A rising tide raises all boats: Regional promotion of process safety through joint government/industry management

With the development of increasingly complex processes and technologies in chemical and manufacturing industries, Process Safety Management (PSM) has been globally recognized as the primary tool for operating companies to reduce process accidents on their industrial sites and the risks posed to their employees and surrounding communities. Yet, industrial facilities are often interdependent and collocated with others. Recognizing this, regional authorities are also applying PSM principles to reduce the cumulative incidents associated with high density industrial areas and the multiplicative risks posed to broader communities. This paper compares Strathcona County Emergency Service (SCES) in Alberta, Contra Costa County Health Service Hazard Material Programs (CCCHSHMP) in California, and Technical Standards & Safety Authority (TSSA) in Ontario and their PSM systems to provide practical recommendations to improve SCES's system. Four aspects of PSM are considered: regulation and guidance, auditing and inspection, annual performance indicators, and public participation. Based on the results of this comparison, we recommend that SCES develop comprehensive PSM regulations based on CSA Z767-17 PSM including clear instructions for assessing technologies and methodologies for consequence analysis. Both worst-case scenarios and alternative scenarios need to be considered as well as the domino effect of primary accidents. Furthermore, regular audits and inspections will ensure compliance with PSM regulations while helping the design of planning, performing, and following-up strategies to ensure effectiveness. In addition, we suggest the use of lagging and leading performance indicators to evaluate the performance of the PSM program. Finally, we recommend using advisory councils or commissions to increase public participation and ensure the representation of stakeholders' perspectives with the PSM system.     

Improved management practice and process hazard analysis techniques for minimizing likelihood of process safety incidents in Taiwan

In Taiwan, process safety accidents often occur despite the prior implementation of process hazard analysis (PHA). One of the main reasons for this is the poor quality of the PHA process; with the main hazards not being properly identified, or properly controlled. Accordingly, based on the findings of 86 process safety management (PSM) audits, dozens of post-accident site resumption review meetings, and hundreds of PSM review sessions, this study examines the main deficiencies of management practice and PHA implementation in Taiwan, and presents several recommendations for improved PHA assessment techniques and procedures. The study additionally examines the feasibility for using PSM-related information, such as process safety information and process incident information, as a tool for further enhancing the PHA quality. Overall, the study suggests that, in addition to following the basic rules of PHA and requirements of OSHA (1992),management in Taiwan should also provide training in the enhanced assessment techniques proposed herein and take active steps to incorporate PSM information into the PHA framework in order to improve the general quality of PHA and reduce the likelihood of process safety accidents accordingly.     

Guidance to improve the effectiveness of process safety management systems in operating facilities

The Process Safety Management (PSM) systems at the operating facilities in the Oil & Gas and in Chemical manufacturing industries have matured over the years and have become, at most facilities, very robust and sophisticated. These programs are administrated by Process Safety (PS) teams at both the corporate business units and plant levels and have been effective in reducing the number and severity of PS events across the industries over the past 25 years or so. Incidents however are occurring at a regular interval and in recent times several noteworthy PS events have occurred in the United States which have brought into question the effectiveness of the PSM programs at play. These facilities have been applying their PSM programs with the expectation that the number and severity of PS events would decrease over time. The expected result has not been realized, especially in context to those facilities that have undergone the recent incidents. Current paper reviews a few publicly available PS performance reports of Oil & Gas and Chemical manufacturing industries. The authors identified a few factors at play that have led to these PS events based on their experience, literature review, and incident investigation reports. Most of the factors are intertwined with multiple PSM elements and it requires a holistic approach to address them. Each of the factors is described and the path forward is proposed to improve the effectiveness of PSM programs.     

