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Process Safety Management (PSM)

Process Safety Management


(PSM)
Part 1

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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Process Safety Management (PSM)

Section 1

Introduction

33

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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Process Safety Management (PSM)

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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Hazards and Risks

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Process Safety Management (PSM)

Hazards and Risks

HAZARD x RISK

77

Hazards and Risks (Cont.)

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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Process Safety Management (PSM)

Hazards and Risks (Cont.)

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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Hazards and Risks (Cont.)

Hazard

10
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Process Safety Management (PSM)

Hazards and Risks (Cont.)

Exposure to Hazard Risk

11
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Hazards and Risks (Cont.)

Risk Management

12
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Process Safety Management (PSM)

Risk: How People See It


League of
Business and
Activity and Deaths
Women College
Professional
Per Year (Est.)
Voters Students Club Members
1. Smoking (150,000)
4
3
4
2. Alcoholic beverages (100,000)
6
7
5
3. Motor vehicles (50,000)
2
5
3
4. Handguns (17,000)
3
2
1
5. Electric power (14,000)
18
19
19
9. X-rays (2,300)
22
17
24
20. Nuclear Power (100)
1
1
8
28. Pesticides (NA)
9
4
15

13
13

Risk: How People See It

You bet your life!


1

10

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Process Safety Management (PSM)

Hazards and Risks (Cont.)

Risk Categories
 Employee safety
 Public safety
 Environmental impacts
 Property or asset damage
 Production losses
 Company image

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15

Hazards and Risks (Cont.)

RISK ASSESSMENT

WHAT CAN GO
WRONG?

HOW FREQUENT
CAN IT HAPPEN?

WHAT ARE THE


CONSEQUENCES?

16
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Process Safety Management (PSM)

Hazards and Risks (Cont.)

Incidents and Accidents

Accident
Near-miss
Incident
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Workshop 1 Identification of main hazards and risks

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Process Safety Management (PSM)

Workshop 1 Identification of main hazards and risks

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Process Safety
Management

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Process Safety Management (PSM)

Process Safety and Occupational Safety

Process Safety refers to major incidents


Occupational Safety refers to slips, falls, trips, etc.
Process Safety Incidents are less frequent
Occupational Safety Incidents occur with a higher frequency
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Process Safety Definition

 Process Safety Prevention of catastrophic releases of chemicals


or energy from a process associated with a facility, which have
great impact on safety, health, the environment, production,
company assets and company image

 Process Safety Management (PSM) A management system that


is focused on prevention of, preparedness for, mitigation of,
response to, or restoration from catastrophic releases of
chemicals or energy from a process associated with a facility

22

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Process Safety Management (PSM)

Process Safety Accidents


 Challenger & Columbia
 Piper Alpha
 Longford
 Chernobyl
 Flixborough
 Texas City
 Bhopal

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Accidents cause
Fatalities by intoxication...

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Process Safety Management (PSM)

Accidents cause

Fatalities by impact of
explosions and burns

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Accidents cause

Destruction of company
assets

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Process Safety Management (PSM)

Accidents occur

Involving various system


and equipment types

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Accidents occur
In various types of
installations and in every
part of the world

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Process Safety Management (PSM)

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

What are the


impacts?
Intuition and
Judgment

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Process Safety Management (PSM)

The Layered Approach to Managing Risk


COMMUNITY EMERGENCY RESPONSE
PLANT EMERGENCY RESPONSE
PHYSICAL PROTECTION (DIKES)
PHYSICAL PROTECTION
(RELIEF DEVICES)
AUTOMATIC ACTION (SIS OR ESD)
CRITICAL ALARMS, OPERATOR SUPERVISION
AND MANUAL INTERVENTION
BASIC CONTROLS, PROCESS ALARMS,
AND OPERATOR SUPERVISION

PROCESS
DESIGN
I

LAH
1

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The Swiss Cheese Model for Causes of Accidents

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Process Safety Management (PSM)

Better Risk Management Means Reducing/Managing:






Technology failures
Human failures
Management system failures
External factors

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The Offshore Production Process


