Korean experience of process safety management (PSM) regulation for chemical industry

From the 1960s, Korean industries have been encouraged by the government to nurture heavy and chemical industry and to modernize the economics and industrial structures. The development of chemical industry particularly became the turning point in industrial development, and played a major role in the construction of a new industrialized country. However, the process systems in the chemical industry have become more complex and larger, and the inventories of dangerous chemicals that are produced or consumed have continuously increased. Therefore, the hazards from potential accidents such as fire and explosion or release of toxic chemicals have also increased. In fact, from the end of 1980s to the beginning of 1990s in Korea, a number of major industrial accidents such as ABS extruder explosion, TDI release and dryer explosion, etc. Occurred and caused many fatalities. As the chemical companies recognized the importance of preventing major hazards, PSM system, the prevention of major industrial accidents, was introduced in January 1995 by amending Industrial Safety and Health Act, and it has been enforced from January 1, 1996. According to the law, the business owner of a workplace with hazardous or dangerous equipment shall submit a process safety report to the Government to prevent any accidents, which could inflict an immediate damage on workers or on areas in the vicinity of the workplaces. As a result of PSM implementation for 19 years, chemical accident prevention system has been stabilized and various kinds of effectiveness and desirable customer satisfaction have been made.     

The effectiveness of process safety management (PSM) regulation for chemical industry in Korea

From the 1960s, Korean industries have been encouraged by the government to nurture heavy and chemical industry and to modernize the economics and industrial structures. The development of chemical industry particularly became the turning point in industrial development, and played a major role in the construction of a new industrialized country. However, the process systems in the chemical industry have become more complex and larger, and the inventories of dangerous chemicals that are produced or consumed have continuously increased. Therefore, the hazards from potential accidents such as fire and explosion or release of toxic chemicals have also increased. In fact, from the end of 1980s to the beginning of 1990s in Korea, a number of major industrial accidents such as ABS extruder explosion, TDI release and dryer explosion, etc. occurred and caused many fatalities. As the chemical companies recognized the importance of preventing major hazards, PSM system, the prevention of major industrial accidents, was introduced in January 1995 by amending Industrial Safety and Health Act, and it has been enforced from January 1, 1996. According to the law, the business owner of a workplace with hazardous or dangerous equipment shall submit a process safety report to the Government to prevent any accidents, which could inflict an immediate damage on workers or on areas in the vicinity of the workplaces. As a result of PSM implementation for 7 years, various kinds of effectiveness have been made. Accident rate including number of fatalities has been decreased, and productivity has been increased as well as product quality.     

The effectiveness of U.S. OSHA process safety management inspection – A preliminary quantitative evaluation

This study attempted to evaluate the inspection effectiveness of the U.S. OSHA process safety management (PSM) standard using statistical correlation test. A total of 6578 citations of past 1277 OSHA PSM inspections from 1992 to 2006 were quantitatively compared with the findings of the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigations on root and contributing causes of 19 major chemical accidents. Nonparametric Spearman's coefficient of rank correlation tests showed a moderately strong agreement between OSHA PSM inspection citations and CSB findings at p < .01 significant level, and the degree of agreement increased with time. These results suggested that past OSHA PSM inspections had cited the problems that were the accident root causes, and the effectiveness of PSM citations has been improved as more inspections were conducted since the standard promulgation. However, factors such as standard coverage, inspection frequency, inspection resources allocation, and inspection strategy, were critical for effective PSM standard enforcement and implementation. Future studies should include more aspects of PSM citations and CSB accident investigation data for better evaluation of inspection effectiveness. The results may be valuable to the PSM enforcement policy makers.     

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.     

Process Safety Management (PSM) for managing contractors in process plant

Accidents involving contractors continue to occur with regular frequency. By using the standard set within the PSM 29 CFR 1910.119(h) regulations, it has been identified that certain aspects of the way contractors do work are not up to the stipulated regulatory requirements especially regarding matters like not providing mandatory personal protective equipment (PPE) to the workers, not discussing hazards related to handling procedures with the workforce and improper control of non-routine activities during changes in shifts. The PSM 29 CFR 1910.119(h) regulations promulgated in 1992 provides standards that covered processes to obtain and evaluate data regarding contractors' health and safety programs as well as the contractors' performance evaluation. Many of the accidents involving contractors are direct result of poor training of contractors and/or poor control of the contracted work. Even though most organizations have their own contractor management systems, there are issues in meeting the requirements of PSM. The PSM standard only state “what to do” not “how to do it”. This is known as self-regulatory policy which depends on the industries understanding to interpret the standard that also contribute to this problem. This paper presents a structured and easy technique to plan and implement a practical and comprehensive contractors' management system in process industries that will comply with OSHA CFR 1910.119. A model has been developed based on this technique and its application has been tested in a pilot plant for compliance to PSM regulation. The model is beneficial to the process industries as any deficiencies in the PSM contractors' management program will be highlighted by the model which will then easily correct the identified deficiency so as to minimize and prevent catastrophic accidents.     

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.     

