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.     

Characterization of fatal occupational versus nonoccupational motor vehicle collisions in Kentucky (1998-2000)

Motor vehicle collisions (MVCs) are the leading cause of occupational fatalities in Kentucky as well as in the nation. The characteristics of and contributing factors for occupational versus nonoccupational MVC fatalities in the Commonwealth of Kentucky were examined from 1998 to 2000. Semi trucks were most frequently involved in fatal occupational MVCs, and passenger cars were most frequently involved in nonoccupational MVCs. More than half of the decedent drivers resided outside of Kentucky. The percentage of occupational fatalities occurring on a four-lane highway was double the percentage observed for nonoccupational MVC fatalities. In addition, an increased proportion of occupational MVC deaths occurred on limited access highways compared to nonoccupational fatalities. When human factors contributing to these fatal incidents were examined, the two primary human factors involved in occupational motor vehicle fatalities were driver distraction/inattention and falling asleep, whereas unsafe speed and alcohol were the primary human factors contributing to a nonoccupational fatality. These results suggest that semi drivers traveling on four-lane highways are more at risk for a fatal occupational injury in Kentucky. Therefore, additional epidemiological studies are needed to further examine human factors, the nature of the Kentucky highway system, and trucking controls (e.g., weigh station hours of operation) within the Kentucky transportation industry.     

Measuring safety climate: identifying the common features

In UK industry, particularly in the energy sector, there has been a movement away from ‘lagging’ measures of safety based on retrospective data, such as lost time accidents and incidents, towards ‘leading’ or predictive assessments of the safety climate of the organisation or worksite. A number of different instruments have been developed by industrial psychologists for this purpose, resulting in a proliferation of scales with distinct developmental histories. Reviewing the methods and results from a sample of industrial surveys, the thematic basis of 18 scales used to assess safety climate is examined. This suggests that the most typically assessed dimensions relate to management (72% of studies), the safety system (67%), and risk (67%), in addition themes relating to work pressure and competence appear in a third of the studies.     

Visibility-related fatalities related to construction equipment

The construction industry annually experiences one of the highest fatality rates among the industrial sectors in the United States. The factors that contribute to this reputation include the nature of the work, human behavior, the tools and equipment involved, and also the compact work zones. Industrial fatalities are investigated by the Occupational Safety and Health Administration (OSHA). While OSHA groups the causes of fatalities into a few general categories, too little information is gleaned to effectively target specific problem areas.To improve safety performance in the construction industry, it is necessary to understand the underlying causes of accidents. With targeted analysis, patterns emerge and causal factors can be identified. These findings may then be used to form the basis for recommendations that will help to improve construction worker safety. Little research has been conducted in this area.Research was conducted that isolated fatalities in which vision or lack of good visibility was the principle factor or contributing cause. The objective of examining the details surrounding these fatalities was to uncover the contributing factors and to identify the agents that compromised visibility. The study identified 659 fatality accidents from a data pool of 13511 OSHA-investigated cases. It was discovered that blind spots, obstructions and lighting conditions were the most common factors contributing to vision-related fatalities. This research also analyzed the specific conditions associated with particular pieces of construction equipment.     

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.     

Analysis of laboratory incident database

With the growth of academic institutions, the number of labs handling hazardous chemicals has increased. Although the chemicals used in academic institutions are well-known, the dosage, usage, and management of these chemicals pose significant threat to researchers at all levels. As a step towards incident prevention, a laboratory incident database was developed to record incidents at universities and secondary schools. The data consisted of 128 entries occurring during the years 2012–2015. Incidents were classified by institution type, hazard type, consequences, substance type, body parts injured and direct causes. Of 128 incidents, 65% of the incidents were taking place in universities. Chemical spills were observed to be the most recurrent hazard type contributing to 45% of the incidents following by explosions (23%) and fires (21%). The consequence which most frequently occurred in incidents was personal injury and hazmat response contributing to 22% each. It was observed that in 41% of the incidents, the body parts injured in the incident was not known or reported. Of the total 128 incidents, about 50 incidents occurred due to improper storage and handling.     

Analysis of fatalities and injuries involving mining equipment

INTRODUCTION: Despite significant reductions, the number of injuries and fatalities in mining remains high. A persistent area of concern continues to be equipment-related incidents. METHOD: Mine Safety and Health Administration (MSHA) and Current Population Survey (CPS) data were used to examine equipment-related injuries over the period 1995-2004. Incidents were reviewed to determine which types of mining equipment were most often involved and to identify and characterize trends. RESULTS: Non-powered hand tools was the equipment category most often involved with non-fatal injuries while off-road ore haulage was the most common source of fatalities. SUMMARY: Younger employees had an elevated risk of injury while workers >55 years had an elevated risk for fatality. A large majority of incidents involve workers with <5 years experience. IMPACT ON INDUSTRY: Results should increase hazard awareness and enable mine management to select and prioritize problem areas and safety system weaknesses in both underground and surface mining.     

