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Most major process safety incidents are preventable and can be avoided as shown in several incident investigation reports. Moreover, these reports indicated that these incidents were certain to occur as shown from the related near-misses and safety control system failures that occurred prior to the incidents. The key element to improve process safety performance is developing effective process safety leading indicators. In the past, the petrochemical industrial organizations used traditional personnel safety measures to measure process safety performance. Now, most of the current industrial facilities focus more on process safety lagging indicators. Ignoring organizational factors and lacking a systematic approach were the major deficiencies during the development of process safety indicators. The main objective of this research is to construct a systematic technique to develop process safety leading indicators by selecting the most effective leading indicators, defining different safety metrics for each leading indicator, conducting accurate measurements, monitoring these metrics on a frequent basis, and revalidating the measures using lagging indicators and near-misses. The effects and contribution of different organizational factors were studied and analyzed within process safety performance. Process safety leadership, data collection system, and proactive monitoring are critical factors that directly impact the development of process safety leading indicators. The electronic version of this dissertation is accessible from http://hdl.handle.net/1969.1/155547
Process safety metrics is a topic of frequent conversation within chemical industry associations. Guidelines for Process Safety Metrics provides basic information on process safety performance indicators, including a comprehensive list of metrics for measuring performance and examples as to how they can be successfully applied over both the short and long term. For engineers, insurers, corporate traininers, military personnel, government officials, students, and managers involved in production, product and process development, Guidelines for Process Safety Metrics can help determine appropriate metrics useful in monitoring performance and improving process safety programs. Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.
The chemical processing industry has faced challenges with achieving improvements in safety performance, and accidents continue to occur. When accidents occur, they usually have a confluence of multiple factors, suggesting that there are underlying complex systemic problems. Moreover, accident investigations often reveal that accidents were preventable and that many of the problems were known prior to those accidents, suggesting that there may have been early warning signs. System-based analysis addresses systemic aspects and leading indicators enable the detection of ineffective controls and degradation of the system. Together, they could enable taking needed actions before an incident or a loss event. To develop process safety indicators, the chemical processing industry currently uses guidelines that are mainly based on the concepts of the "Swiss Cheese Model" and the "Accident Pyramid." The current guidelines lack a systemic approach for developing process safety indicators; the guidelines view indicators as independent measures of the safety of a system (e.g. a failure of a barrier), which can be misleading because it would not identify ineffective controls, such as those associated with the migration of the system towards an unsafe state, or associated with interdependencies between barriers. Moreover, process safety indicators that are currently used in the chemical industry are more focused on lagging as opposed to leading indicators. This main objective of this thesis is to develop a structured system-based method that can assist a hydrocarbon/chemical processing organization in developing system-based process safety leading indicators. Building on developed safety control structures and the associated safety constraints, the proposed method can be used to develop both technical and organizational leading indicators based on the controls, feedbacks, and process models, which, ultimately, can ensure that there is an effective control structure.
Describes a six-stage process which can be adopted by organisations wishing to implement a programme of performance monitoring for process safety risks.
Process safety management (PSM) systems are only as effective as the day-to-day ability of the organization to rigorously execute system requirements correctly every time. The failure of just one person in completing a job task correctly just one time can unfortunately lead to serious injuries and potentially catastrophic incidents. In fact, the design, implementation, and daily execution of PSM systems are all dependent on workers at all levels in the organization doing their job tasks correctly every time. High levels of Operational Discipline, therefore, help ensure strong PSM performance and overall operational excellence. This book details management practices which help ensure rigor in executing process safety programs in order to prevent major accidents.
Use this guideline to develop an effective Process Safety Knowledge Management system When managing the risks of hazardous materials and energies, a well-developed process safety program is critical for maintaining a healthy workforce, for protecting the environment, and for sustaining the business. The Center for Chemical Process Safety (CCPS) has identified Process Knowledge Management as one of its twenty Elements in its Risk Based Process Safety (RBPS) approach. With an effective Process Safety Knowledge Management (PSKM) system, an organization will be able to capture, organize, maintain, and access its technical, engineering, and administrative information. Thus, an effective PSKM system will help an organization successfully manage its risks. This book provides a set of comprehensive guidelines for implementing a Process Safety Knowledge Management (PSKM) system, which will help an organization improve its process safety performance. The book begins with a discussion on the characteristics of a PSKM system. Then it describes the underlying factors for successful implementation and ends with guidance on overcoming common implementation difficulties. Produced by a leading global process safety organization, this book is essential for any organization looking to ensure that systems are in place to sustain their process safety knowledge during the life of the process. Guidelines for Process Safety Knowledge Management readers will also find: Case studies throughout the book, with PSKM-related lessons Detailed discussions of how a PSKM system helps cultivate leadership, improves organizational culture, and involves employees A business case for PSKM, demonstrating the benefits to the business Guidelines for Process Safety Knowledge Management is ideal for process safety professionals, engineering managers, facility managers, maintenance managers, production managers, and others responsible for creating or managing their process safety knowledge management systems.