Example: FPSO CIDADE DE ANCHIETA
 Crude Oil Production 100,000 bpd
1. Turret Mooring System
2. Topsides Process System
3. Vessel
Crude Oil Storage
Tandem Offloading
Accomodation
Helideck
Services
Utilities
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Process Safety Management (PSM)

The Offshore Production Process


FPSO CIDADE DE ANCHIETA
Marine Systems
1. Crude Oil Washing
2. Oil Content Monitoring
3. Cargo Loading and Export
4. Cargo Tank Blanketing
5. Inert Gas System
6. Slop Water System

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The Offshore Production Process


FPSO CIDADE DE ANCHIETA
Engineering Systems
1. Power Generation and Distribution
2. Steam Generation and Feed Water System
3. Steam and Condensate System
4. Potable and Distilled Water Systems
5. Cooling Water System
6. Fire Fighting Systems
7. Bilge & Ballast System
8. Marine Diesel Oil (MDO) System
9. Lube Oil (LO) System
10.Hydraulic Systems
11.Sewage Treatment System
12.Compressed Air System
13.HVAC Systems
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Process Safety Management (PSM)

The Offshore Production Process


FPSO CIDADE DE ANCHIETA
Topsides Process Systems
1.Flowlines and Pigging Operations
2.Oil Processing System
3.Well Test System
4.Produced Water
5.Flash Gas Compression System
6.Lift Gas Compression System
7.Amine System
8.Gas Dehydration System
9.Fuel Gas System

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The Offshore Production Process


FPSO CIDADE DE ANCHIETA
Topsides Process Systems
10.Flare System
11.Drain System
12.Cooling Medium System
13.Seawater System
14.Chemical Injection System
15.Water Injection System
16.Nitrogen System
17.Well Service Pump

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Process Safety Management (PSM)

The Offshore Production Process


FPSO CIDADE DE ANCHIETA
Turret
1. Transfer Systems
2. Swivel Stack and Ancillaries
3. Utility Systems
4. Control Systems

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The Safety Pyramid

Learn Lower on the Pyramid Helps Ensure Each Layer


Remains Effective
Accidents
Near-misses

Deviations

Management System Failures

Unsafe Actions and Behaviors

Culture Individual and Organizational Trends

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Process Safety Management (PSM)

HSE Accident Prevention Strategies

Standards Based
Strategy

Compliance
Based Strategy

What should I do?

What do I have to do?

Continuous
Improvement
Based Strategy

Risk Based
Strategy
How can I optimize what I
do to reduce risk?

How can I improve based on


my experience?

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Improvements in Process Safety/HSE


Culture
Technology
and standards
HSE

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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Process Safety Management (PSM)

What Are the Distinguishing Marks of Good HSE


Continuous Improvement?

 Requires regular efforts to get better


Spaced not too far apart in time
 Also requires
Goals
Periodic course correction
Recognition of the value to the business

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What Are the Distinguishing Marks of Good HSE


Continuous Improvement? (Cont.)
 Resistant to resource cutbacks made without regard to
consequences considers the business case
 Makes the paradigm shift to thinking in terms of EHS
effectiveness, not only performance

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Process Safety Management (PSM)

Motivations for Improving HSE

 Recent major accident


 Series of incidents







Regulatory new rule or enforcement actions


Industry group membership obligation
Peer pressure/comparisons of existing practices
Perception that risk is not tolerable/increasing
Resource pressures
Company policy of continuous improvement

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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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Process Safety Management (PSM)

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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Effective Management Systems Address


All Types of Risk





Process safety management systems


Environmental management systems
Reliability management systems
Security management systems

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Process Safety Management (PSM)

A Dynamic Tension

Increasing
Expectations for
Improved HSE
Performance

Decreasing
Resources,
Dynamic Change,
More Competitive
Environment

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Process Safety Management Systems









OSHA PSM: Process Safety Management


EPA RMP: Risk Management Program
CCPS RBPS: Risk Based Process Safety
Petrobras: HSE Corporate Guidelines
ANP OSMS: Operational Safety Management System
OHSAS 18001: Occupational Health and Safety System
API RP 750: Management of Process Hazards

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Process Safety Management (PSM)

