Professional Documents
Culture Documents
Process Safety Management - Part1
Process Safety Management - Part1
SBM
Rio de Janeiro
February, 2015
Rev 00
11
Contents
SECTION 1 Introduction..............................................................................slide 3
SECTION 2 Experience in RBPS..................................................................slide 52
SECTION 3 Commit to Process Safety........................................................slide 79
SECTION 4 Understand Hazards and Risk................................................slide 108
SECTION 5 Manage Risk..........................................................................slide 191
SECTION 6 Learn from Experience...........................................................slide 276
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Section 1
Introduction
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Course Objectives
Understand Process Safety Management (PSM)
Understand the concepts of Risk Based Process Safety (RBPS)
Learn how to develop, correct or improve a PSM system based on
objectives
Understand how the safety culture influences PSM and how to
evaluate and improve it
Enable the participant to implement or improve RBPS elements in
the company
Discuss the applicable process safety regulation
Learn the main methodologies for hazard identification and risk
assessment
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Course Agenda
Introduction
Risk Based Process Safety
The RBPS Pillars and Elements
Commit to Process Safety
Understand Hazards and Risks
Manage Risk
Learn from Experience
Evaluating and Improving Safety Culture
Managing Process Safety Performance
Workshops and Case Studies
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HAZARD x RISK
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HAZARD x RISK
Hazard
Chemical or physical condition that has the potential for causing
harm to people, property, company image, or the environment
Risk
The combination of three attributes: What can go wrong?, How
bad could it be?, and How often might it happen?
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Risk
The product of frequency (F) and consequence (C), calculated as
R=FxC
Risk management comprises two risk categories:
Risks that can be eliminated or mitigated
Residual risks
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Hazard
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Risk Management
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Risk Categories
Employee safety
Public safety
Environmental impacts
Property or asset damage
Production losses
Company image
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RISK ASSESSMENT
WHAT CAN GO
WRONG?
HOW FREQUENT
CAN IT HAPPEN?
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Accident
Near-miss
Incident
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Process Safety
Management
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Accidents cause
Fatalities by intoxication...
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Accidents cause
Fatalities by impact of
explosions and burns
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Accidents cause
Destruction of company
assets
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Accidents occur
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Accidents occur
In various types of
installations and in every
part of the world
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Experience in
Accident Prevention
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What is Risk?
Managing Risk
What can go
wrong?
How likely
is it?
Historical
Experience
Analytical
Approaches
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PROCESS
DESIGN
I
LAH
1
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Technology failures
Human failures
Management system failures
External factors
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Deviations
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Standards Based
Strategy
Compliance
Based Strategy
Continuous
Improvement
Based Strategy
Risk Based
Strategy
How can I optimize what I
do to reduce risk?
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Risk
management
Standards
systems
Engineering
Management
improvements
Hardware improvements
Systems
Design review
Integrated HSE MS
Compliance
Reporting
Assurance
Competence
Risk Management
Organizational and
individual behaviour
aligned with goals
Felt leadership
Personal
accountability
Shared purpose &
belief
Improved
culture
Time
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A Management System Is
A formal, established set of activities explained in sufficient detail
and designed to accomplish a specific goal by the intended users
in a consistent fashion over a long time
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A Management System
Management Systems should consider the following items:
Purpose
Scope
Roles and responsibilities
Tasks and procedures
Necessary inputs and anticipated results
Personnel qualifications and training
Activity triggers, desired schedule, and deadlines
Resources, tools, and methods
Measurement, management review, and continuous improvement
Auditing
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A Dynamic Tension
Increasing
Expectations for
Improved HSE
Performance
Decreasing
Resources,
Dynamic Change,
More Competitive
Environment
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EPA
40 CFR 68
AIChE CENTER
FOR CHEMICAL
PROCESS SAFETY
Management System
Management System
Accountability
Employee Participation
Employee Participation
Operating Procedures
Operating Procedures
Training
Training
Contractors
Contractors
Process Equipment
Integrity
Mechanical Integrity
Mechanical Integrity
Incident Investigation
Management of Change
Management of Change
Human Factors
Incident Investigation
Incident Investigation
Compliance Audits
Compliance Audits
Trade Secrets
CMA
RESPONSIBLE
CARE
Management Leadership
Commitment
Accountability
Performance Measurement
Incident Investigation
Information Sharing
CAER Integration
Technology
Design Documentation
Process Hazards Information
Process Hazards Analysis
Management of Change
Facilities
Siting
Codes and Standards
Safety Reviews
Maintenance and Inspection
Multiple Safeguards
Emergency Management
Personnel
Job Skills
Safe Work Practices
Initial Training
Employee Proficiency
Fitness for Duty
Contractors
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Section 2
Experience in RBPS
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Balanced System
Resources
Results
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Resources
Results
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Balanced System
Resources
Results
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Why is it Important
Improved performance
Effective systems requiring fewer resources
Assurance that PSM systems are achieving expected results
Results
Resources
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CCPS Books
Several books on RBPS are available from:
http://www.aiche.org/ccps/resources/publications/books
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1.
2.
3.
4.
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Section 3
Commit to
Process Safety
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Defer to expertise
Ensure open and effective
communications
Establish a questioning/
learning environment
Foster mutual trust
Provide timely response to
safety issues and concerns
Provide continuous
monitoring of performance
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4. Workforce Involvement
Seeks out and engages the workforce in a dialogue about process
safety
Includes contractors as well as direct hire employees
Includes ALL layers of executive, management, supervision,
operators, and mechanics
Establishes an evergreen process for soliciting input and responding
to same regarding how to improve process safety and PSM
effectiveness
Helps sustain a strong
process safety culture
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5. Stakeholder Outreach
Seek out and engage stakeholders in a dialogue about process
safety
Establish a relationship with community organizations, other
companies and professional groups, and local, state, and
federal authorities
Provide accurate information about company/facility
operations, products, plans, hazards, and risks
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