical & Commercial Consultancy

UreaKnowHow.com CEAMAG France Technical BID evaluation for grass root Ammonia/Urea complex

Tech Safety Group

Urea Technology Client Location Scope of Service

UreaKnowHow.com SKW Germany Providing consultancy regarding mechanical and safety topics

UreaKnowHow.com OCI Nitrogen Netherlands Providing consultancy regarding product quality and process topics

UreaKnowHow.com Process Services

SBN Austria

Providing process services to redesign heat exchangers to avoid baffle hammering, HTRI calculations

UreaKnowHow.com Linde Gas Germany

Providing technical consultancy regarding operational and maintenance aspects of a new grass root urea complex.

Tech Safety Group

Contact details:

UREAKNOWHOW.COM

Cannerweg 123

Maastricht, 6213 BA

The Netherlands

Mark Brouwer

Email: mark.brouwer@ureaknowhow.com

Mobile: +31 (6) 295 76 845

TECH SAFETY GROUP LIMITED

3 Othello Grove, Bracknell

Berkshire, RG42 3TZ

United Kingdom

Dan Cameron Cojocaru

Email: dan.cojocaru@techsafetygroup.com

Mobile: +44 7494 783 534