The definitive leadership guide on safe practices The release of chemicals and other hazardous materials pose significant, potentially catastrophic threats worldwide. An alarming number of such events, all of which are preventable, occur too often. Reducing the frequency of serious incidents is a fundamental responsibility of leadership at all levels, from frontline managers and supervisors to C-suite executives and the board of directors as well. Process Safety Leadership from the Boardroom to the Frontline is a practical, authoritative guide that clearly demonstrates how to create a viable culture of safety within an organization, implement and maintain disciplined management systems, and address the risks of process safety deficiencies. The most important factor in any management system is leadership. For chemical process safety management, effective and informed leadership provides direction, reinforces commitment, and drives responsibility. Written by experts from the Center for Chemical Process Safety, the world's largest provider of engineering curriculum materials for process safety, this pragmatic book contains the critical information and guidelines required to lead and manage process safety. Detailed yet accessible chapters examine topics such as strengthening management system accountability, driving operation within constraints, ensuring corporate memory, verifying execution, and more. Designed to be frequently used, shared, and discussed by leadership teams throughout an organization, this indispensable resource: Demonstrates the many ways process safety benefits an organization, based on benchmarking and broad industrial experience Develops skills and expands knowledge needed to drive consistent, reliable process safety performance Describes essential behaviors and actions for leaders to drive excellence in process safety cultures and disciplined management systems Helps establish risk criteria and safeguards for companies Presents new and previously unpublished experiences, approaches, and thinking Written for executives, plant leaders, functional managers, frontline supervisors and also individual contributors, Process Safety Leadership from the Boardroom to the Frontline provides a much-needed guide for instituting safe practices within a company. The Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology since 1985. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 10 training modules through its Safety in Chemical Engineering Education (SAChE) series.
The Department of Defense, through the Assembled Chemical Weapons Alternatives program, is currently in the process of constructing two full-scale pilot plants at the Pueblo Chemical Depot in Colorado and the Blue Grass Army Depot in Kentucky to destroy the last two remaining inventories of chemical weapons in the U.S. stockpile. These two storage sites together account for about 10 percent of the original U.S. chemical agent stockpile that is in the process of being destroyed in accordance with the international Chemical Weapons Convention treaty. Unlike their predecessors, these facilities will use neutralization technologies to destroy agents contained within rockets, projectiles, and mortar rounds, requiring the use of specially designed equipment. As part of its focus on safe operation of the planned facilities, the Program Manager for Assembled Chemical Weapons Alternatives asked the National Research Council (NRC) to conduct a study to offer guidance on the application of process safety metrics at the Pueblo Chemical Depot and Blue Grass Army Depot. Process safety is a disciplined framework for managing the integrity of operating systems, processes and personnel handling hazardous substances, and operations by applying good design principles, engineering, and operating practices. Process Safety Metrics at the Blue Grass and Pueblo Chemical Agent Destruction Pilot Plants discusses the use of leading and lagging process safety metrics that could provide feedback on the effectiveness of controls to mitigate risks and minimize consequences of potential incidents. The book makes several recommendations that will facilitate the development and application of process safety metrics at both sites.
This book combines the synergies between performance improvement systems to help ensure safe and reliable operations, streamline procedures and cross-system auditing, and supporting regulatory and corporate compliance requirements. Many metrics are common to more than one area, such that a well-designed and implemented integrated management system will reduce the load on the Process Safety, SHE, Security and Quality groups, and improve manufacturing efficiency and customer satisfaction. Systems to improve performance include: process safety; traditional safety, health and environment; and, product quality. Chapters include: Integrating Framework; Securing Support & Preparing for Implementation; Establishing Common Risk Management Systems – How to Integrate PSM into Other EH; Testing Implementation Approach; Developing and Agreeing on Metrics; Management Review; Tracking Integration Progress and Measuring Performance; Continuous Improvement; Communication of Results to Different Stakeholders; Case Studies; and Examples for Industry.
Human Factors Handbook for Process Plant Operations Provides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasks Human Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do—and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance. Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully. Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance Describes how to use indicators to both recognize and learn from human error and performance issues Written by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries. The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI’s Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.