Learning from the application of nuclear probabilistic safety assessment to the chemical industry

This paper introduces the new approach of risk analysis established by the French Ministry of the Environment and develops the benefits of applying nuclear probabilistic safety assessment approaches to the chemical industry.In the aftermath of the AZF disaster in Toulouse on 21 September 2001, a new law was proposed by the French government asking for the investigation of all representative scenarios and the assessment of the probability of the resulting dangerous phenomena to demonstrate an acceptable level of safety. Therefore, any accident is investigated from a global point of view, according to its gravity and its probability.In 2000, the French Ministry of the Environment asked the Institute for Radiological Protection and Nuclear Safety (IRSN), and in particular its Systems and Risk Protection Assessment (SESPRI) and its Industrial Risks, Fire and Containment Assessment and Study (SERIC) departments, to conduct a Probabilistic Safety Assessment (PSA) study of an LPG distribution facility, specially for the BLEVE scenario. This study has showed the power of PSA for defining and prioritizing actions to be carried out to improve safety of facilities; however, it requires credible data for reliability and failure of the equipment, not available in generic failure databases.Since 2007, IRSN has taken several initiatives in collaboration with operators in order to provide more precise and representative failure rates for main safety equipment, ready to use in future PSA relative to LPG plants.     

Ensuring emergency planning & response meet the minimum Process Safety Management (PSM) standards requirements

When incidents happen and the consequences are not mitigated effectively, one of the indicated failures consists of ineffective emergency planning and response (EPR). EPR is an important aspect of the Process Safety Management (PSM) Standards, and the guidelines are stated in CFR 1910.119 (n) which explains the minimum elements of emergency response and procedures in handling emergency or small releases. Despite its implementation in 1992, CSB finds ineffective EPR system in certain accidents such as the Missouri DPS Enterprise Chlorine Gas Release accident in 2002. DPS EPR failed in planning on location of emergency equipment and accessibility. Many other accidents have occurred throughout the decade and even though organizations have their own EPR system, there are issues in meeting minimum PSM requirements. There also exists the problem of self-regulatory policies practiced by organizations, which might not meet these requirements as well. To help organizations meet these minimum requirements, the purpose of this paper is to present a structured and easy technique to plan and implement EPR as per PSM requirements. A model has been developed based on this technique, and its application has been tested as a case study in a refinery in Malaysia and discussed throughout this report. The results reflected the feasibility of this model as it helped users to track and manage documents efficiently. This technique has the potential to help users to manage EPR better and to reduce adverse impacts to people, environment and assets.     

Factors contributing to US chemical plant process safety incidents from 2010 to 2020

Process safety incidents can result in injuries, fatalities, environmental impacts, facility damage, downtime & lost production, as well as impacts on a company's and industry's reputation. This study is focused on an analysis of the most commonly reported contributing factors to process safety incidents in the US chemical manufacturing industry. The database for the study contained 79 incidents from 2010 to 2019, partly investigated by the Chemical Safety Board (CSB). To be included in the study, the CSB archive of incident investigations were parsed to include only incidents which occurred at a company classified as 325 in the North American Industry Classification System (NAICS), assigned to businesses that participate in chemical manufacturing. For each incident, all of the identified contributing factors were catalogued in the database. From this list of identified contributing factors, it was possible to name the ‘top three’ contributing factors. The top three contributing factors cited for the chemical manufacturing industry were found to be: design; preventive maintenance; and safeguards, controls & layers of protection. The relationship between these top contributing factors and the most common OSHA citations was investigated as well. The investigation and citation history for NAICS 325 companies in the Occupational Safety & Health Administration (OSHA) citations database was then analysed to assess whether there was any overlap between the top reported contributing factors to process safety events and the top OSHA citations recorded for the industry. A database consisting of the inspection and citation history for the chemical manufacturing industry identified by NAICS code 325 was assembled for inspections occurring between 2010 and 2020 (August). The analysis of the citation history for the chemical manufacturing industry specifically, identified that the list of the top contributing factors to process safety incidents overlapped with the most common OSHA violations. This finding is relevant to industry stakeholders who are considering how to strategically invest resources for achieving maximum benefit – reducing process safety risk and simultaneously improving OSHA citation history.     

