Professional Documents
Culture Documents
Environment in the
U.S. Process Industry
October 21, 2008
Introduction
Health, Safety, and Environment (HS&E) Initiatives
OSHA 1910.119 - Process Safety Management of Highly
Hazardous Chemicals
OSHA National Emphasis Program
Risk-based Process Safety
Company Culture and Safety Performance
Closing Comments
CONFIDENTIAL 1
Introduction
CONFIDENTIAL 2
Phillips Pasadena Explosion (1989)
CONFIDENTIAL 3
SH&E Initiatives
CONFIDENTIAL 4
OSHA Process Safety Management (PSM)
The OSHA PSM standard (29 CFR 1910.119) was published in the
Federal Register on Monday, February 24, 1992.
PSM is a management system developed to manage the safety of any
process involving highly hazardous chemicals.
The objective of PSM is to prevent the occurrence or minimize the
consequence of a catastrophic release of toxic, flammable, or
explosive highly hazardous chemical from a process.
PSM consist of 14 individual elements that can be categorized into four
areas:
System implementation
Incident reduction
Incident management
System control
CONFIDENTIAL 5
PSM Elements
The 14 elements of PSM are:
Employee participation
Process safety information
Process hazard analysis (PHA)
Operating procedures
Training
Contractors
Pre start-up safety review
Mechanical integrity
Hot work permit (safe work practices)
Management of change (MOC)
Incident investigation
Emergency planning and response
Compliance audits
Trade secrets
Combined, each of these 14 points are intended to produce a holistic
approach to developing and implementing an effective PSM system.
CONFIDENTIAL 6
PSM Elements 1 thru 4
Employee participation states that employees must be given the opportunity to
participate in the development, implementation, and review of the PSM system.
Benefits include:
Employees are generally most knowledgeable of daily operations of the facility.
There is a significant advantage to encouraging participation and gaining support.
Process safety information consists of knowledge and data needed to
understand hazards associated with a process including:
Chemical hazards.
Process technology and equipment information.
Updated piping and instrumentation diagrams (P&IDs).
PHA is necessary to develop an effective PSM system by:
Identifying hazards associated with a system.
Assessing hazards, and then develop a mitigation to eliminate or reduce the risk.
Operating procedures are required to:
Standardize the way duties and tasks are performed.
Assure that operations are accomplished in a safe and environmentally sound
manner.
CONFIDENTIAL 7
PSM Elements 5 thru 9
CONFIDENTIAL 8
PSM Elements 10 thru 14
CONFIDENTIAL 9
Renewed Industrial Focus
CONFIDENTIAL 10
BP Texas City Explosion (2005)
CONFIDENTIAL 11
OSHA - National Emphasis Program
CONFIDENTIAL 12
Industry Initiatives
CONFIDENTIAL 13
Professional Organization Recommendations
CONFIDENTIAL 14
Risk Based Decision Making
RBDM is:
Analyzing the consequence of an event versus the likelihood of the event
occurring (Risk = Consequence x Probability).
Making decisions based on risks associated with these events.
RBDM is not about taking risk, but understanding and managing risk.
Risk-based methodology is discussed in more detail during a later presentation.
RBDM will help focus efforts by:
Determining areas of highest risk, which directly affects the safe and
environmentally-conscious operations of the facility.
Improving utilization of resources by focusing efforts in areas of highest risk.
Eliminating or reducing activities focused in areas with little or no risk.
Professional organizations have begun recommending utilization of
RBDM methodology in areas such as inspection, maintenance, and
safety improvements.
CONFIDENTIAL 15
Risk-based Process Safety
For example, the AIChE created the Center for Chemical Process
Safety (CCPS) in 1985.
CCPS developed a publication concerning Risk-based Process
Safety (RBPS), including 20 elements dedicated to:
Understanding hazards and risk associated with operating a facility.
Focusing limited resources on the areas of highest risk.
Understanding safety culture within an organization.
RBPS does not replace PSM, but can be utilized to enhance and
optimize the PSM process.
RBDM can also be used to optimize other programs, such as
safety, maintenance, materials management, and capital projects.
The most effective companies will integrate their RBDM programs
to:
Reduce duplication of efforts or resources.
Assure each program complements the other.
Utilize the foundations of a continuous improvement process to evaluate
results and improve areas of concern.
CONFIDENTIAL 16
Company Culture
CONFIDENTIAL 17
Space Shuttle Challenger Explosion (1986)
CONFIDENTIAL 18
Company Culture and
Safety Performance
Organizations exist with poor safety performance that have excellent:
Written procedures.
Training programs.
Engineering design and safety technology.
Audits of facilities have revealed:
Craftsman performing unsafe tasks directly after:
Completing a job task analysis of work to be performed.
Filling out safety permits outlining safe working procedures.
Procedures for safe start-up of a facility have been bypassed to improve start-up
durations.
Operators trained in proper safe work practices were performing maintenance
task without:
Following line clearing and lock-out/tag-out procedures.
Filling out required permits.
CONFIDENTIAL 19
Effective Safety Culture
CONFIDENTIAL 20
Statistics
5.0
4.8
5 4.6 TRC Total Recordable Cases
4.4
DAFW Days Away from Work Cases
4 ORC Other Recordable Cases
3
2.4 2.3 2.2 2.1
2 1.5 1.4 1.4 1.3
1
0
TRC DAFW ORC
CONFIDENTIAL 21
Closing Comments
CONFIDENTIAL 22
QUESTIONS
CONFIDENTIAL 25
Baker & OBrien, Inc.
CONFIDENTIAL 26
Contact Information
Dallas Houston
Headquarters Office
12221 Merit Drive 1333 West Loop South
Suite 1150 Suite 1350
Dallas, TX 75251 Houston, TX 77027
Phone: 1-214-368-7626 Phone: 1-832-358-1453
Fax: 1-214-368-0190 Fax: 1-832-358-1498
London
41 Queens Gate Terrace
Suite 4
London, SW7 5PN
Phone: 44-207-823-8967
Fax: 44-207-823-7223
www.bakerobrien.com
CONFIDENTIAL 27