Enhanced Learning from Incidents Through Refinement of LOPC-Related HPI

This work presents a structured and standardized approach to identifying High Potential Incidents (HPIs) arising from Loss of Primary Containment (LOPC) events within oil and gas industrial operations, with the goal of enhancing proactive learning and preventing Major Accident Events (MAEs). The current challenge in incident classification lies in the subjective interpretation of what constitutes a high potential scenario, particularly in complex environments such as offshore platforms and congested process areas. To address this, the comprehensive set of criteria has been developed by integrating in engineering calculations, barrier-based safety analysis, and incident management standards. The classification system is designed to be both technically robust and operationally simple, ensuring accurate identification of high-impact incidents while remaining accessible to field personnel. The methodology introduces two complementary classification approaches: Immediate HPI Classification, which includes Tier 1 and Tier 2 LOPC events, explosions, fires (including small, flash, and smoldering), and hydrocarbon gas detection in safe areas. Conditional HPI Classification, which evaluates sensibly sized releases that may escalate under specific conditions. This involves predefined engineering calculations to assess release volumes and a review of existing safeguards to determine escalation potential. Furthermore, it integrates the evaluation of mitigation measures in place to collectively determine whether the event qualifies as a High Potential Incident (HPI). Gas release thresholds are based on simulations of cloud sizes capable of causing significant explosion damage, while liquid releases exceeding secondary containment capacity are flagged due to their potential to cause widespread fires. The presence or absence of effective mitigation barriers further informs the classification. To ensure consistency and ease of use, the methodology is distilled into a simplified checklist and flowchart system. This approach enhances incident investigation protocols, strengthens corrective actions, and supports a proactive safety culture. By systematically extracting lessons from incidents with high potential consequences, the framework contributes novel insights to the field of process safety and aligns with the industry's goal of achieving zero incidents.