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Commitment to Process Safety

Process Safety Culture

o Within an organization, some accepted, others not
o Acceptance of situations as normal that pose hazards is unacceptable
o Ignoring alarm because it goes off regularly ex
Compliance w/ standards
o All relevant (internal and external) safety standards, codes, regulations, and laws must
be identified and addressed
o Must be monitored or audited
o Action items must be completed in a timely fashion
Process safety competency
o Safety knowledge needs to be continuously improved
o Must be readily available
o Must be consistently used
Work force involvement
o Workers at all levels should have roles and responsibilities for ensuring safety
Stakeholder outreach
o Seek out individuals and organizations that believe can be affected by company
o Build a relationship with these groups
o Provide accurate info about process hazards and risks

Understand Hazards and Risks

Process knowledge management

o Maintain appropriate documentation of all aspects of the process: equipment design,
fabrication, installation, and the chemicals
Hazard ID and Risk Analysis (HIRA)
o Document analysis of hazards and risks at facilities throughout their life cycle
o Include all standard modes of operation (normal, startup, shutdown, and maintenance)
o Consider impacts to employees, the public, and/or environment

Manage Risk

Operating procedures
o Ensure proper development, timely maintenance and consistent use of operating
o Include safe operating limits
o Include consequences of deviations from safe operating limits
Safe work practices
o Practices governing maintenance and non-routine work should be documented
o Document conditions that work can be conducted
Asset integrity and reliability
o Systematically inspect and test equipment to ensure it will be suitable for its intended
application throughout its lifetime
Contractor management
o Implement practices to ensure contract workers can perform jobs safely; contractor
activities will not increase facility operational risk
Training and performance assurance
o Worker training programs are essential to ensuring reliable performance of critical tasks
Management of Change
o Changes to processes can create unanticipated hazards
o MOC requires review and authorization of proposed changes prior to implementation
o Documentation and worker training must be kept up to date regarding changes
Operational Readiness
o Ensure safe startup processes over the life of the facility
o Includes shutdown conditions which leave the facility in a safe condition for startup
Conduct of Operations
o Execute operation and management tasks in a structured process to ensure workers at
all levels perform their duties properly
o Things dont stay fixed
Emergency management
o Plan for possible emergencies
o Allocate resources, practice and improve plans
o Effectively inform employees and stakeholders in the event of an incident

Learn From Experience

Incident Investigation: a formal process for investigating process safety incidents, including
appropriate timely follow up
Measurement and Metrics
o Identify and use relevant measures of process safety over the life of a process
o Outcome-oriented measurements may provide information after incidents:
Fatal Accident Rate (FAR) involves aspects of personal safety
OSHA Incident Rate (involves aspect of personal safety
o Leading indicators of the effectiveness of safety critical systems
Regular, documented inspections of safety critical items (with action items)
Documentation of proper handling of safety audit action items
Number of demands on safety systems (including pressure relief devices)
o A system of scheduling, staffing, effectively performing, and documenting all aspects of
Management Review & Continuous Improvement
o The routine evaluation of whether management systems are performing as intended
and producing desired results as efficiently as possible

Related Interests