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.     

Actual safety performance of the Malaysian offshore oil platforms: Correlations between the leading and lagging indicators

IntroductionThis study establishes the correlations between performance of a set of key safety factors and the actual lagging performance of oil platforms in Malaysia, hence the relevance of the key safety factors in evaluating and predicting the safety performance of oil and gas platforms. The key factors are crucial components of a safety performance evaluation framework and each key safety factor corresponds to a list of underlying safety indicators.MethodIn this study, participating industrial practitioners rated the compliance status of each indicator using a numbering system adapted from the traffic light system, based on the actual performance of 10 oil platforms in Malaysia. Safety scores of the platforms were calculated based on the ratings and compared with the actual lagging performance of the platforms. Safety scores of two platforms were compared with the facility status reports' findings of the respective platforms.ResultsThe platforms studied generally had good performance. Total recordable incident rates of the platforms were found to show significant negative correlations with management and work engagement on safety, compliance score for number of incident and near misses, personal safety, and management of change. Lost time injury rates, however, correlated negatively with hazard identification and risk assessment. The safety scores generally agreed with findings of the facility status reports with substandard process containment found as a contributor of hydrocarbon leaks.ConclusionsThis study proves the criterion validity of the safety performance evaluation framework and demonstrates its usability for benchmarking and continuous improvement of safety practices on the Malaysian offshore oil and gas platforms.Practical applicationsThis study reveals the applicability of the framework and the potential of extending safety reporting beyond the few conventional lagging safety performance indicators used. The study also highlights the synergy between correlating safety factors to streamline safety management on offshore platforms.     

A comparison of required coefficient of friction for both feet in level walking

The required coefficient of friction (RCOF) is one of the critical elements in determining whether a slip incident might occur. Most researchers, when measuring RCOF, do not differentiate between the two feet of the same participant under the same walking condition. Results from a recent study (Chang et al., 2010) indicated that the stochastic distributions of the RCOF of both feet were different in 76% of the cases. Using the previous data (Chang et al., 2010), this paper presents a comparison of the RCOF for both feet of 50 participants under four level walking conditions resulting from two footwear types and two walking speeds using a t-test, commonly used by safety professionals to compare two pools of data. The current results indicated that 78% of the RCOF data showed a statistically significant difference between the RCOF from two feet for the same participant under each walking condition. The results of the logistic regression analysis used to identify factors that contributed to the outcome of the t-test indicated that the walking speed was the only factor with a statistical significance (p = 0.044).     

The role of local communities in chemical accident prevention and preparedness

Since the adoption of community right-to-know programs in the US there has been an increase in the number of groups known as local emergency planning committees. These committees have matured in focus over the intervening years since the Bhopal incident and even more so since the events of September 11, 2001. There is a strong recognition that local communities working very closely with chemical handling facilities in their areas can directly and meaningfully reduce the threat of a chemical release incident, regardless of cause. Likewise, through similar means they can better prepare themselves to respond should an incident occur. Especially as regards modern concepts of process chemical safety and facility security, local communities can be of great assistance to smaller facilities that do not otherwise necessarily have the resources to accomplish these tasks. As the vulnerabilities of a facility to accident or intentional act, the impacts of these events and the ability of communities to react are all a function of local conditions, it is clear that these local efforts can be more meaningful than large-scale national efforts. While national legislation is certainly helpful to the process of bringing people together, it is the local relationships that produce results.     

Safety issues related to the maintenance operations in a vegetable oil refinery: A case study

The present work was focused on maintenance hazards related to vegetable oil refining. An incident occurred in an Italian vegetable oil refinery was presented to evidence this safety criticality. The incident took place during a maintenance shut down, and was associated to the ignition of the solid residual in a packed column. No fatalities or injuries were reported, but the column was strongly damaged and removed from the plant. A specific experimental characterization of the solid residues accumulated in the column, sampled both from the damaged and undamaged parts of the column, was carried out in order to determine the conditions leading to unwanted combustion of the residues. At the same time, samples taken from the damaged column steelwork were subjected to metallurgical analysis aimed at the thermal and mechanical characterization of the steel, obtaining information about the incident duration and temperature reached during the combustion phenomenon. The study evidenced the need of adequate maintenance procedures and safety management in the generic framework of food industry, identified as key lessons learned.     

