Is risk analysis a useful tool for improving process safety?

To improve safety one has to know where risks are. For determining risks, hazards have to be identified and representative accident scenarios defined. This needs effort and technique. Man is quite limited in foresight without having experience and lessons from the past. For knowing the risk of an incidental, undesired event both its severity and probability has to be estimated. Then ways to reduce risk become clear. In a process plant risks are many and it is not possible to remove them all. One has to attribute priorities. Intuitive and qualitative methods can do much, but plant complexity may be large and communication on risk may become difficult without formal methodology. Quantitative risk analysis offers much, but has its weaknesses and drawbacks. The required effort is considerable, specialists are needed, and variability in answers is large. Yet, a model built to go along with the life of an installation and updated periodically may be very useful. This paper presents an overview of the demand, problems encountered, possible remedies, and an outlook on useful improvement and extension of risk analysis methodology, including decision making.     

Self-directed workteams and safety: a winning combination?

The organization of work into self-directed work teams (SDWT) has considerably changed the power structure within companies. In addition to carrying out the work, SDWT members make decisions that are traditionally the jurisdiction of first line supervisors. This exploratory research examines the impact of this type of group empowerment on the management of health and safety in twelve factories in Quebec. As expected, the management of health and safety is greatly modified when self-directed work teams are implemented. These teams play a major role in the planning, implementation and monitoring of corrective measures on the shop floor. Staff and management provide support and advice to the work teams, but make fewer and fewer decisions themselves. Peer pressure, when perceived as legitimate, is likely to positively influence the safety attitudes and behaviours of team members. Furthermore, the safety performance of these organizations is actually better than average. However, our respondents were concerned about the growing lack of health and safety leadership displayed by some managers. They worry about the definition of roles, integration of occupational health and safety (OHS) concerns and adoption of OHS measures by less mature work teams. Peer pressure is not always seen as legitimate, thereby causing tension. Finally, our respondents were concerned about the stress and health difficulties that may be related to group decision-making and added responsibilities.     

How do children learn to cross the street? The process of pedestrian safety training

Objective: Pedestrian injuries are a leading cause of child death and may be reduced by training children to cross streets more safely. Such training is most effective when children receive repeated practice at the complex cognitive–perceptual task of judging moving traffic and selecting safe crossing gaps, but there is limited data on how much practice is required for children to reach adult levels of functioning. Using existing data, we examined how children's pedestrian skills changed over the course of 6 pedestrian safety training sessions, each composed of 45 crossings within a virtual pedestrian environment.

Methods: As part of a randomized controlled trial on pedestrian safety training, 59 children ages 7–8 crossed the street within a semi-immersive virtual pedestrian environment 270 times over a 3-week period (6 sessions of 45 crossings each). Feedback was provided after each crossing, and traffic speed and density were advanced as children's skill improved. Postintervention pedestrian behavior was assessed a week later in the virtual environment and compared to adult behavior with identical traffic patterns.

Results: Over the course of training, children entered traffic gaps more quickly and chose tighter gaps to cross within; their crossing efficiency appeared to increase. By the end of training, some aspects of children's pedestrian behavior was comparable to adult behavior but other aspects were not, indicating that the training was worthwhile but insufficient for most children to achieve adult levels of functioning.

Conclusions: Repeated practice in a simulated pedestrian environment helps children learn aspects of safe and efficient pedestrian behavior. Six twice-weekly training sessions of 45 crossings each were insufficient for children to reach adult pedestrian functioning, however, and future research should continue to study the trajectory and quantity of child pedestrian safety training needed for children to become competent pedestrians.     