Comparison of PSM Systems


OSHA
29 CFR 1910.119

EPA
40 CFR 68

AIChE CENTER
FOR CHEMICAL
PROCESS SAFETY

Management System

Management System

Accountability

Employee Participation

Employee Participation

Process Safety Information

Process Safety Information

Process Knowledge and


Documentation

Process Hazard Analysis

Process Hazard Analysis

Operating Procedures

Operating Procedures

Training

Training

Contractors

Contractors

Pre-startup Safety Review

Pre-startup Safety Review

Process Equipment
Integrity

Mechanical Integrity

Mechanical Integrity

Incident Investigation

Hot Work Permit

Hot Work Permit

Training and Performance

Management of Change

Management of Change

Human Factors

Incident Investigation

Incident Investigation

Emergency Planning and


Response

Emergency Planning and


Response

Standards, Codes and


Laws

Compliance Audits

Compliance Audits

Trade Secrets

Project Reviews and


Design Procedures
Risk Management
Management of Change

Audits and Corrective


Actions
Enhancement of Process
Safety Knowledge

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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Process Safety Management (PSM)

RBPS Risk Based Process Safety


 RBPS was developed for two main reasons:

To be able to provide better results with less resources


To supply an objective and an approach for all types of
companies to implement, correct and improve their process
safety management systems

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Most Companies Face a Resource Challenge

Balanced System
Resources

Results

But when resources diminish,


results are likely to diminish too

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Process Safety Management (PSM)

Resulting in an Out-of-Balance System

Resources

Results

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We Have To Do Something Different!!

Balanced System
Resources

Results

RBPS Helps You Move the Fulcrum


Results
Resources

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Process Safety Management (PSM)

Possible Causes of Process Safety Management


Performance Stagnation
 Regulation sometimes leads to a minimum cost, compliancebased approach
 Declining worker injury rates may give management a sense
of complacency that the risk of process safety incidents must
likewise be declining
 PSM may have been implemented as a separate, stand-alone
system that was not integrated into the organizations overall
management system, or as a one-time project instead of an
ongoing process

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Possible Causes of Process Safety Management


Performance Stagnation (Cont.)
 Audits have focused on symptoms of problems; they have failed
to identify underlying causes
 Diminishing resources are devoted to process safety; facilities
face increased pressure to achieve short-term financial
objectives
 Mergers, acquisitions, and divestitures have decreased
organizational stability
 Success has led to complacency the absence of major
accidents lessens a companys sense of vulnerability

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Process Safety Management (PSM)

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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RBPS is a 20-element PSM System

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Process Safety Management (PSM)

CCPS Books
 Several books on RBPS are available from:
http://www.aiche.org/ccps/resources/publications/books

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Risk Based Process Safety

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Process Safety Management (PSM)

Risk Based Process Safety


 Management systems should be the simplest that they can be
while still being fit-for-purpose
 Consider the following issues when determining management
system rigor
Perception of complexity, hazard, and risk
Demand for the system results and the resources required
to deliver them
Current company/facility culture
 To design, correct, and improve process safety management
activities

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Example of How RBPS Criteria Affects Implementation of Work


Activities
 Risk high drives greater rigor; low demands less
 Demand for resources High activity/demand situations require
simpler/more streamlined systems; low activity/demand can
allow more elegant solutions
 Process safety culture Good, mature culture allows more
flexible, performance-based solutions, while poor culture
demands more prescriptive, command-and-control solutions

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Process Safety Management (PSM)

Preparation for Change


Implementation

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Preparation for Change Implementation


 In the dynamic corporate environment changes are constantly
occurring and this requires that the companies accept these changes
and that the workforce is also able to accept these changes and
leave the present status quo
 These changes may include changes in corporate culture and values

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Process Safety Management (PSM)

Preparation for Change Implementation (Cont.)


Key components for a successful change implementation
 Auto efficiency
The organization and the people have the required knowledge
and desired skill level to support the change?
 Support as a principle
Top management supports and has the leadership style that
emphasizes team work for the people involved in the project
development (sense of property)?
 Individual validation
When people perceive that they will benefit from the changem,
helping them maintain their competitive position, they are more
willing to help the change process.

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Preparation for Change Implementation (Cont.)