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.     

Developing safety indicators for preventing offshore oil and gas deepwater drilling blowouts

An important question with respect to the Macondo blowout is whether the accident is a symptom of systemic safety problems in the deepwater drilling industry. An answer to such a question is hard to obtain unless the risk level of the oil and gas (O&G) industry is monitored and evaluated over time. This article presents information and indicators from the Risk Level Project (RNNP) in the Norwegian O&G industry related to safety climate, barriers and undesired incidents, and discusses the relevance for deepwater drilling. The main focus of the major hazard indicators in RNNP is on production installations, whereas only a limited number of incident indicators and barrier indicators are related to mobile drilling units. The number of kicks is an important indicator for the whole drilling industry, because it is an incident with the potential to cause a blowout. Currently, the development and monitoring of safety indicators in the O&G industry seems to be limited to a short list of “accepted” indicators, but there is a need for more extensive monitoring and understanding. This article suggests areas of extensions of the indicators in RNNP for drilling based on experience from the Macondo blowout. The areas are related to schedule and cost, well planning, operational aspects, well incidents, operators’ well response, operational aspects and status of safety critical equipment. Indicators are suggested for some of the areas. For other areas, more research is needed to identify the indicators and their relevance and validity.     

Alcohol-related deaths among young passengers: An analysis of national alcohol-related fatal crashes

Introduction: There is consensus that riding with an impaired driver (RWI) constitutes a major threat to public health. The aim of this study was to characterize the factors contributing to the motor-vehicle deaths of 15–20 year-old (y/o) passengers that RWI with a peer. Method: Secondary analyses of the 2010–2018 Fatality Analysis Reporting System. 5,673 passengers aged 15–20 y/o killed while riding in passenger cars with a driver aged 21 or older, 3,542 of these drivers also aged 15–20 y/o. Analyses were conducted between October 2019 and December 2020. Results: Sixty-three percent of the young passengers were killed while riding with a driver 15–20 y/o. Of these drivers, 26.8% had a blood alcohol concentration (BAC) >0.00 g/dL and 77.1% had a BAC ≥0.08 g/dL. Compared with those occurring during the day on weekdays, fatalities of young passengers who RWI with a peer driver with a BAC ≥ 0.08 g/dL often occurred on weekend nights (OR = 8.2) and weekday nights (OR = 5.2), and when the passenger and driver were both male (OR = 1.8). Race/ethnicity was not a significant contributor to RWI fatalities. Conclusions: Most 15–20 y/o RWI fatalities occurred on weekends, at night, when the driver was a young peer with a high BAC, and the passenger and driver were male. The high prevalence of fatalities in these high-risk situations suggests that young driver-passenger dynamics may contribute to alcohol-related fatalities. Practical Applications: To curb RWI fatalities among underage passengers, countermeasures should focus not only on underage drinking drivers and riders, but also on drinking drivers of all ages. Prevention should increase focus on situations in which both the young passenger and young driver are males.     

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

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

Case study analysis of the financial impact of catastrophic safety events

Several catastrophic events in the process industry have caused extensive damage to life and property and have forever changed the process safety landscape. Despite the commitment from the industry, incidents still occur with similar root causes, impacting major companies in various ways. This work examines the financial impact of such incidents on the stability and future of affected companies in different industries. Several devastating incidents were analyzed to evaluate the direct impact in the short- and long-term and to discuss factors influencing the ability of affected companies to withstand the consequence of catastrophic events.     

Behavior and lifestyle characteristics of male Kuwaiti drivers

Introduction: The high traffic accident risk among young drivers is a well-known and well-documented fact in most countries. Lifestyle has proven to affect driving behavior as well as accident risk. This study covers the lifestyle component of the problems related to young male Kuwaiti drivers’ accident risk. Methods: The purpose of the study is to measure the relationship between lifestyle and accident risk. Lifestyle is measured through a questionnaire, where 302 male Kuwaiti drivers (mean age = 28 years; range 25-35 years) answer 39 questions related to behavioral and social factors, road conditions, police enforcement, and life satisfaction. They also report their involvement in accidents and traffic violations. Results: The questionnaire's validity and reliability (Cronbach's alpha = 0.7) were achieved. Principal component analysis reduced the 39 items on the questionnaire to 5 factors. Inadequate police enforcement is strongly correlated (r = 0.862) to accident risk and traffic violations and is thus considered the best predictor of traffic accidents in Kuwait. Impact on Industry: As driving-related incidents (on-the-job and off-the-job) are a significant source of fatalities and lost-work-days, the study points to the importance of considering cultural factors in the design of comprehensive safety programs for industry.     