Cost–benefit analysis approach for the management of industrial safety in chemical and petrochemical industry

The high complexity of chemical and petrochemical installations determines a complex safety management of these establishments, therefore, there is a need to find innovative solutions to guarantee the prevention of failures and losses of containment from process equipment. In this frame, the use of the API Risk Based Inspection (RBI) assessment approach permits a significant reduction of maintenance costs and, simultaneously, the increase of plant's reliability and availability. To increase the level of industrial safety, a proper selection of measures is also needed, even if the adoption of such measures poses costs. Given that resources for the companies are usually limited, a comparison amongst various solutions has to be done with the aim to find the best one, based on a comparison of costs and benefit. To this scope, recently a software, named Inspection Manager, has been developed by ANTEA and implemented thanks to a cooperation with the University of Padova (Italy). The Inspection Manager provides support in the application of the RBI approach by means of the use of plant-specific data, which are stored in its database; its further implementation, presented in this paper, has made it able to support also cost-benefit analysis and, thus, the selection of measures to be adopted to prevent accidental events causing the release of hazardous materials. A case-study is presented to test the new functionality of the tool; after the identification of the most effective measures, a careful cost-benefit assessment has been executed as a basis for decision-making.     

What safety models and principles can be adapted and used in security science?

Engineering risk management is comprised of managing operational safety risks on the one hand and managing physical security risks on the other. Although some basic management principles are obviously the same for both safety and security, some important conceptual and calculation differences exist, as is explained in this paper. For instance, safety risk is usually calculated based on the scenarios’ consequences and likelihoods, while security needs to be determined by the assessment of vulnerability, the likelihood of attack and potential consequences. Nonetheless, there are also many similarities. Conceptual models, metaphors and principles that have been elaborated in the safety domain during the past century, many of them based on major accidents and their investigation, can easily be translated to the security domain. In the present study, we will explain how physical security should be seen in relation to safety, and what models and principles, derived from safety science, can be employed to manage the security aspects associated with physical threats.     

How do organizational practices relate to perceived system safety effectiveness? Perceptions of safety climate and co-worker commitment to safety as workplace safety signals

Introduction: Integrating safety climate research with signaling theory, we propose that individual perceptions of safety climate signal the importance of safety in the organization. Specifically, we expect that three work-related organizational practices (training effectiveness, procedure effectiveness, and work pressure) relate to the broader risk control system in the workplace via individual perceptions of safety climate as a broad management signal. Further, we expect this broad management signal interacts with a local environmental signal (co-worker commitment to safety) to amplify or diminish perceived system safety effectiveness. Method: In a field study of oil and gas workers (N = 219; Study 1), we used mediation modeling to determine the relationships between work-related organizational practices, perceived safety climate, and perceived safety system effectiveness. In a field study of railway construction workers (N = 131; Study 2), we used moderated mediation modeling to explore the conditional role of co-worker commitment to safety. Results: We found that training effectiveness, procedure effectiveness, and work pressure predicted perceived system safety effectiveness indirectly via perceived safety climate (Studies 1 and 2) and that these indirect paths are influenced by co-worker commitment to safety (Study 2). Conclusions: Findings suggest that perceived safety climate is driven in part by work practices, and that perceived safety climate (from managers) and co-worker commitment to safety (from the local environment) interact to shape workplace safety system effectiveness. Practical applications: The insight that training, procedures, and work pressure are meaningful predictors of perceived safety climate as a signal suggests that organizations should be cognizant of the quality of work-related practices for safety. The insight we offer on the competing versus complimentary nature of managerial safety signals (perceived safety climate) and co-worker safety signals (co-worker commitment to safety) could also be used by safety personnel to develop safety interventions directed in both areas.     

How important is vehicle safety in the new vehicle purchase/lease process for fleet vehicles?

OBJECTIVE: Despite the potential benefits that fleet vehicle purchase decisions could have on road safety, the role that vehicle safety plays in fleet managers' purchase decisions is poorly understood. METHODS: In this study, fleet managers from Sweden and Spain completed a questionnaire regarding the importance of vehicle safety in the new vehicle purchase/lease process and the importance that is placed on safety options/features relative to other convenience and comfort features. RESULTS: The findings of the current study suggest that vehicle safety is generally not the primary consideration in the vehicle purchase process and is consistently outranked by factors such as price and dependability/reliability. For example, when asked to indicate the vehicle factors that are included in their company's criteria for purchasing/leasing a new vehicle, fleet managers from both Sweden and Spain were more likely to list the vehicle's price, reliability, running costs, size, and fuel consumption than the vehicle's safety (defined as the vehicle's EuroNCAP rating/other safety reports). In addition, the findings of this study suggest that the importance of vehicle safety did not differ across the two countries. For example, there was no significant difference in the proportion of fleet managers who indicated that EuroNCAP ratings were part of their official policy across the two countries. CONCLUSION: The findings highlighted the need to educate fleet managers about vehicle safety in the new vehicle purchase/lease process. In addition, vehicle safety information, such as EuroNCAP results or other crash test results need to be promoted more widely and effectively so that they play a more prominent role in their new vehicle choices.     