Principles
 At all time involve and obtain support from the people involved
in the system (system = environment, process, culture,
relationship, behavior, etc., be it personal or organizational);
 Understand where you / the organization are at the moment;
 Understand where you want to go, when, why and what metrics
will indicate that you arrived there;

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Process Safety Management (PSM)

Preparation for Change Implementation (Cont.)


Principles (Cont.)
 Plan the development to reach the goal in mesurable and
reachable steps;
 Communicate, involve, empower and facilitate the
integration of the participants as early as possible and as
clearly as possible.

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John Kotter 8-Step Model for Successful Changes


1. Create Urgency Develop a sense of urgency around the need for
change. This may help spark the initial motivation to get things
moving.
2. Form a Powerful Coalition Convince people that change is
necessary. This often takes strong leadership and visible support
from key people within the organization.
3. Create a Vision for Change A clear vision can help everyone
understand why they are being asked to do something. When
people see for themselves what the organization is trying to achieve,
then the directives they're given tend to make more sense.
4. Communicate the Vision The message will probably have strong
competition from other day-to-day communications within the
company, so you need to communicate it frequently and powerfully.
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Process Safety Management (PSM)

John Kotter 8-Step Model for Successful Changes (Cont.)


5. Remove Obstacles Removing obstacles can empower the
people you need to execute the vision, and it can help the
change move forward.
6. Create Short-Term Wins Create short-term targets not just
one long-term goal. You want each smaller target to be
achievable, with little room for failure.
7. Build on the Change Each success provides an opportunity to
build on what went right and identify what you can improve.
8. Anchor the Changes in Corporate Culture Make continuous
efforts to ensure that the change is seen in every aspect of
your organization. This will help give that change a solid place
in your organization's culture.
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RBPS Pillars for Accident Prevention

1.
2.
3.
4.

Commit to Process Safety


Understand Hazards and Risk
Manage Risk
Learn from Experience

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Process Safety Management (PSM)

Pillar 1: Commit to Process Safety

 The cornerstone of process safety excellence


 A workforce that is convinced the organization fully supports
safety as a core value will tend to do the right things, in the
right ways, at the right times even when no one is looking
 Stakeholders who see this commitment regularly
demonstrated will tend to trust you more because of deposits
you have made in your relationship bank account with them

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Pillar 2: Understand Hazards and Risks

 The foundation of a risk-based approach


 Must be based upon sound information and seek to preserve
knowledge
 A company that understands hazards and risk is better able to
manage them, which helps sustain long-term, accident-free, and
profitable operations
 Understanding hazards and risk allows a company to allocate
limited resources in the most effective manner
 Hazards can be present throughout the life cycle of a
process/facility

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Process Safety Management (PSM)

Pillar 3: Manage Risk

 The ongoing execution of RBPS tasks


 Organizations must
Operate and maintain the processes that pose the risk
Keep changes to those processes within risk tolerances
Prepare for, respond to, and manage incidents that do occur

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Pillar 4: Learn from Experience


 The opportunities for correction and improvement
Metrics provide direct feedback on the workings of RBPS
systems, and leading indicators provide early warning signals
of ineffective process safety results
Incident root cause learnings and corrective actions should
help prevent future incidents, even at facilities where the
incident has not yet occurred

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Process Safety Management (PSM)

Pillar 4: Learn from Experience (Cont.)

Audits should seek to know what is real in the field and


compare conditions to an established standard of care
Periodic management review will highlight successes that
need reinforcement and weaknesses that need attention
 When an elements performance is unacceptable, organizations
must use their mistakes and those of others as motivation for
action

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Risk Based Process Safety Elements


Commit to Process Safety
1. Process Safety Culture
2. Compliance to Standards
3. Process Safety Competency
4. Workforce Involvement
5. Stakeholder Outreach
Understand Hazards and Risk
6. Process Knowledge
Management
7. Hazard Identification and
Risk Analysis
Manage Risk
8. Operating Procedures
9. Safe Work Practices

Manage Risk (cont.)