Process safety challenges for SMEs in China

While process safety regulations and standards have been in place in western countries for more than two decades, China has only recently started to officially embrace these issues with the adoption of its Process Safety Management (PSM) regulation AQ/T 3034-2010 (SAWS, 2010). However, compliance with this regulatory framework requires substantial resources and may therefore appear too complex to be efficiently implemented by small and medium sized enterprises (SMEs) in the chemical sector. This is of particular relevance as about 99% of chemical companies in China are SMEs, accounting for more than 80% of all chemical accidents. To address this issue, additional local regulations and planning activities related to process safety have been implemented in China, including the establishment of hundreds of chemical industry parks. Some of the process safety problems faced by chemical industry parks are identified and discussed in this paper. To help solve these problems, UNEP's “Responsible Production approach for Chemical Hazards Management along the Value-Chain” is introduced in this paper and suggested as a simplified PSM approach targeted specifically at SMEs which, regardless of handling hazardous chemicals in their daily operations, may not have the knowledge or capacity to efficiently implement PSM and may not fall in the scope of the PSM regulation AQ/T 3034-2010. By introducing PSM to SMEs in a more manageable way, relevant steps can be progressively implemented by companies towards full compliance with the current regulatory framework, contributing to increased safety in chemical industry parks in China.     

Overview of GHS (Globally Harmonized System) in Korea and the direction of further development

Many chemicals are being developed with the growth of science technology. Such chemicals bring many advantages to humans but also cause many social problems because of the hazards of the materials. Therefore, it is necessary to have a system which identifies the hazards of chemicals. Some acts or regulations about information on warning labels or MSDS (Material Safety Data Sheet) information for chemicals are similar in each country but there are differences in definitions of degree of hazard, standard classification of harmful level, and indication methods. GHS is the indication method of worldwide integrated classification standard in order to prevent damage caused by disease or risks of accidents resulting from confusion by the users. In keeping pace with the world trend, Korea has conducted translation of the GHS manual from UN and selected it as the official GHS manual of the Korean government. The official Korean GHS translated version was published in July 2005. After that, the Korea Ministry of Employment and Korea Labor and the Ministry of Environment have implemented GHS MSDS for chemical substances since July 1, 2010 so that manufacturers and importers are required to apply it. The full implementation for compound materials will start on July 1, 2013. In Korea, database information for chemicals is provided by four organizations including The Korea Occupational Safety and Health Agency. However, domestic information on chemicals provided by domestic information providers has problems including differences in basic content and incorrect recording because of trade secrets. Efforts for improvement including reinforcing training for manufacturers and importers on recording consistent information for different organizations are urgently needed.     

重大事故应急救援法律法规体系建设

重大事故应急救援法律法规体系作为生产安全应急救援体系建设的重要内容之一 ,在重特大事故多发的今天 ,已显得尤为重要。笔者结合国内外重大事故应急救援立法的现状 ,论述加强我国应急救援法律法规体系建设的必要性 ;提出重大应急救援法律法规体系建设要从法律、行政法规及部门规章、地方性法规及规章3个方面进行 ;同时提出建立联席会议制度、应急预案编制审核和备案制度、报告与信息发布制度、应急救援的分级响应制度、应急救援演习制度、应急救援资金补偿制度、应急救援的奖惩制度等急救援工作制度体系。最后 ,还强调建立重大事故应急救援体系对于提高政府对国家危机的管理能力有着深远的影响和意义。     

建立我国重大事故预防控制体系之探讨

简述了我国重大工业事故发生的主要原因，提出了建立重大事故预防控制体系的建议，制定《重大事故预防和控制法》，实行重大危险源上报、登记、评价、分级监察管理，建立国家、省、市三级重大事故应急反应系统和重大危险源动态监控网络系统。     

Safety evaluation of major hazard installations based on regional disaster system theory

Major accidents have catastrophic effects on humans and all of society. To prevent the occurrence of major accidents, it is essential to strengthen the management of major hazard installations. Generally, effective identification and reasonable evaluation of major hazard installations are the basic steps in safety management. At present, the evaluation methods for major hazard installations mainly focus on consequence analysis and probabilistic analysis without considering the vulnerability of hazard-affected bodies. Therefore, the proposed method will introduce regional disaster system theory and comprehensively analyze hazard-formative factors, the hazard-formative environment and hazard-affected bodies to achieve a more complete and effective assessment of major hazard installations. Hazard-formative factors are evaluated based on the rapid ranking method, hazard-formative environments are evaluated based on Bayesian networks, and hazard-affected bodies are evaluated based on the fuzzy comprehensive evaluation method. A tank group and a chemical industrial park are used to verify the feasibility and effectiveness of the new method.     