Where to focus? Insights from safety personnel and external safety consultants on lessons learned about safety climate interventions – A qualitative approach

Introduction: Safety climate is important for promoting workplace safety and health. However, there is a dearth of empirical research on the effective ways of planning, designing, and implementing safety climate interventions, especially regarding what is going to be changed and improved. To address this gap, the present study sought to extract a comprehensive pool of compiled suggestions for safety climate intervention based on qualitative interviews with professionals in occupational safety and health management from potentially hazardous industries. Method: A series of systematic semi-structured interviews, guided by a comprehensive sociotechnical systems framework, were conducted with company safety personnel (n = 26) and external safety consultants (n = 15) of 21 companies from various industries. The taxonomy of five work system components of the sociotechnical systems approach served as overarching themes, representing different areas of improvement in an organization for occupational safety and health promotion, with an aim of enhancing safety climate. Results: Of the 36 codes identified, seven codes were based on the theme of external environment work system, four were based on the theme of internal environment work system, five were based on the theme of organizational and managerial structure work system, 14 codes were based on the theme of personnel subsystem, and six were based on the theme of technical subsystem. Conclusions: Safety climate intervention strategies might be most commonly based upon the principles of human resource management (i.e., codes based on the personnel subsystem theme and organizational and managerial structure work system theme). Meanwhile, numerous attributes of external/internal environment work system and technical subsystem can be jointly improved to bolster safety climate in a holistic way. Practical Applications: More systematic and organized management of safety climate would be available when various interrelated codes pertinent to a given context are carefully considered for a safety climate intervention.     

The digital representation of safety systems at “Seveso” plants and its potential for improving risk management

At Seveso plants, duty holders must have a complex system for assessing and managing risks. The pillars of this system are the safety report and the safety management system, with a number of underlying documents. The strength of the system is the high standardization of these documents. Regulations, standard codes and guidelines define content, structure and formats. The weakness is the high complexity. Managers and workers perceive documents as difficult to understand and far from actual operations. Major threats for the credibility of documents (and therefore for the safety systems) come from the continuous organizational and technical changes, which in a short time can make most documents obsolete; as well as by near misses, which continuously show the holes in safety systems. A big effort is required to follow up the plant changes and the near misses. In order to help safety managers, a new software has been developed. At Seveso plants, it has been possible build an integrated digital representation, because all documents are perfectly structured. This representation may be used both for updating the relevant documents after a change and to improve documents after a near miss or an accident. In this way, safety documents are always up to date and trustworthy and the huge knowledge, which is usually hidden inside safety documents, is clearly revealed and revived. The approach is basically “knowledge based” and the intention is to provide safety managers with an easy and simple tool. IRISonLine is a software that has been developed by ISPESL to provide safety managers of “Seveso” establishments with a tool for improving the management of change and of near misses.     

Got a risk reduction strategy?

Process safety can be viewed as part of a triad that supports safety in a petrochemical facility. The other two parts are OSHA-type people safety (slips, falls, etc.) and industrial hygiene. The paper will look at process safety from a top down, plant centric view. Process safety can be distilled down to the basic concept of risk reduction. If we reduce risk, our facility will be safer. The obvious problem is that we have potential risks everywhere so how are we going to reduce all these risks to an acceptable level. Clearly we need a strategy or to use a less fancy word – a plan.Too many times it is easy to concentrate on certain aspects such as safety instrumented systems (SIS), layer of protection analysis (LOPA), behavioral safety, prevention, etc. and lose track of the whole picture of what risk reduction entails in a plant.This paper will look at risk reduction in a facility from a plant viewpoint and will cover the details and concepts of risk reduction across a wide spectrum of plant functionalities – safety climate and culture, process safety management, mechanical integrity and risk, layers of protection in risk reduction, loss of containment/hazard relationship, the risk reduction bow-tie diagram, developing a risk reduction strategy, risk reduction strategy elements, and sustainability.It will also discuss some key concepts in dealing with risk reduction in general.     

