INCORPORATION OF INHERENT SAFETY PRINCIPLES IN PROCESS SAFETY MANAGEMENT

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INCORPORATION OF INHERENT SAFETY PRINCIPLES IN
PROCESS SAFETY MANAGEMENT

• Paul Amyotte Attiq Goraya
• Dalhousie University
• Dennis Hendershot
• Chilworth Technology Inc.
• Faisal Khan
• Memorial University of Newfoundland

21st CCPS International Conference
Orlando, FL (April 23 27, 2006)
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With Thanks to TrevorINHERENT SAFETYWHAT YOU
DO NOT HAVE CANT LEAKTHE WISDOM OF KLETZ
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OUTLINE

• Introduction
• Inherent Safety (IS)
• Process Safety Management (PSM)
• PRIM Analysis
• Framework for IS in PSM
• Conclusion
• Acknowledgements

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INTRODUCTION

• Scope
• Prevention and mitigation of process incidents
• Objective
• Explicitly incorporate principles of inherent
  safety (IS) in a process safety management system
  (PSM)
• Motivation
• IS increasingly viewed as integral component of
  PSM
• But more linkages between IS and PSM are needed
  to enhance use of IS principles

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INTRODUCTION

• Previous work
• IS and dust explosion prevention and mitigation
  (PSEP, JHM, JLPPI, CEP)
• IS considerations in Dow FEI and CEI (JLPPI)
• IS-based incident investigation (PSP)
• Linkages between IS and cost of process safety
  (PSEP)
• Bhopal Conference (Kanpur, India 2004)

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INHERENT SAFETY

• Minimization
• Minimize amount of hazardous material in use
  (when use of such materials cannot be avoided
  i.e. elimination)

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INHERENT SAFETY

• Substitution
• Replace substance with less hazardous material
  replace process route with one involving less
  hazardous materials

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INHERENT SAFETY

• Moderation
• Use hazardous materials in least hazardous
  forms run process equipment with less severe
  operating conditions (e.g. T and P)

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INHERENT SAFETY

• Simplification
• Simplify equipment and processes that are used
  avoid complexities make equipment robust
  eliminate opportunities for error

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Hierarchical Approach
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PROCESS SAFETY MANAGEMENT

• Process safety the operation of facilities that
  handle, use, process or store hazardous materials
  in a manner free from episodic or catastrophic
  incidents
• Process safety management the application of
  management principles and systems to the
  identification, understanding and control of
  process hazards to prevent process-related
  injuries and incidents (fire, explosion,
  toxicity, corrosivity)
• CCPS Guidelines for Technical Management of
  Chemical Process Safety
• MIACC ? CSChE PSM Guide (3rd edition)

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PROCESS SAFETY MANAGEMENT

• Accountability objectives and goals
• Process knowledge and documentation
• Capital project review and design procedures
• Process risk management
• Management of change
• Process and equipment integrity
• Human factors
• Training and performance
• Incident investigation
• Company standards, codes and regulations
• Audits and corrective actions
• Enhancement of process safety knowledge

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PRIM ANALYSIS
Process-Related Incidents Measure 2004 Data (89
incidents)
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FRAMEWORK FOR IS IN PSM

• Elements 2 7 or all 12 elements
• Example-based guidance (IS examples)
• Everyday life
• Technical
• Process-related
• Qualitative methods (IS-based)
• Protocol ? Plan/Do/Check/Act
• IS guidewords and checklists
• Validation with case studies
• Quantitative methods (IS-based)
• Validation with case studies

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1. Accountability Objectives and Goals

• Process safety is a corporate value
• Requires management commitment and leadership
• Hopkins (2005) Safety, Culture and Risk
• Safety culture (reporting, just, learning and
  flexible subcultures)
• Collective mindfulness
• Risk-awareness
• Hierarchy of controls

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Royal Australian Air Force F111 Deseal/Reseal
Program The absence of any commitment to the
hierarchy of controls is another manifestation of
the priority of platforms over people (Hopkins,
2005).
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2. Process Knowledge and Documentation

• Company memory (management of information)
• Inherently Safer Design (ISD) features may not
  have obvious purposes unless well-documented
• Normal and upset conditions (operating
  procedures)
• Procedures must be current, accurate and reliable

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3. Capital Project Review and Design Procedures

• Early consideration for this element early
  consideration for inherent safety high
  potential impact on effective PSM
• Quantitative techniques for hazard reviews
• INSET (European Union)
• Overall IS Index Prototype (UK)
• IS Index (Finland)
• Fuzzy-Based IS Index (USA)
• IS Index/Expert System (Singapore)
• Hierarchical Approach (Switzerland)

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Other Examples of IS in Element 3
Hazard Reviews Polyethylene Facility
Siting/Plot Plan Flixborough
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4. Process Risk Management

• New quantitative tools (e.g. I2SI)
• Existing quantitative tools
• Dow Fire and Explosion Index
• Dow Chemical Exposure Index
• Existing qualitative tools
• What-If analysis extended to What-If/Checklist
  analysis
• Use of IS-based checklists in identifying both
  hazards and additional risk reduction measures

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5. Management of Change

• Elimination
• Minimization
• Substitution
• Moderation
• Simplification
• Inherent safety involves change that must be
  managed
• Inherent safety opportunities when making process
  changes

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7. Human Factors

• Operator-process/equipment interface
• IS-based WI/CL tool
• Administrative control versus hardware control
• Ideal opportunity to name inherent safety
• Human error assessment
• Need for objectivity in an otherwise subjective
  process

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Giant Industries Ciniza Refinery (US CSB)
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Offshore Platform Musters - SLIM
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Offshore Platform Musters - SLIM
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9. Incident Investigation
Team Planning

• .

• People
• Property
• Production
• Environment

Incident
Loss
Notification to Activate Team

• Position
• People
• Parts
• Paper

Inherent Safety Guidewords
On-Site Investigation
Identification of Immediate Causes
Inherent Safety Checklist
Identification of Basic Causes

• Immediate/
• Technical
• Avoid Hazards
• Improve
• Management
• System

Lack of Management Control Factors
Inherent Safety Guidewords
Recommendations
Implement Recommendations
Follow-Up
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Remaining PSM Elements

• 6. Process and Equipment Integrity
• Preventative maintenance (IS implications of
  RBIM)
• Maintenance procedures (IS implications)
• 8. Training and Performance
• IS needs analysis (e.g. incident investigation
  reports)
• IS learning objectives (measurable action verbs)
• IS resources (e.g. US CSB reports, AIChE, IChemE)

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Remaining PSM Elements

• 10. Company Standards, Codes and Regulations
• External/Internal (IS requirements)
• 11. Audits and Corrective Actions
• Evidence of commitment to IS usage
• 12. Enhancement of Process Safety Knowledge
• Include enhancement of IS knowledge

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CONCLUSION

• Inherent Safety is an integral component of
  effective PSM.
• Inherent Safety is a common thread throughout PSM
  elements.
• Inherent Safety is, however, an implicit
  consideration in PSM documentation.
• Examples and methodologies qualitative and
  quantitative new and existing are available to
  make Inherent Safety an explicit part of PSM.

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ACKNOWLDEGEMENTS

• Natural Sciences and Engineering Research Council
  of Canada
• Financial assistance
• Canadian Chemical Producers Association
• PRIM data and analysis results
• Colleagues in the process safety community
• Technical advice and critique of research

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With Thanks to DennisTO REDUCE HAZARDSMAKE
IT SMALLER OR CHANGE ITSO NO ONE GETS HURT