TABLE OF CON TEN TS

Acronyms and Abbreviations .......................................................... xi

Acknowledgements ........................................................................ xiii
Nomenclature and Style ................................................................. xv

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Preface ............................................................................................ xvii
Executive Summ ary ........................................................................ xix

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How to Use this B ook .................................................................... xxv

1 THE BUSIN ESS CASE FOR PROCESS SAFETY ................. 1

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1.1 Corporate Social Responsibility ................................................ 2
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1.2 B usiness Flexibility ...................................................................... 4
1.3 Loss Prevention ........................................................................... 5
1.4 Sustainable Growth .................................................................... 7
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1.5 Leadership Excellence ................................................................ 9

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1.6 Summ ary ...................................................................................... 9

1.7 References ................................................................................. 10
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1.8 Incidents Represented in Figure 1.2 ...................................... 12

2 LEADIN G AN D MAN AGIN G PROCESS SAFETY ........... 13

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2.1 Process Safety Definition ........................................................ 13

2.2 How Process Safety Works: Risk Reduction and Risk
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Management to Eliminate Accidents ..................................... 22

2.3 Learning from Incidents .......................................................... 25
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2.4 Personal Leadership Accountability ...................................... 30

2.5 Downturns and B oom Times: Special Process Safety
Leadership Challenges ............................................................. 34
2.6 Com pliance: Required but not Enough ................................. 39
2.7 Management Systems: Helpful but not Sufficient............... 43
2.8 References ................................................................................. 44

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3 LEADERSHIP ATTRIBUTES ........................................... 47

3.1 Creating a Shared Vision ......................................................... 48
3.1.1 Establish the Im perative for Process Safety ............... 48
3.1.2 Reflect the Im perative in Your Words and Actions .... 51
3.1.3 Drive the Im perative Throughout the Organization .. 54
3.1.4 Earn the Social License to O perate .............................. 57
3.2 Develop and M aintain Knowledge and Competence ......... 60
3.2.1 Personal Knowledge and Com petence ....................... 60
3.2.2 Develop and Em power Others ..................................... 64
3.3 Show Integrity and Com m itment........................................... 71
3.3.1 Courage and Conviction ................................................ 71
3.3.2 Accountability .................................................................. 73
3.3.3 Responsiveness ............................................................... 76
3.3.4 Consistency ...................................................................... 78
3.4 Communicate with Inspiration ............................................... 80
3.4.1 Stay Connected and Visible ........................................... 80
3.4.2 Influence and Drive Process Safety Culture ................ 83
3.5 References ................................................................................. 91

4 Leadership of the Process Safety Managem ent

System ..........................................................................................................93
4.1 Identify Required B arriers ....................................................... 94
4.1.1 Start with Risk Criteria and a Risk M atrix .................... 95
4.1.2 Analyze Hazards and Risks ............................................ 98
4.1.3 Identify Required B arriers ........................................... 101
4.2 Manage B arriers ..................................................................... 102
4.2.1 Conduct of O perations and O perational Discipline 102
4.2.2 Standards ....................................................................... 110
4.2.3 Asset Integrity and Mechanical Integrity ................... 113
4.2.4 O perating Procedures and Safe Work Practices ...... 116
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4.2.5 M anagement of Change .............................................. 118

4.2.6 Emergency Management – Preparation and
Response ............................................................................................................ 123
4.3 Manage Com petency (Organizational Capability) ............. 127
4.3.1 Com petency ................................................................... 128
4.3.2 Effective Training .......................................................... 130
4.3.3 Process Knowledge M anagem ent .............................. 133
4.3.4 Contractor M anagement ............................................. 135
4.4 Verify Perform ance and Improve ........................................ 139
4.4.1 Audits .............................................................................. 139
4.4.2 Metrics ............................................................................ 141
4.4.3 Incident Investigation and Resulting Actions ............ 143
4.4.4 M anagement Review and Continual Im provement. 146
4.5 B uild and Strengthen Culture ............................................... 151
4.5.1 Introduction to Culture ................................................ 151
4.5.2 Workforce Involvem ent ............................................... 152
4.5.3 Stakeholder O utreach .................................................. 155
4.6 Summ ary ................................................................................. 158
4.7 References ............................................................................... 159

5 Leadership Roles and Accountabilities .................. 161

Table 5.1 Executive Leadership Role ......................................... 164
Table 5.2 Operations Leadership Role ...................................... 166
Table 5.3 Engineering Leadership Role ..................................... 168
Table 5.4 EH& S Leadership Role ................................................ 170
Table 5.5 Research and Development (R& D) Leadership Role 172
Table 5.6 Purchasing Leadership Role ...................................... 174
Table 5.7 Human Resources Leadership Role .......................... 176
Table 5.8 Plant Superintendent Role ......................................... 178
Table 5.9 Maintenance Leadership Role ................................... 180
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Table 5.10 Plant Engineer Role ................................................... 182

Table 5.11 Plant Operator Role .................................................. 184
Table 5.12 M aintenance Technician Role .................................. 187
Table 5.13 Process Safety Specialist Role ................................. 189

6 Deploying Process Safety Leadership Accountability

and Responsibility ...................................................... 191
Table 6.1 Corporate Process Safety Leadership Team
RACI Matrix ................................................................. 193
Table 6.2 Operations Leadership Team RACI M atrix .............. 197

7 Make it Happen ........................................................ 201

7.1 References ............................................................................... 207

Index ............................................................................ 209