Ranking of process safety cultures for risk-based inspections using indicative safety culture assessments

Although major hazard industries have no legal obligations to demonstrate a good safety culture, it is an increasingly important factor for risk-based inspections. This paper describes the development and evaluation of a relatively simple method for external indicative assessment of the process safety culture in major hazard industries. As a first step, a tool was developed. Second, the tool was successfully tested in a workshop with major hazard inspectors. After this ‘proof of concept’ and a few adaptations to improve the tool, quantitative evaluation and validation were carried out with a representative sample of major hazard inspectors in the Netherlands. In this stage, the tool comprised 30 questions, of which 19 sufficiently frequent valid responses were given for the validity test. The evaluations demonstrate that without specific preparations, inspection teams can use the tool to discriminate between plants with poor or good safety cultures. That is sufficient for ranking as additional input for risk-based inspection strategies. The resulting indicative ‘scores’ for safety culture correlate meaningfully with the quality of process safety management systems and the number of (legal) non-compliances, which were identified by the inspection team at the same occasion. The use of the tool can be further improved by training inspectors, making minor adaptations of the inspection process, and broadening the scope of a few questions. It is expected that external assessments of safety culture will become increasingly important not only for inspectorates, but also for a range of other external stakeholders.     

Survey-based analysis on the diffusion of evacuation advisory warnings during regional evacuations for accidents that release toxic vapors: A case study

This paper analyzes the diffusion of evacuation advisory warnings during regional evacuations for accidents that release toxic vapors. Investigations results on the propagation of evacuation advisory warnings in the ‘4.16’ chlorine release and the explosion accident at Chongqing Tianyuan Chemical Factory in China, and a comparison analysis of the evacuation notification process of six typical leakage accidents are presented in this paper. After conducting the evacuation notification investigation on the ‘4.16’ accident, in which 401 valid questionnaires were collected from people who should have evacuated during the accident, the methods and channels of the evacuation notification, the notification efficiency, and the actual response efficiency of the recipients after the issuing of the evacuation advisory warnings were analyzed. A comparison analysis of the evacuation notification process is performed by analyzing six typical leakage accidents, and basic principles of evacuation notification for a regional evacuation for toxic vapor release accidents are proposed.     

Technological disaster factors

Major Hazard Installations (MHIs) deal with the hazardous substances which exceed the threshold quantity. Although MHIs are safe organizations, they cannot fail due to a single error. However, due to their high complexity, the designer and the operator make errors during the design, and operation of the plants. Consequently, the technical, operational and organizational errors may lead to a major accident. The world has seen many incidents due to the operation of the MHIs. Malaysia has experienced several technological disasters. Four investigation reports have been reviewed in detail. This paper reviews the causes of the technological disasters in general. This paper also summarizes the causes of the technological disasters in Malaysia. Finally the paper rearranges the technological disaster causes and errors.     

Use of safety barriers in operational safety decision making

Operational personnel in complex hazardous industries are regularly called upon to make decisions that balance the production and safety objectives of their organisation. Regulations and industry standards focus on defining and complying with operating limits of various kinds as the primary method of achieving the right balance. Such limits remove the need in many cases for in-the-moment judgements about safety and production priorities.Focussing solely on the compliance with a pre-defined envelope underestimates the direct contribution to safety from operational managers based on their professional judgement. Research in a chemical plant, a nuclear power station and an air navigation service provider has identified a “line in the sand” approach taken by experienced operating personnel when abnormal situations arise. In developing these situation-specific self-imposed limits, operational managers focus on the status of safety barriers, rather than considering risk from first principles. This approach could form the basis of a new procedure, which lays out the process to be followed in determining how best to proceed (similar to job safety analysis or permit to work). This would acknowledge that such decisions are necessary, assist operational personnel in making better choices and open such decisions to appropriate audit and scrutiny.     

Overcoming the blame game to learn from major accidents: A systemic analysis of an Anhydrous Ammonia leakage accident

This article aims to demonstrate the need for changing the methods with which accidents are analyzed, if we truly wish to use what we uncover from them to learn and enrich our knowledge base of organizational management. The goal is to relinquish the broadly adopted and rather simplistic paradigm that accepts the search for human error and unsafe acts performed by workers, and produces “guilt diagnostics”. Instead, we use a systemic accident analysis methodology, based on the sociotechnical principle of understanding the real operating conditions in which accidents take place. In order to demonstrate the benefits of the theoretical framework, we compare the analyses of an Anhydrous Ammonia gas leakage accident in a fish processing plant using the traditional accident analysis model based on unsafe acts and the proposed systemic approach. The results favor the latter since it tends to be more reliable and offering useful recommendations to safety management processes, thus helping to prevent accidents, especially in complex systems.     

