Enhanced analysis of Safety Critical Elements (SCEs) to mitigate Major Accident Hazards (MAH) in Early Production Facilities (EPF): A case study in Indonesia

Early Production Facilities (EPF) is a temporary processing facility that allow oil production at low initial cost and reduced financial risk. EPF still faces significant challenges related to process safety despite its financial advantages. Although existing studies have addressed various aspects of EPF, including risk assessment, design, and economic feasibility, a significant gap remains in the identification and analysis of Major Accident Hazard (MAH) and Safety Critical Elements (SCEs) specific to EPF operations. This study addresses the research problem of identifying potential MAH and the corresponding SCEs to reduce the risk of major accidents in EPF. The study focused on EPF located in three (3) areas: AMJ, BMH, and HGD which are located in West Java, Indonesia. HAZOP and Bowtie methods were employed to systematically identify potential MAH and relevant SCEs in the selected EPF. 32 MAH scenarios on EPF identified in this study. 72 % of accidents have an impact on fire/explosion, which poses a risk to personal safety and facility integrity. Most MAH scenarios on EPF are triggered by two primary causes: overpressure and corrosion. A major proportion of MAH scenarios are identified in equipment such as Separator, Flowline & Manifold, and Scrubber. 188 SCEs were identified in this study. By prioritizing the identified SCEs, maintenance resources can be focused on critical elements that directly prevent or mitigate MAH, thereby improving cost-effectiveness without compromising safety. 74 % were classified as technical/hardware barriers. This highlights the necessity of a robust maintenance strategy to guarantee the reliability and effectiveness of these technical elements over time. Future efforts could also focus on refining the current Bowtie analysis by incorporating quantitative risk modeling methods and on developing performance standards for SCEs, which can be used to enhance the robust maintenance strategy.