10. Asset Integrity and Reliability
11. Contractor Management
12. Training and Performance
13. Management of Change
14. Operational Readiness
15. Conduct of Operations
16. Emergency Management
Learn from Experience
17. Incident Investigation
18. Measurement and Metrics
19. Auditing
20. Management Review and
Continuous Improvement
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Process Safety Management (PSM)

Section 3

Commit to
Process Safety

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Pillar 1: Commit to Process Safety

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Process Safety Management (PSM)

Pillar 1: Commit to Process Safety

Process Safety Culture


Compliance with Standards
Process Safety Competency
Workforce Involvement
Stakeholder Outreach

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1. Process Safety Culture


 Culture is the tendency in all of us and our organization to
want to do the right thing in the right way at the right time,
ALL the time even when no one is looking
 Culture is the result of all the actions and inactions in
institutional/workforce memory
 Individual and organizational HSE culture is affected by ethnic
culture and off-the-job behavior
 Culture is hard to measure and more difficult to change; it will
be the root cause of the decade

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Process Safety Management (PSM)

1. Process Safety Culture The 12 Essential Features


Ensures the evaluation of and nurturing of process safety culture
throughout the lifetime of a company/facility
Establish safety as a core value
Provide strong leadership
Establish and enforce high
standards of performance
Formalize the safety culture
emphasis/approach
Maintain a sense of
vulnerability
Empower individuals to
successfully fulfill their safety
responsibilities

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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1. Process Safety Culture


Possible Work Activities
 Do things to make the 12 essential features happen
PLUS
 Educate managers in process safety culture, vision, expectations,
roles, responsibilities, and standards
 Demonstrate personal values, priorities, and concerns for process
safety through what is asked about, measured, commented on,
praised, or criticized
 Implement a process for defining process safety goals

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Process Safety Management (PSM)

1. Process Safety Culture


Possible Work Activities
 Provide employees with the resources necessary to achieve
their process safety responsibilities
 Conduct periodic reviews of the organizations process safety
culture
 Strive to identify and correct cultural issues that underlie
failures to adequately fulfill process safety responsibilities
 Implement an effective management review system

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1. Process Safety Culture


Possible Work Activities
 Require that responsibility and accountability for process
safety leadership be shared at all levels of the organization
 Ensure that process safety performance rewards and
corrective actions are consistently applied
 Determine and address the causes of significant or persistent
non-compliances and failures to fulfill process safety program
deliverables
 Document how the organization approaches evaluating and
nurturing process safety culture

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Process Safety Management (PSM)

Workshop 2 RBPS Element #1

1. Based on the examples of Possible Work Activities for this


element, the group should propose items (including non-listed
items if deemed applicable) that can improve the present system
element in the company
2. Based on the Metrics provided, the group should propose items
(including non-listed items if deemed applicable) that can be useful
to evaluate the present system element in the company

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2. Compliance with Standards

 Identify, develop, acquire, evaluate, disseminate, and provide


access to applicable standards, codes, regulations, and laws
that form the process safety standards of care
 Address both internal and external standards; national and
international codes and standards; and local, state, and federal
regulations and laws
 Make this information easily and quickly accessible to potential
users

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Process Safety Management (PSM)

2. Compliance with Standards (Cont.)


 The standards system must keep up with changes so the
company can adjust its compliance activities
 The standards system also forms the basis for the standards of
care used in an audit program to determine management system
conformance
 The main products of a standards system are an accurate,
complete, up-to-date, and accessible set of documents, data, and
information
Internal company guidelines
Consensus codes and standards
Applicable regulations, and laws

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2. Compliance with Standards (Cont.)


Possible Work Activities
 Develop a written program that identifies all process safety
obligations
 Establish a standards element owner
 Define the roles and responsibilities for personnel assigned to
perform activities to help ensure compliance with applicable
process safety-related standards
 Identify all sources and applicability of process safety
obligations, voluntary and required
 Determine the schedule for compliance with all process safety
obligations
 Develop the appropriate risk tolerance criteria or guidance for
use in risk-based decision making situations

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Process Safety Management (PSM)

2. Compliance with Standards (Cont.)


Possible Work Activities
 Define the technical and regulatory knowledge/skills needed
for compliance
 Provide initial and refresher awareness training on relevant
standards to the workforce
 Create a list of all relevant process safety-related standards
 Collect and evaluate performance/efficiency data on
standards compliance activities
 Provide input to improvement activities, such as metrics,
management reviews, and audits
 Solicit needs from within the company concerning standards,
changes to or interpretation of standards, or other new
initiatives

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2. Compliance with Standards (Cont.)