陆上含硫气井安全规划方法探讨

本文对我国陆上含硫化氢天然气井的安全规划方法进行了研究。通过对国内外含硫气井安全规划方法及支撑技术手段的调研,结合我国含硫气井实际情况,提出了以公众防护为目标,以含硫气井分级方法为基础,以事故后果分析及定量风险分析为支撑技术手段,以公众安全防护距离及应急计划区划分为主要内容的含硫气井安全规划方法,并就新建及已有含硫气井分别加以了讨论。该方法为含硫气田勘探开发的政府安全监管及企业安全管理提供了参考依据。     

Consequence modeling of a real rupture of toluene storage tank

Chemicals used in paint industry are generally comprised of toxic and inflammable substances; they may cause serious problems for humans and environment if safety conditions are neglected. In 2012, rupture of a toluene tank in a paint factory in Iran claimed lives of two workers near the tank. The present study is formulated in order to model the incident. The results showed the area prone to flash fire occurrence and extension. Furthermore, radiation was measured in terms of distance to the tank. A bund wall is also assumed around the vessel in order to determine its influence on evaporation in flash fire area, radiation, and maximum concentration of vapor cloud. The results provided important hints on minimum and required distance of electrical equipment or electrical enclosure (PLC) installation from vessels as well as suitable distance between the vessels. Finally, preventive recommendations were proposed to reduce the risk of potential accidents.     

Harnessing database resources for understanding the profile of chemical process industry incidents

Analyzing historical databases can provide valuable information on the incident occurrences and their consequences for assessing the safety of the chemical process industry. In this study, the RMP and HSEES databases were utilized to understand the patterns and the factors influencing chemical process industry incidents. Frequency exceedance curves were generated by utilizing the different incident consequences from the databases to understand the profile of societal loss from reported incidents. Understanding the statistics and trends of the historical incidents could serve as important lagging indicators in order to assess the probable proximity to major consequences from the low-probability/high-consequence incidents. To this regard, the safety pyramids were also generated to better understand the relationship between the different consequences of the reported incidents. Furthermore, the safety pyramids were analyzed in comparison with the traditional safety pyramid proposed by Heinrich to understand the US process industry incident occurrence trends.     

Case study: T2 Laboratories explosion

A tragic explosion resulting from a runaway chemical reaction occurred at the T2 Laboratories, Inc. facility in December 2007. The U.S. Chemical Safety Board (CSB) completed an incident investigation of the T2 explosion, identifying the root cause as a failure to recognize the runaway reaction hazard associated with the chemical it was producing. Understanding the consequences of process upset conditions is critical to determine risk. This paper will focus on lessons learned from this incident including a comprehensive hazard assessment for reactive chemicals as well as proper collection and application of adiabatic calorimetry data to characterize the chemical reaction and determine appropriate mitigation strategies. Examples will be provided to establish safer operating conditions, implement safeguards and reduce the overall risk.     

Statistical evaluation and analysis of safety intervention in the determination of an effective resource allocation strategy

This paper provides an analytical background for the development of an effective safety intervention program with the aim of minimizing incident rates. Safety intervention data were collected from the environmental health and safety department of an American-owned oil company in the Niger-Delta region of Nigeria. A safety model was developed to determine the safety intervention factors and interactions which minimize incident rates, with the aim of predicting a better resource allocation strategy. Five main safety intervention factors (factor A: leadership and accountability; factor B: qualification selection and pre-job; factor C: employee engagement and planning; factor D: work in progress; factor E: evaluation, measurement and verification) were highlighted and investigated to show their effects on incident rate performance. Analysis of variance test showed that four safety factors (A, C, D, and E) were significant. Statistical techniques such as response surface design plots were used to determine the resource allocation method. The developed safety model recommended the allocation of 16.66% of the available resources to the significant safety intervention activities in order to achieve the desirable incident rate. In order to reap the benefits of this research, it will be important to concentrate more efforts and resources on significant factors which have positive impacts in minimizing incident rates.     

Do industrial incidents in the chemical sector create equity market contagion?