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.     

Impact of safety attitude,safety knowledge and safety leadership on chemical industry workers’ risk perception based on Structural Equation Modelling and System Dynamics

In chemical industry, major accidents occur occasionally. Past research has demonstrated that risk perception was relevant to safety as it might affect the behavior, which could exert influence on the probability of accidents. It is important to adjust workers' risk perception to reduce accidents in chemical industry. To achieve this goal, some key influencing factors of workers’ risk perception of were identified from 3 aspects including safety attitude, safety knowledge and safety leadership. This was accomplished by gathering empirical data from 287 workers employed in 6 Chemical plants in Jiangsu, China. The model of influencing factors of risk perception for workers was established based on Structural Equation Modelling (SEM), and the path coefficients and weights were analyzed by the SEM. On that basis, the System Dynamics (SD) model of risk perception for workers was established. The study findings revealed safety attitude and safety leadership have a direct positive impact on perception of risk probability and perception of risk severity, safety knowledge has a direct positive impact on perception of risk severity, while safety knowledge has no direct positive impact on perception of risk probability. The findings of the study can provide theoretical supports and method guidance for adjusting the risk perception of workers in chemical industry.     

Should 'Cyrus the Centipede' take a hike? Effects of exposure to a pedestrian safety program on children's safety knowledge and self-reported behaviors

INTRODUCTION: We report the first evaluation of the popular "Cyrus the Centipede" child pedestrian safety program. METHOD: A pre-test/post-test control versus experimental condition design was used to assess Cyrus' impact on third graders' pedestrian safety knowledge, and self-reported pedestrian behaviors. RESULTS: Although some beneficial effects were observed, the program was not reliably effective. In particular, the impact of exposure to Cyrus was strongly influenced by the individual teacher who delivered it, likely due to the highly unstructured nature of the curriculum. SUMMARY: We suggest that: (a) the effectiveness and reliability of such programs be demonstrated before they are widely adopted; and (b) programs that focus on training children in actual or simulated traffic environments may be more effective than those that primarily focus on teaching safety facts and rules.     

The role of risk avoidance and locus of control in workers’ near miss experiences: Implications for improving safety management systems

The process industry has made major advancements and is a leader in near-miss safety management, with several validated models and databases to track close call reports. However, organizational efforts to develop safe work procedures and rules do not guarantee that employees will behaviorally comply with them. Assuming that at some point, every safety management system will need to be examined and realigned to help prevent incidents on the job, it is important to understand how personality traits can impact workers' risk-based decisions. Such work has been done in the mining industry due to its characteristically high risks and the results can be gleaned to help the process industry realign goals and values with their workforce. In the current study, researchers cross-sectionally surveyed 1,334 miners from 20 mine sites across the United States, varying in size and commodity. The survey sought to understand how mineworkers' risk avoidance could impact their near miss incidents on the job – a common precursor to lost-time incidents. Multiple regressions showed that as a miner's level of risk avoidance increased by 1 unit in the 6-point response scale, the probability of experiencing a near miss significantly decreased by 30% when adjusting for relevant control variables. Additionally, a significant interaction between risk avoidance and locus of control suggested that the effect of risk avoidance on near misses is enhanced as a miner's locus of control increases. A one-unit increase in locus of control appends the base effect of risk avoidance on near misses with an additional 8% decrease in the probability. Findings are discussed from a near-miss safety management system perspective in terms of methods to foster both risk avoidance and locus of control in an effort to reduce the probability of near misses and lost time at the organizational level within the process industry and other high-hazard industries.     

The safety barometer: How safe is my plant today? Is instantaneously measuring safety level utopia or realizable?