Possible Work Activities
 Coordinate with company legal counsel regarding regulatory
and legal compliance issues
 Communicate compliance obligations to all appropriate
personnel
 Provide access to standards materials for all personnel who
need them
 Monitor changes to standards
 Maintain a compliance schedule for relevant standards
sources

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Process Safety Management (PSM)

2. Compliance with Standards (Cont.)


Possible Work Activities
 Maintain compliance with each process safety-related
obligation
 Participate in audits to ensure that audit team members use
the appropriate standards of care
 Provide feedback to management concerning the compliance
status
 Based on potential new obligations or changes to existing
obligations, determine the potential applicability and
compliance impact to facility operations

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2. Compliance with Standards (Cont.)


Possible Work Activities
 Provide information to management, regulatory affairs
personnel, and industry groups regarding company concerns
about changes to process safety obligation
 Modify compliance documents as needed based on changes
in status
 Provide awareness-level communication and training items on
changes in process safety standards

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Process Safety Management (PSM)

2. Compliance with Standards (Cont.)


Applicable Process Safety Regulation








ANP Operational Safety Management System (SGSO)


CONAMA Rule 237
MTE Regulations (Normas Regulamentadoras)
MARPOL Annex I
ISM Code
NORMAM
Others Applicable

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3. Process Safety Competency


 Maintains, improves, and broadens knowledge and expertise
 Works at all levels of the organization, including hourly
workers, supervision, engineering, management, and
executives in plants and at corporate offices

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Process Safety Management (PSM)

3. Process Safety Competency (Cont.)


Possible Work Activities
 Develop a set of measurable objectives for maintaining and
enhancing process safety competency
 Assign responsibility for championing efforts to maintain and
enhance process safety competency
 Link efforts to maintain and enhance process safety knowledge to
initiatives that support near-term business objectives
 Identify and fund activities that are likely to promote competency
 Establish a longer term (e.g., 3- to 5-year) plan
 Promote activities that help create, acquire, interpret, transfer,
and retain knowledge

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3. Process Safety Competency (Cont.)


Possible Work Activities
 Appoint a technology steward for each type of process operated
by the company
 Appoint a technology steward for broader technology areas that
are critical to the company, such as corrosion, inspection of fixed
equipment, predictive maintenance methods for rotating
equipment, dust explosion hazards
 Create a technology manual that documents the history of the
process as well as knowledge that is critical to maintaining
process safety competency
 Proactively push safety-critical information to potentially
affected facilities and key personnel

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Process Safety Management (PSM)

3. Process Safety Competency (Cont.)


Possible Work Activities
 Consider individual and organizational competency in
succession planning
 Extend succession planning efforts to technical and staff
functions, including process safety professionals
 Participate in industry associations and other networks that
provide insight to how process safety is managed at other
companies
 Based on a periodic review with senior management and key
personnel from operating facilities, adjust plans or the resources
provided to various plans/activities

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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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Process Safety Management (PSM)

4. Workforce Involvement (Cont.)

Possible Work Activities


 Develop written program documentation for managing the
overall workforce involvement element
 Describe for each RBPS element relevant worker activities for
participating in the design, development, implementation,
and continuous improvement of the RBPS management
system
 Establish an owner for the workforce involvement element
 Provide awareness training on the workforce involvement
element to all workers

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4. Workforce Involvement (Cont.)

Possible Work Activities


 Provide detailed training to all affected workers who are
assigned specific roles within the RBPS management system
 Design systems to ensure the active involvement of workers in
the implementation of the various RBPS elements
 Solicit input on issues related to the design, development,
implementation, and continuous improvement of the RBPS
management system.
 Establish protocols for management to follow when
considering and responding to worker suggestions

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Process Safety Management (PSM)

4. Workforce Involvement (Cont.)

Possible Work Activities


 Provide appropriate feedback to workers who suggest changes,
including an explanation of the manner and rationale for resolving
their suggestions
 Ensure timely implementation of recommendations accepted
under the workforce involvement program
 Actively publicize the workforce involvement program, its goals, the
progress of its implementation, and notable successes achieved

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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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