IntroductionThis paper examines a number of US chemical industry incidents and their effect on equity prices of the incident company. Furthermore, this paper then examines the contagion effect of this incident on direct competitors.MethodEvent study methodology is used to assess the impact of chemical incidents on both incident and competitor companies.ResultsThis paper finds that the incident company experiences deeper negative abnormal returns as the number of injuries and fatalities as a result of the incident increases. The equity value of the competitor companies suffer substantial losses stemming from contagion effects when disasters that occur cause ten or more injuries and fatalities, but benefit from the incident through increasing equity value when the level of injury and fatality is minor.ConclusionsPresence of contagion suggests collective action may reduce value destruction brought about by safety incidents that result in significant injury or loss of life.Practical ApplicationsThis research can be used as a resource to promote and justify the cost of safety mechanisms within the chemical industry, as incidents have been shown to negatively affect the equity value of the not just the incident company, but also their direct competitors.     

Key airborne concentrations of chemicals for emergency response planning in HAZMAT road transportation- margin of safety or survival

The release of chemicals due to road transportation accidents could have adverse consequences such as fatality, physical and financial loss and environmental damage. The purpose of this study was to determine the suitable margin of safety/survival of individuals in HAZMAT road transportation accidents for use in Emergency Response Planning (ERP). In this study, at first, the safety margin and survival margin were defined and proposed. Then, as a case study, the chemical tanker trucks in Iran's road transport fleet were investigated and the full bore rupture of the tanker trucks was considered as the selective scenario. Eventually, safety margin and survival margin were determined using ALOHA and PHAST software and the Chemical Exposure Index (CEI). The results showed that using the CEI, among the selected chemicals, ammonia, chlorine and 1,3-butadiene had the highest chemical release potential with the exposure indices of 597, 548 and 284, respectively, and need further investigation. The possible safety margin obtained in this study was distances over 5100 m (using ALOHA software for ammonia) and 10,983 m (using PHAST software for chlorine). On the other hand, the survival margin was distances over 980 m away from the accident area (using ALOHA software for ammonia) and 620 m away from the accident area (using the PHAST software for chlorine). The results of this study indicate that determining the safety and survival margins surrounding the tanker trucks and containers of chemicals is a critical issue for the emergency response planning and determining the standards of road's safety and survival margins. On the other hand, due to the obtainment of different results by various methods and software, in road accidents, the highest hazard distance is suggested to be considered to determine the safety margin (distances longer than 10,983 m) and survival margin (distances longer than 980 m) for ERP, regardless of the type of used material and software.     

HAZOP与风险矩阵组合技术应用研究

通过对国外风险矩阵和个体风险研究,同时结合国内相关法律法规和企业事故管理规定,首次提出风险矩阵制定的依据,为企业行业制定风险矩阵提供理论基础,并制定出适合自身企业的风险矩阵。将HAZOP分析方法与风险矩阵相结合,提出"HAZOP+风险矩阵"组合技术,并采用该组合技术对精对苯二甲酸(PTA)装置氧化反应器单元的危险与可操作性问题进行系统分析,识别出装置中存在的过程安全问题并提出建议,对整个装置重大工艺安全事故的预防和安全平稳运行起到重要作用。     

Modeling of BP Texas City refinery incident

This paper presents detailed modeling results of the BP Texas City refinery incident. Three different approaches and explosion modeling tools were used to study the event. The results predicted by all three approaches are similar and all approaches identified a hazard potential comparable to what was witnessed on March 23, 2005. This confirms that quantitative risk assessment (QRA) has the ability to model a realistic scenario, and is therefore useful in safety measure design and emergency preparedness decision making to improve overall safety performance. Had QRA been conducted during a management of change (MOC) decision-making process, personnel trailers likely would not have been sited in such close proximity to the process units. The resulting severe consequences would then not have occurred. This work also aims to emphasize the importance of QRA in process safety management.

The paper presents the authors’ perception of the sequence of events involved in the incident based on the published literature available at the time of writing. It also assesses potential consequences for the perceived sequence of events using a variety of consequence assessment tools. In doing so, the analysis illustrates how this incident could have been prevented in spite of many operational difficulties. The observations and commentary presented in this paper are intended solely for the purpose of process safety enhancement on the basis of the lessons learned. BP has published its own detailed report; the incident is also the subject of a recent investigation by the US Chemical Safety and Hazard Investigation Board, with the CSB's final report being available at http://www.csb.gov/index.cfm?folder=completed_investigations&page=info&INV_ID=52 (as of April 2007).     

