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The Next Generation of Chemical Process Safety A Comparison with the Nuclear Industry

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DOW RESTRICTED - For internal use only. Global Process Safety Culture ... Describe Dow's drive for improved process safety performance ... – PowerPoint PPT presentation

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Title: The Next Generation of Chemical Process Safety A Comparison with the Nuclear Industry


1
The Next Generation of Chemical Process
Safety? --A Comparison with the Nuclear Industry
  • Greg Schultz
  • The Dow Chemical Company
  • April 24, 2006

2
Objectives
  • Describe Dows drive for improved process safety
    performance
  • Discuss the concept of High Reliability
    Organizations (HROs) as a model for process
    safety performance improvement
  • Demonstrate the differences between an HRO
    (Nuclear Power Plant) and a typical Chemical
    Plant using Layers of Protection Analysis
  • Discuss key learnings

3
Dows EHS Vision
4
Dows Process Safety Goals
  • In 1996, Dow publicly announced 2005 EHS Goals
  • Process Safety Incidents Reduce 90
  • 2005 Performance vs Goal
  • Actual Process Safety Incidents reduced 71
  • Put another way, 1100 Process Safety Incidents
    did NOT occur
  • 2015 Sustainability Goals will soon be announced
  • Process Safety Incidents Reduce an additional
    75

How?
5
(No Transcript)
6
Characteristics of High Reliability Organizations
(HROs)
HRO
  • Deploy more people than necessary
  • Are pre-occupied with failure
  • Enhanced ability to discover and correct errors
    before they escalate into a crisisgive strong
    responses to weak signals
  • Employ highly developed incident reporting and
    follow-up systems
  • Actively seek to know what they dont know

Are These Applicable in the Chemical Industry?
Compiled from various sources, mainly Managing
the Unexpected Ensuring High Performance in an
Age of Complexity. Weick and Sutcliffe
7
Plant Similarities Chemical vs. Nuclear
  • Basic technology
  • make power
  • Values and Culture
  • ethics, safety, community, shareholders
  • People
  • professional, proud

8
Dow Use of LOPA (Layers of Protection Analysis)
  • Semi-quantitative method for analyzing and
    assessing risk
  • Standard feature of Dows corporate Process Risk
    Management Standard
  • Determine number of protection layers needed to
    mitigate individual scenarios

9
LOPA Onion
10
Process Design
Process Design Nuclear Plant stronger than
Chemical Plant.
11
Basic Process Control System (BPCS)
  • ISA-84 definition
  • system which responds to input signals from the
    process, its associated equipment, other
    programmable systems and/or an operator and
    generates output signals causing the process and
    its associated equipment to operate in the
    desired manner
  • Includes sensor, logic solver, and final element
    (e.g. temperature controller)

Basic Process Control Nuclear Plant equivalent
to Chemical Plant.
12
Alarms and Manual Intervention
HRO 1
  • Effective, Independent, Auditable
  • Nuclear plant has significantly more personnel
    assigned to daily operations

Human Intervention Nuclear Plant stronger than
Chemical Plant.
13
Safety Instrumented System
  • Safety Instrumented System (SIS)
  • ISA84-2004 Safety Instrumented Systems for the
    Process Industry Sector
  • CCPS Guidelines Book "Guidelines for Safe and
    Reliable Instrumented Protective Systems" (2006)
  • Triple redundant reactor rod mechanism

Safety Instrumented Systems Nuclear Plant
equivalent to Chemical Plant.
14
Physical Protection
  • Relief devices
  • Dikes

Safety Valves Nuclear Plant equivalent to
Chemical Plant.
15
Emergency Response
HRO 2
  • Emergency Planning and Drills
  • Security

Emergency Response Nuclear Plant stronger than
Chemical Plant.
16
Technical Resources
HRO 3
  • Technical Expertise
  • Reliability, Design, Reactor
  • Experience, Training, Drilling

Technical Resources Nuclear Plant stronger than
Chemical Plant.
17
Personnel Safety
HRO 4
  • Fundamental to any successful EHS effort is
    Personnel Safety
  • Injury/Illness performance tracking
  • Root Cause Investigation
  • Housekeeping
  • Personnel Protective Equipment
  • Personnel Monitoring Devices
  • Unplanned Event Reporting

Personnel Safety Nuclear Plant equivalent to
Chemical Plant.
18
Training
HRO 5
  • Operators, engineers
  • Maintenance
  • hands-on exhibits
  • labs

Training Nuclear Plant equivalent to Chemical
Plant.
19
Key Learning 1
  • Due to additional intolerance to risk of an
    accident, a nuclear plant employs several
    stronger layers of protection than do chemical
    plants
  • Process Design
  • Human Intervention
  • Technical Resources
  • Emergency Response

20
Key Learning 2
HRO
  • The chemical industry must be diligent in
    evaluating technology and characteristics of High
    Reliability Organizations in order to continue to
    improve performance in Process Safety
  • Deploy more people than necessary
  • Are pre-occupied with failure
  • Enhanced ability to discover and correct errors
    before they escalate into a crisisgive strong
    responses to weak signals
  • Employ highly developed incident reporting and
    follow-up systems
  • Actively seek to know what they dont know

21
Questions and Comments?
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