Elements of the modern production safety system

UDK: 658.382.3:622.276

DOI: 10.24887/0028-2448-2025-11-64-71

Key words: safety, system, element, production, injury, accident rate

Authors: M.V. Anfimov (Rosneft Oil Company, RF, Moscow); M.A. Dias (IAS Engineering and consulting LLC, RF, Moscow; Gubkin University, RF, Moscow) I.S. Sivokon (Rosneft Oil Company, RF, Moscow; Gubkin University, RF, Moscow)

Based on the requirements specified in the previous publication dedicated to the forming of a modern third generation production safety system, its structure was developed, which includes 5 main elements: № 1 «Model», № 2 «Control», № 3 «Monitoring and Forecast», № 4 «Action» and № 5 «Culture». The third generation security system is the successor of the previous generation systems «0», «1» and «2», which were based on natural self-preservation instincts of workers, supervisory and prescriptive regulation, risks assessment, analysis and management. The goal of the third generation security system is to eliminate the gaps of the previous systems, due to which it is extremely problematic to completely eliminate (prevent) severe and fatal injuries to personnel and third parties at production facilities, as well as accidents at industrial sites and/or such work requires significant additional costs for materials, equipment and additional qualified personnel. The main system elements are defined based on the analysis of public statistics on the injury and accident rate root causes, as well as accidents internal investigations and analysis of efficiency measures to ensure production safety conducted by Rosneft Oil Company specialists. The implemented work resulted in the formulation of the main elements functions for the third generation production safety system.

References

1. Chernoplekov A.N., Chemical processes safety risks control and management (In Russ.), Problemy analiza riska, 2024, V. 21, no. 6, pp. 10–39.

2. Anfimov M.V., Dias M.A., Sivokon’ I.S., Industrial safety systems (In Russ.), Neftyanoe khozyaystvo = Oil Industry, 2025, no. 9, pp. 118–124,

DOI: https://doi.org/10.24887/0028-2448-2025-9-118-124

3. Neave H.R., The Deming dimension, SPC Press, 1990, 440 p.

4. A guide to the project management body of knowledge (PMBOK® Guide), Project Management Institute, 2000, URL: https://pagesperso.g-scop.grenoble-inp.fr/~tollenam/best/PMBOK.PDF

5. Bow ties in risk management: A concept book for process safety, Center for Chemical Process Safety, 2018, 224 p.

6. Reason J.T., The contribution of latent human failures to the breakdown of complex systems, Philosophical Transactions of the Royal Society, 1990, Ser. B.327,

pp. 475–484, DOI: https://doi.org/10.1098/rstb.1990.0090

7. Sivokon’ I.S., Anfimov M.V., Andreeva G.V., Rassledovanie proisshestviy na proizvodstve (Investigation of industrial accidents), Moscow–Vologda: Infra-Inzheneriya Publ., 2024, 254 p.

8. Sklet S., Safety barriers: Definition, classification, and performance, Journal of Loss Prevention in the Process Industries, 2006, V. 19, pp. 494–506,

DOI: https://doi.org/10.1016/j.jlp.2005.12.004

9. Akhmetova A.M., Khomyakova V.S., Analiz prichin proizvodstvennogo travmatizma v otdel’nykh otraslyakh promyshlennosti (Analysis of the causes of occupational injuries in certain industries), Ekaterinburg: Ural’skiy gosudarstvennyy agrarnyy universitet, 2020, URL: https://min.urgau.ru/images/2022/10-2022/38-10-2022.pdf

10. Uroven’ travmatizma prodolzhaet snizhat’sya (The injury rate continues to decline). – https://srg-eco.ru/news/uroven-travmatizma-v-rossii-prodolzhaet-snizhatsya/

11. Report no. 8/25. Performance of European cross country oil pipelines. Statistical summary of reported spillages in 2023 and since 1971, Concawe Brussels, July 2025, URL: https://www.concawe.eu/wp-content/uploads/Rpt_25-8.pdf

12. 12th Report of the European Gas Pipeline Incident Data Group. Doc. Number VA 23.0304. Gas pipeline incidents, September 2023, URL: https://www.egig.eu/reports/$60/$178

13. UKOPA/RP/24/001. Product loss incidents and faults report (1962–2022). Edition 1, November 2024, URL: https://ukopa.co.uk/document/ukopa-pipeline-fault-database/

14. Recommended Practice 754. Process safety performance indicators for the refining and petrochemical industries, URL: https://www.api.org/oil-and-natural-gas/health-and-safety/refinery-and-plant-safety/process-safety/p...

15. Sivokon’ I.S., Kulagin V.A., Anfimov M.V., Target programs formation methodology on prevention of major incidents at production (In Russ.), Neftyanoe

khozyaystvo = Oil Industry, 2021, no. 2, pp. 102–106, DOI: https://doi.org/10.24887/0028-2448-2021-2-102-105

16. Hart C., Stuck on a plateau: A common problem, workshop paper, paper prepared for the national academy of engineering program office accident precursors project, Washington: D.C., 2003, URL: https://nap.nationalacademies.org/read/11061/chapter/12

17. Artem’ev V.B., Rudenko Yu.F.. Levin S.E. et al., Integrated monitoring of the state of production processes, industrial and environmental safety of hazardous production facilities. Part 1. Environmental risks in industry. Ways of risk minimization (In Russ.), Ugol’, 2024, no. 4, pp. 63–69, DOI: https://doi.org/10.18796/0041-5790-2024-4-63-69

18. Artem’ev V.B., Rudenko Yu.F.. Levin S.E. et al., Integrated monitoring of the state of production processes, industrial and environmental safety of hazardous production facilities. Part 2. Purpose, objectives and approaches to implementation of risk-oriented monitoring of industrial and environmental safety (In Russ.), Ugol’, 2024,

no. 8, pp. 95–101, DOI: https://doi.org/10.18796/0041-5790-2024-8-95-101

19. ExxonMobil. Operations integrity management system, URL: https://corporate.exxonmobil.com/who-we-are/technology-and-collaborations/energy-technologies/risk-m...

20. Phillips 66. Health, safety and environmental management system, URL: https://phillips66.widen.net/s/tfv7cfvqmm/hse-policy