我国大型游乐设施风险分析研究

通过对我国大型游乐设施的发展概况、风险管理现状、危险因素辨识、风险评价和风险控制等五个方面进行了分析总结.研究发现,目前已初步建立游乐设施法规体系,逐渐形成了法律、法规、规章、安全技术规范和技术标准的五层次体系,大型游乐设施运营单位安全管理正在向标准化、体系化管理方向发展.我国还没有对各类大型游乐设施进行危险性分析,有关标准和规范中并没有提到明确的风险分析和评估方法,在游乐设施的设计、制造、安装、使用、改造、修理和检测过程中也没有形成一套系统、科学的风险分析和评估方法.     

工程系统的安全分析与风险管理

安全性是许多工程系统设计、研制和运行时要考虑的一项重要内容,其中安全分析和风险管理是两项主要的工作。在基于事故场景的安全性模型的基础上。研究了工程系统的安全分析和风险管理技术方法,提出了进行安全分析和风险管理的工作流程。     

Dynamic-risk-informed safety barrier management: An application to cost-effective barrier optimization based on data from multiple sources

An integrated approach for performance assessment and management of safety barriers in a systemic manner is needed concerning the prevention and mitigation of major accidents in chemical process industries. Particularly, the effects of safety barriers on system risk reduction should be assessed in a dynamic manner to support the decision-making on safety barrier establishments and improvements. A simulation approach, named Simulink-based Safety Barrier Modeling (SSBM), is proposed in this paper to conduct dynamic risk assessment of chemical facilities with the consideration of the degradation of safety barriers. The main functional features of the SSBM include i) the basic model structures of SSBM can be determined based on bow-tie diagrams, ii) multiple data (periodic proof test data, continuous condition-monitoring data, and accident precursor data) may be combined to update barrier failure probabilities and initiating event probabilities, iii) SSBM is able to handle uncertainty propagation in probabilistic risk assessment by using Monte Carlo simulations, and iv) cost-effectiveness analysis (CEA) and optimization algorithms are integrated to support the decision-making on safety barrier establishments and improvements. An illustrative case study is demonstrated to show the procedures of applying the SSBM on dynamic risk-informed safety barrier management and validate the feasibility of implementing the SSBM for cost-effective safety barrier optimization.     

我国通用航空安全管理体系建设研究

安全管理体系是一种新的航空安全管理理念,通用航空安全管理体系的建立是落实民航安全方针的基本保障。根据通用航空运行环境复杂、保障设施薄弱和航空器品种繁杂等特点,基于安全目标管理、PDCA、系统原理和风险管理理论,参考《ICAO SMS手册》,结合我国通用航空安全管理模式,从通用航空安全管理体系基础模块、运行模块、监督模块和改进模块构建了适合我国通用航空安全管理体系,并详细探讨了通用航空安全管理体系实施和评估步骤。建立适合我国国情的通用航空安全管理体系,旨在提高我国通用航空安全管理的水平,为航空安全管理部门提供了科学的安全管理模式,实现安全管理的科学化、系统化和标准化。     

Managing process chemicals,technology and equipment information for pilot plant based on Process Safety Management standard

Injuries, accidents or even fatalities while working in pilot plant are reported worldwide. The OSHA Laboratory Standard and Hazard Communication Standard have been used as a guideline to manage safety of laboratories and pilot plant. In spite of the implementation of these standards, incidents which result in injuries and property loss are continuously occurring. The implementation of OSHA Process Safety Management (PSM) Standard in pilot plant is expected to further reduce the risks of accidents. This paper presents a new system for managing process chemicals, technology and equipment information in pilot plant and the concept is developed based on Process Safety Information (PSI) element of PSM 29 CFR 1910.119(d). It provides organized strategies to manage documentations, communicate information, and written program for maintaining, revising and updating related information. Process and Instrumentation Diagram (P&ID) is used as a foundation for data management. Implementation of this system at the CO₂ Hydrocarbon Absorption System pilot plant as a case study is examined and discussed.     