A causal analysis of time-varying speed camera safety effects based on the propensity score method

Introduction: Speed limit enforcement cameras provide an effective approach to reduce vehicle speeds and the number of road accidents. However, it is still unclear whether the safety effects of speed cameras show durability over long periods of time. This paper analyses how the effects of speed cameras on road accidents change over time. A total number of 771 camera sites and 4787 potential control sites are observed for a period of 18 years (1999–2016) across England. Method: Covariates such as road class, crash history, speed limit, and annual average daily traffic (AADT) are included in the data set. A difference in difference (DID) based propensity score matching (PSM) method is employed to select proper control sites and estimate the treatment effects. The safety effects of speed cameras are then evaluated from a long-term perspective. The post-treatment period is divided into four equal-length periods: early, medium 1 and 2, and late. Results and Conclusions: The results show that speed cameras have significantly reduced the number of road accidents near the camera sites. However, the effects vary across different time periods. The safety effects of speed cameras experienced a sharp decrease during the medium periods after an initial period of highly reduced accidents (medium 1: −53.1%, medium 2: −40.7%) and recovered slightly during the late period. In addition, to evaluate the criteria for selecting camera sites in the UK, we further investigated whether speed cameras at high risk sites have better safety performance. The results show that while safety effects at high risk camera sites also decreased during the medium periods, the reduction was smaller (medium 1: −20.8%, medium 2: −2.1%). Practical Applications: Appropriate road traffic regulations and management, as well as proper camera sites selection criterion, are important to maintain the effectiveness of speed cameras.     

What is this thing called a safety regulation?

Regulation is generally perceived as an important way to achieve safety. Controversy about enforcing, amending, reforming, reducing, improving, and evaluating safety regulations abounds. Questions about the need for, validity, and effectiveness of safety regulations also continue. This paper explores the nature of a safety regulation, what can be expected of a safety regulation in view of its nature, and what this means to persons affected by safety regulation. The role of regulation in safe task performance is reviewed. Consequences of these findings on regulation promulgation, employee training, and regulatory enforcement programs are discussed. Steps to enhance the effectiveness of safety regulations are suggested.     

基于行为安全理论的化工事故统计及分析

行为安全理论是事故分析和预防的理论和方法,应用基于行为安全理论的事故致因“2-4”模型对10起化工事故的直接、间接、根本、根源原因进行分析。结果表明:该模型是化工事故分析的有效方法。10起事故的直接原因主要为一线员工在涉及高温加热工艺、带压设备、有毒有害环境和动火作业中的违规违章操作,管理人员未建立或运行安全管理体系等不安全动作及不安全物态,且不安全物态与管理人员不安全行为有关;间接原因是一线员工缺乏岗位安全操作等知识,管理人员缺乏安全管理、技术等知识,导致其安全意识薄弱,养成不良的安全习惯;根本原因是组织安全教育等管理程序缺失和执行不力;根源原因是组织成员对安全的重要度等安全文化元素缺乏理解。     

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.     

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.     

Have government regulations improved workplace safety? : A test of the asynchronous regulatory effects in China's coal industry, 1995-2006

Problem

Empirical studies on the effectiveness of workplace safety regulations are inconclusive. This study hypothesizes that the asynchronous effects of safety regulations occur because regulations need time to become effective. Safety regulations will work initially by reducing the most serious accidents, and later by improving overall safety performance.

Method

The hypothesis is tested by studying a provincial level aggregate panel dataset for China's coal industry using two different models with different sets of dependent variables: a fixed-effects model on mortality rate, which is defined as fatalities per 1,000 employees; and a negative binominal model on the annual number (frequency) of disastrous accidents.

Results

Safety regulations can reduce the frequency of disastrous accidents, but have not reduced mortality rate, which represents overall safety performance.

Discussion and summary

Policy recommendations are made, including shifting production from small to large mines through industrial consolidation, improving the safety performance of large mines, addressing consequences of decentralization, and facilitating the implementation of regulations through carrying on institutional actions and supporting legislation.

Impact on industry

Until recently, about 4,000 coal miners perished annually in China, demonstrating that workplace safety in China's coal industry is an urgent and important issue. This research provides evidence that safety regulations have asynchronous effects and identifies the priorities in improving safety in China's current coal mining. This may assist the Chinese government to design more effective safety improvement policies and improve the effectiveness of safety regulations and safety performance.     

《煤矿安全监察条例》与安全生产立法问题探讨

基于对国务院 2 96号令《煤矿安全监察条例》和我国现行的安全生产法律、行政法规的全面比较分析 ,从执法主体、执法内容、执法监督及行政强制措施、即时强制和法律责任等 5个方面 ,研究、总结了《煤矿安全监察条例》在立法上的 13个特点及其对新时期安全生产立法的指导意义     

安全生产基础建设继承与创新——近期几起重特大事故的反思

针对近期我国重特大生产安全事故频发、安全生产形势严峻的实际情况,分析了事故多发的特点和原因,认为我国安全生产工作中存在系统脆弱性,其中最突出的问题是基础薄弱,本质上是结构性缺陷。提出当前最紧迫的战略性任务是强化安全生产基础工作的制度化设计与安排。建议：逐渐实现安全生产执法监察“暗查”制度化;事故分级与分级标准中经济损失指标的导向性作用不容忽视;应从制度上保证事故调查客观、独立和公正;建立现代生产安全事故统计系统与指标体系;从制度上加强对企业安全生产的职工参与和社会监督;强化监察员队伍的专业化建设;安全监督应实行安全生产事故风险分级与分级管理。