The Perdido Norte Project in the Gulf of Mexico is set to create history, ably aided by Corus Tubes, a business unit of Corus. Corus Tubes has won a major contract to manufacture and deliver about 312 kms of uncoated steel and line-pipe for the deepest pipeline in the world. The line-pipe will run at depths of 3500 – 8300 feet under water in a rugged seabed terrain and will be manufactured in keeping with ANSI 1500 service ratings.

Corus Tubes will incorporate the “Crimp” and “O” press combination in manufacturing the 18” pipes. This process, used in conjunction with Corus Tube’s expansion system, will make the pipes dimension tolerant and collapse resistant, attributes ideally suited for extreme conditions of ultra deep waters. Once in operation, the project shall bring Corus Tube’s cutting edge pipe production capabilities to the fore.

Tackling process safety

Safety is the number one priority for Corus. Ensuring that its operations meet the legislative requirements designed to prevent devastating accidents is a key activity. Corus has made significant improvements in its safety record in recent years, with Lost Time Incidents falling from 16.8 in 2000 to an all-time low of 1.8 in the second quarter of 2007. But those figures are a measure of occupational or personal safety.

Process Safety is linked to the operation and maintenance of installations and equipment. Corus operates some high hazard facilities and recognises the potential for major accident risks to employees and neighbours, the business and the environment. CEO Mr Philippe Varin (who is on the Corus Board alongside independent director Mr Tony Hayward,

also the chief executive of BP), has made process safety a priority for Corus. He demanded “a focus on the integrity and safe operation of our assets and equipment to prevent catastrophic incidents.”

Corus Health & Safety Director Mr Stan Booth says: “In essence it is about preventing very serious incidents such as an explosion, a fire, or a major escape of gas. This means a lot of challenges in understanding complex processes.”

“We wanted to take a proactive stance,” says Director, Engineering, Ms Anne Cnossen, who is leading the Corus process safety strategy group and who presented a paper on the company’s approach to a meeting of the IISI (International Iron and Steel Institute). Corus is determined to be at the forefront of the steel industry in addressing process safety. Ms Cnossen has now been asked to lead a worldwide group on this issue.

An independent review of how process safety is managed in Corus has been undertaken. A strategy group of senior Corus engineers, production managers and safety experts has developed a company standard and policy for the potentially high hazard processes.

“We are talking about events of extremely low probability but high consequence,” says Mr Andrew Murray, Engineering Director of Corus Construction & Industrial, who is on the working group. All Corus facilities will have to examine closely whether a loss of equipment integrity could cause an on-site fatality, a serious injury to a member of the public, or a major accident to the environment within and beyond the site boundary.