Interactions of risk analysis and contingency planning in risk management

Risk management entails knowledge of the risk and how best to reduce it; its objective is to minimize losses arising from existing or potential risk. With effective contingency planning, risk analysis and its corollary, consequence analysis, can contribute synergistically to improved risk management. Until recently, risk analysis and contingency or emergency response planning were considered distinct disciplines with little interactive potential. Fortunately, industry now recognizes that linking the two can help ensure public safety as well as preserve the financial integrity of plant owners. Both areas are receiving increased and well-deserved attention; several incidents in recent years have demonstrated that losses could have been greatly reduced if better precautions and procedures had been in place as a result of risk analysis and contingency planning.     

Insights into process safety incidents from an analysis of CSB investigations

Many incidents have helped to define and develop process safety. Each has provided valuable learning opportunities. However, it is even more important to identify insights that can be obtained from an analysis of a large set of incidents that represents those that typically occur. This larger picture illuminates trends and commonalities and provides learning opportunities that are even more important than the causes of any one individual incident.The Chemical Safety Board has published the results of over 60 investigations of process safety incidents. These data have been analyzed to identify commonalities and trends so that measures to help protect against future incidents can be developed. Recommendations are made to address key issues identified.     

History of Dutch process equipment failure frequencies and the Purple Book

In the middle of 70s concerns of the public in the Netherlands about fire, explosion and toxic risks due to mishaps in the expanding process industry, causing political pressure led to the embracement of quantitative risk analysis as tool for licensing and land-use planning. Probabilistic treatment of risk had been exercised before to design flood defense. A ‘test’ on six different plants, the COVO study, favored the idea. Failure rate values were in immediate need. For storage vessels AKZO’s chlorine vessel data and British steam boiler data have been the first. Risk criteria to make decisions on were also developed and in 1985 embodied in legislation. As licensing and land-use planning are tasks of provincial authorities, under the auspices of the Inter-Provincial Consultation (IPO), further details such as failure frequency values have been worked out. In the late 90s the Purple Book consolidated the information as a guideline for Dutch quantitative risk assessment of process installations.The paper will give a condensed historical overview, guidance to published papers; it will further make comments, explain policy backgrounds, present comparison with other data and will briefly indicate in which direction developments should go to improve QRA.     

A comparative analysis of process safety management (PSM) systems in the process industry

The root cause of most accidents in the process industry has been attributed to process safety issues ranging from poor safety culture, lack of communication, asset integrity issues, lack of management leadership and human factors. These accidents could have been prevented with adequate implementation of a robust process safety management (PSM) system. Therefore, the aim of this research is to develop a comparative framework which could aid in selecting an appropriate and suitable PSM system for specific industry sectors within the process industry. A total of 21 PSM systems are selected for this study and their theoretical frameworks, industry of application and deficiencies are explored. Next, a comparative framework is developed using eleven key factors that are applicable to the process industry such as framework and room for continuous improvement, design specification, industry adaptability and applicability, human factors, scope of application, usability in complex systems, safety culture, primary or secondary mode of application, regulatory enforcement, competency level, as well as inductive or deductive approach. After conducting the comparative analysis using these factors, the Integrated Process Safety Management System (IPSMS) model seems to be the most robust PSM system as it addressed almost every key area regarding process safety. However, inferences drawn from study findings suggest that there is still no one-size-fits-all PSM system for all sectors of the process industry.     