During the last decade, serious accidents have continued to occur in the process industry. Apparently the scenarios of various undesired events leading to those accidents are still not sufficiently controlled. The key question is how potentially hazardous situations develop, what processes form the basis for this development, and how to control them? Safety level is not static but depends on many risk factors that change in presence and intensity over location and time. Safety level is dependent not only on technical process parameters that have immediate effects on the ‘frequency’ or probability of catastrophic consequences, but also depends on equipment integrity degradation, operational and management quality, attitudes, and cultural processes which may change over a prolonged time. The time and human interaction aspects make dynamic risk assessment complex. This paper will outline a conceptual approach using in addition to the regular process parameter signals received, also weak and slowly changing signals from various safety indicators, enabling to keep track of the risk factors. In theory this could lead to obtaining an instantaneous safety level ‘measure’ making possible forecast alarming for an imminent event to occur. Such concept could be regarded as a ‘writing’ safety barometer, or barograph. However, there are quite a number of problems to be solved which in the paper will be discussed.     

The typology for allocations of societal risk and safety management tasks at the local governmental level – Framing the current directions in Sweden

The starting point for this article is the need to develop empirical insights about contemporary societal risk and safety management practice and executive structures. In order to facilitate insights about societal risk and safety management in a Scandinavian welfare context we use Sweden and its local governmental level (municipal) as an empirical frame in this paper. The aim for this article is to analyse how a variety of risk and safety management tasks are divided within the Swedish municipalities. The objectives are to frame the current directions for internal allocations of risk and safety issues by providing an empirically based executive typology and to contemplate the implications and future research needs that arise from that management pattern.The analysis is based on statistical analysis of information from a web-survey with chief officials (n = 1283) with responsibilities for different municipal functions and sectors. In this study the responses to one of the survey questions are used for statistical analysis. The analyzed question focused on the degree that the respondents estimated that their administrative sector or function handled a selection of risk and safety management assignments (n = 45). A factor analysis was applied to identify patterns in the dataset. The analysis resulted in an eight factor solution with a high degree of explained variance (74.3%). The results provide an elementary contribution to the understanding of the current societal risks and safety management directions.     

Shopping online for children: Is safety a consideration?

Introduction: There has been a significant increase in online purchasing and product safety problems have been identified in e-commerce. This study examines consumer behavior and safety perceptions among parents purchasing child products online. Method: A mixed methods approach, including focus groups and a survey with parents, identified key characteristics and behaviors. Cluster analysis was used to determine different population segments (including “Informed,” “Uninformed,” and “Infrequent” consumer groups) based on their frequency of online shopping and search for product information. “Safe” and “Unsafe” behavior groups were identified related to their search for safety information on child products. Logistic regression analysis was used to study the effects of consumer type groups and demographic variables on the chances of being a safer consumer. Results: Findings indicate that child product safety considerations are not a priority for parents when shopping online. Only 62% of the survey respondents indicated that they search for information prior to buying a child product online, of which only 13% of the respondents noted that they search for information on product safety. Risky consumer behaviors were identified including the purchase of imitation products (counterfeit or knockoff products) and autonomous checks for product safety in lieu of safety standards. The logistic regression analysis found that being an “Uninformed Consumer” increases the odds of an individual being an “Unsafe Consumer” by 8.4 times (χ²(11) = 97.33, p < .001). Practical Applications: Design of a social marketing campaign that targets these different population segments to change perceptions and promote safe online purchasing is recommended.     

Quantitative risk assessment: How realistic are those frequency assumptions?

Although much has changed in recent decades in how the consequences are treated in risk assessment of major industrial accidents, estimation of frequencies still appears to be largely based on values from several decades ago. This paper reviews briefly some of the implications of this, drawing on lessons not only from the process industries but also from other not so obviously relevant fields such as aerospace and finance, where the significance of such factors such as organizational culture, normalization of deviance, ownership, demographic change, etc. is becoming increasingly recognized in the analysis and hence the control of risk.Failure to consider such factors and their effects can pose a problem, because risk assessment is not simply an abstract concept but can have a real influence on the level of risk. If protective measures such as the safety culture of the site, etc. can be shown to significantly change the risk zone, this can persuade the risk generator to improve those factors or take other steps to reduce the risk such as reducing the inventory in the process. Conversely, assessments conducted for well-run companies may misrepresent the risk if the site ownership changes to a financial holding company with a focus on maximizing short-term profit and resale of the assets, and it can be difficult even for well-motivated management to justify protective measures if they produce no apparent difference in the risk.This paper introduces these and other issues for consideration in the symposium which follows.