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.     

Cultural influences on risks and risk management: six case studies

Ever since the accident at the Three Mile Island nuclear power plant on 28 March 1979, the term ‘safety culture’ has been a hot topic for both researchers and organisations. Both the content and causes of a poor safety culture have been the focus of numerous research projects, but also its consequences on an organisation's safety performance and the way organisations should be ‘designed’ to facilitate a ‘good’ safety culture. Since others in this issue focus on the content and causes of safety culture, this article focuses on its consequences from two different but inter-related angles. In the first place, the cultural influences on incident causation are considered. In the second place, the cultural influences on risk management, or specifically incident reporting and analysis, are considered. Both angles are supported by empirical incident data collected in the Dutch steel industry and the medical domain. To collect this data, a risk management approach called PRISMA was used. Further, cultural differences between the domains investigated are highlighted and discussed.     

Challenges and needs for process safety in the new millennium

Process industries have made quite a bit of progress in process safety since the tragic night of December 2, 1984 in Bhopal. Nonetheless, incidents continue to occur on a regular basis due to insufficient understanding of the urgency to identify best practices and drive for process safety improvements in the organization. This paper addresses some of the critical challenges in implementing effective safety programs: (a) failure to learn from past incidents and to capture those lessons into process design, procedures, training, maintenance, and other programs, (b) insufficient attention to leading indicators, and (c) an increase in complexity of process operations and lack of communication. In the presence of these challenges, there is a great need to develop better solutions by utilizing good science based approaches and best practice studies. Potential research areas include, but are not limited to, incident database analysis, reactive chemicals, inherently safer design, combustible dust explosion, facility siting, and the flammability of fuel mixtures and aerosols. In addition, an example was presented on LNG industry safety to illustrate that science-based research is needed to ensure the safe operation and to avoid or mitigate unintended consequences.     

Enhancing regional process safety management

As industrial operations expand, major incidents continue to affect people, damage facilities, and impact the environment. In the last 20 years, about 50% of these incidents occurred in facilities that had implemented some form of Process Safety Management (PSM) and 50% came about in smaller facilities that did not include such planning (Demichela et al., 2004). The objective of this article is to use PSM principles to create practical recommendations at the regional level, to complement those previously developed for singular facilities. This article compares Strathcona County Emergency Service (SCES) in Alberta with Technical Standards & Safety Authority (TSSA) in Ontario, with respect to safety, facility licensing, permit requirements, risk assessment procedures and land use planning aspects to determine PSM enhancements for SCES. Furthermore, for a better overview, two supplemental provincial organisations in Alberta, namely Alberta Boiler Safety Association (ABSA) and Safety Codes Council (SCC), were also considered. We proposed that SCES could develop more detailed facility-specific licensing procedures, auditing, and inspection. SCES could also provide details of accredited organisations that carry out inspections and audits on their behalf. When reviewing the quantitative risk assessment processes for SCES and TSSA, we recommend that SCES should update their probability data sources used in their cumulative risk assessment study. Based on the authors’ experience and gathered data, the use of additional facility practices such as safety management system, internal audits, and checklists can enhance incident prevention.     

Global process safety incidents in the pharmaceutical industry

The objective of this research is to analyse global process safety incidents within the pharmaceutical industry in terms of their consequences and factors contributing to the incidents. There were 73 process safety incidents leading to 108 fatalities found between 1985 and 2019. Trends between the number of incidents, number of fatalities, location, and contributing factors were identified and summarized. The most reported fatalities occurred in 2018 & 2019. 83% of fatalities occurred in China and India. Explosions were associated with 71% of incidents, which resulted in 89% of fatalities. For most of the international incidents, incident investigations were not available and thus insufficient details were available to determine the causes. Contributing factors were available or estimated from available data for about half of the incidents, with the following most common: hazard awareness & identification; operating procedures; design; safeguards, controls & layers of protection; safety culture; and preventive maintenance. These findings can be used as a basis to improve process safety performance in the pharmaceutical industry.