Lessons learned for process safety management in China

A number of chemical accidents have occurred in China over the past two decades with significant impact on humans and the environment. It is expected that lessons will have been learned from these accidents that will help industries to reduce the risk that catastrophic chemical accidents occur in future. In fact, to some extent there is evidence that lessons have been learned, to the extent that the Chinese government has substantially strengthened legislation and regulatory standards. Nonetheless, there remains a concern that much more still needs to be done to reduce chemical accidents risks in China. Important progress in this area requires not only government support but a commitment across all hazardous industries to learn from past accidents that may in many cases require establishment or considerable improvement of their safety management systems. To assist small and medium-sized enterprises (SMEs), in this effort, results of an analysis of common causes of the chemical accidents reported in the Major Accident Information (MAI) website of Chinese State Administration of Work Safety (SAWS) are presented in this paper In particular, inadequate process hazard analysis (PHA), training and emergency response planning (ERP) were identified as the top three process safety management (PSM) elements that contribute to most of the SMEs accidents in China. Seven recommendations are proposed in order to improve the effectiveness of lesson learning for government agencies and SMEs.     

基于RBI与多米诺效应的输气站场设备定量风险评价

针对目前输气站场设备风险评价方法仅以单个设备为评价对象,并未考虑设备间相互影响的特点,提出将多米诺效应分析引入输气站场设备风险评价当中,再结合RBI(基于风险检测方法)对输气站场设备进行定量风险评价。首先,计算所评价设备的失效概率与危险指数,得到设备固有风险;然后对设备的多米诺效应风险进行计算;最后,得到设备总风险。实例分析表明,考虑多米诺效应风险后,站场单个设备的风险要明显增大。     

Migrating an incident reporting system to a CCPS process safety metrics model

A major chemical company established a formal incident investigation and reporting system several years ago. The original system focused heavily on worker-related injuries, illnesses, and near-misses and was used primarily to track statistics reportable to the Occupational Safety and Health Administration (OSHA). This Occupational Injury and Illness (OII) approach has been recognized to be an ineffective tool for measuring, predicting, and preventing process safety incidents. The Center for Chemical Process Safety (CCPS) recently published guidelines on how to establish safety metrics for the measurement and reduction of process safety incidents. The process safety metrics approach relies upon leading and lagging metrics to improve organization process safety. This paper is a case study of the analysis of one organization’s incident database, which represents approximately five years of data from over a dozen facilities. The aim of this investigation was to extract useful process safety metrics from the incident investigation and reporting system, which would be pertinent to the types of process units and process functions at these facilities. This paper will discuss the approach taken to extract process incident information from an OII-based database and present the difficulties of performing an analysis on such a database. This paper provides guidance on how to migrate an existing OII-based reporting system to a program that includes process safety metrics in accordance with industry best practices.     

一种安全分析新思路--安全薄弱环节评价

职业安全和公共安全有许多共同点,可以把公共安全技术用于职业安全,公共安全主要有3种工作方法：安全监察、风险评价（或叫设计隐患）和薄弱环节评价。后者常常最有效。公共安全的薄弱评价法可以用于职业安全分析,象“坏人”一样思考有利于辨识安全薄弱环节。安全薄弱环节评价可以为职业安全分析提供新的视角。     

工作安全分析在管理实践中的应用

管理者有责任确保员工的健康和安全,包括告之员工工作场所存在的危险,提供必要的设备以确保健康和安全,并建立适当的健康和安全规程。因此,管理者有义务在员工开展工作之前评估健康和安全风险,进一步完善消除或减轻这些风险。而工作安全分析job safety analysis（JSA）,就是提供了这样一种方法,是一种常用于评估与作业有关的基本风险分析工具,以确保风险得以有效的控制。JSA一般在控制房或作业现场进行。对于大型或复杂的任务,初始的JSA可以作在办公室以桌面练习的形式进行。其实施关键是JSA应由熟悉现场作业和设备的、有经验的人员进行。JSA分析方法的优点就是把工作中潜在危害的关键活动或重要步骤作为分析对象,发挥集体的智慧,采用定量的方法把风险描述出来,从而进一步实施风险预防和控制,同时又和现场作业票证管理相结合,在现场的实际工作中取得了良好的效果。