基于GIS的污染源自动监测数据综合分析系统设计和实现

基于地理信息系统(GIS),将污染源在线监测数据信息与空间地理信息相结合,建立北京市重点锅炉烟气、污水处理厂两类主要污染源和水环境质量等大量在线监测数据的监控和综合分析系统。系统不仅实现了对重点污染源在线监测数据的实时监控、数据展示、统计分析、超标报警等常规业务功能,还在污染源扩散模拟展示、污染源与环境质量信息相互作用的空间综合分析等方面进行了初步研究,为进一步提高北京市的污染源监控管理和自动监测数据利用水平做出了创新性的技术尝试。     

Quantitative assessment of domino and NaTech scenarios in complex industrial areas

Since the late 80s the application of quantitative risk assessment to the issue of land-use planning with respect to major accident hazards emerged as a topic to be addressed within the safety assessment of chemical and process plants. However, in the case of industrial clusters or complex industrial areas specific methodologies are needed to deal with high-impact low-probability (HILP) events. In the present study, innovative methodologies developed for the quantitative assessment of risk due to domino and NaTech scenarios are presented. In recent years a set of models for the calculation of equipment damage probability were developed. A specific effort was dedicated to the improvement of models for the calculation of equipment damage probability in these accident scenarios. In the present study, the application of these models to case-studies was analyzed. The results of the improved models obtained for NaTech quantitative assessment were compared to previous results in the literature. A specific innovative approach was developed to multi-level quantitative assessment of domino scenarios, and its potential was analyzed. The results were examined also evidencing the role and the progress with respect to the pioneering work started on these topics by Franco Foraboschi.     

Global process industry initiatives to reduce major accident hazards

In the past 10 years, the vapor cloud explosion at Texas City, the ammonium nitrate explosion in Toulouse, a pipeline disaster in Belgium, and three near total loss events in Norway have highlighted that major accident process safety is still a serious issue. Hopes that PSM or Safety Case regulations would reduce process events by 80% have not proven true. The Baker Panel, convened after Texas City developed a series of recommendations, mainly around leadership, incentives, safety culture and more effective implementation of PSM systems. Many US-based companies are working hard to implement the Baker recommendations. In Europe, an approach built around safety barriers, especially relating to technical safety systems, is being widely adopted.The author’s company has carried out a global survey of process industry initiatives, for both upstream and downstream activities, to identify what the industry itself is planning to enhance process safety in the next 5-10 years. This paper presents a summary of some of the major programs and initiatives as apply to traditional oil majors, newer national oil companies, and the chemical industry. These are a mixture of Baker recommendations, barrier approaches and tighter integration of process safety and asset integrity. While the factor of 10 improvement achieved in occupational safety over the past 20 years seems unattainable for process safety, a factor of 3-4 improvement in the next 20 years does seem possible. This would call for significant effort on the part of operators, but the benefits fully justify the effort.     

The successes and challenges of implementing high reliability principles: A case study of a UK oil refinery

Research conducted on organisations that are able to sustain excellent safety records over long time periods suggests that there are a number of practices that organisations can adopt to achieve high levels of reliability and safety. These practices are often discussed in the context of major incidents to highlight the safety standards that high hazard organisations should try to emulate. However, previous research has predominantly focused on non-profit organisations, and comparatively little research has examined whether high reliability practices may be meaningfully applied to commercial contexts. This paper addresses this gap by using a qualitative approach to explore the types of reliability-enhancing practices implemented in a UK-based oil refinery in its attempt to achieve its ethos of ‘safe and reliable operations’. The findings illustrate the successful application of reliability-enhancing practices in several domains, including: hazard identification and control; emergency preparedness and collection; and analysis of incidents and near misses. Management commitment to safety emerged as an important factor underpinning the successful implementation of reliability-enhancing practices, highlighting its potential significance in the context of commercial organisations. However, promoting an open reporting culture and maintaining high levels of management visibility may be some of the challenges encountered by organisations striving to implement reliability-enhancing practices.     

Nitrogenous and carbonaceous aerosols in PM2.5 and TSP during pre-monsoon: Characteristics and sources in the highly polluted mountain valley

This study reports for the first time a comprehensive analysis of nitrogenous and carbonaceous aerosols in simultaneously collected PM_2.5 and TSP during pre-monsoon (March–May 2018) from a highly polluted urban Kathmandu Valley (KV) of the Himalayan foothills. The mean mass concentration of PM_2.5 (129.8 µg/m³) was only ~25% of TSP mass (558.7 µg/ m³) indicating the dominance of coarser mode aerosols. However, the mean concentration as well as fractional contributions of water-soluble total nitrogen (WSTN) and carbonaceous species reveal their predominance in find-mode aerosols. The mean mass concentration of WSTN was 17.43±4.70 µg/m³ (14%) in PM_2.5 and 24.64±8.07 µg/m³ (5%) in TSP. Moreover, the fractional contribution of total carbonaceous aerosols (TCA) is much higher in PM_2.5 (~34%) than that in TSP (~20%). The relatively low OC/EC ratio in PM_2.5 (3.03 ± 1.47) and TSP (4.64 ± 1.73) suggests fossil fuel combustion as the major sources of carbonaceous aerosols with contributions from secondary organic aerosols. Five-day air mass back trajectories simulated with the HYSPLIT model, together with MODIS fire counts indicate the influence of local emissions as well as transported pollutants from the Indo-Gangetic Plain region to the south of the Himalayan foothills. Principal component analysis (PCA) also suggests a mixed contribution from other local anthropogenic, biomass burning, and crustal sources. Our results highlight that it is necessary to control local emissions as well as regional transport while designing mitigation measures to reduce the KV's air pollution.