Occupational electrical injuries in the United States, 1992-1998, and recommendations for safety research

PROBLEM: CFOI and SOII data show that 2,287 U.S. workers died and 32,807 workers sustained days away from work due to electrical shock or electrical burn injuries between 1992 and 1998. METHOD: The narrative, work activity, job title, source of injury, location, and industry for each fatal electrical accident were examined. A primary causal factor was identified for each fatality. RESULTS: Electrical fatalities were categorized into five major groups. Overall, 44% of electrical fatalities occurred in the construction industry. Contact with overhead power lines caused 41% of all electrical fatalities. DISCUSSION: Electrical shock caused 99% of fatal and 62% of nonfatal electrical accidents. Comprising about 7% of the U.S. workforce, construction workers sustain 44% of electrical fatalities. Power line contact by mobile equipment occurs in many industries and should be the subject of focused research. Other problem areas are identified and opportunities for research are proposed. IMPACT ON INDUSTRY: Improvements in electrical safety in one industry often have application in other industries.     

Work-related deaths in Washington State, 1998-2002

INTRODUCTION: In Washington State, 87 workers are killed each year, on average, while in work status. To understand these incidents and to assist in focusing on and development of potential prevention measures, they must be well characterized. METHODS: Work-related fatalities between the years 1998 and 2002 are described by the demographics of the victims, types of incidents, the victims' occupations, and industries and location in which they worked. RESULTS: Motor vehicle- and machinery-related incidents accounted for nearly 33% and 14% of the incidents, respectively. Agriculture, forestry, fishing, hunting, and mining (n=87), and construction (n=83) had the most fatalities. Fatality rates per 100,000 workers for these industries were 25.7 and 8.7, respectively, compared to the state-wide average of 3.1 fatalities/100,000 workers. DISCUSSION: These data indicate numerous areas for prevention of work-related traumatic injuries and fatalities.     

Factors associated with occupational injury severity in the New South Wales underground coal mining industry

The relationship between a large number of mine and mine worker characteristics and injury severity was examined using multiple regression techniques. The study was based on data extracted from the New South Wales (N.S.W.) Joint Coal Board's computer based accident/incident reporting system describing 21,372 non-fatal, lost-time injurious incidents that occurred in the N.S.W. underground coal mining industry during the 4 year period from 1 July 1986 to 30 June 1990. The number of days lost as a result of an injurious incident was the best available proxy measure of injury severity. Over the study period, the number of days lost per 100,000 tonnes of raw coal production declined by 73%. Over the same period, injurious incidents involving more than 20 days off work, which constituted only 16% of all injurious incidents in underground mines, resulted in 75% of the total days lost for the whole N.S.W. underground coal mining industry. Factors that had practical importance and that were significantly associated with injury severity included mine worker's age, part of the body injured, type of accident, agency of accident, and mine worker activity. Factors not important or not significant in their relationship with injury severity were: time into shift, previous hours worked, mine location of incident, occupation, work experience, frequency of task, shift, and mining region. This study suggests that factors related to the susceptibility of a mine worker's body tissue to damage or repair, and factors related to the concentration of energy on the mine worker by vehicle and environmental characteristics are important determinants of injury severity.     

Analysis of accidents and incidents occurring during transport of packaged dangerous goods by sea

The release of packaged or containerized dangerous goods during transport can have serious consequences on board a ship. This study was focused on identifying factors contributing to these types of releases and on investigating the contribution of dangerous goods accidents to overall container ship accident rates. Records of dangerous goods releases from a US and a UK database for an 11-year period covering 1998–2008 were analyzed to identify and categorize main contributing factors. The majority of releases, estimated as 97% of the US events and 94% of the UK events, did not follow another primary accident type such as a collision. Faults that occurred during activities such as preparation of the goods for transport, packaging, stuffing containers, and loading the ship were main factors contributing to the release of the dangerous goods on board the ship. For container ship casualties occurring worldwide during the same period, 1998–2008, accidents involving packaged dangerous goods were estimated to account for 15% of all fatalities. Self-ignition or ignition of incorrectly declared dangerous goods was identified as a contributing factor for the fatal accidents. Ensuring that dangerous goods are correctly prepared and documented for marine transport is thus very important for preventing releases and improving on board safety.     

An analysis of equipment-related fatal accidents in U.S. mining operations: 1995–2005

Despite significant reductions in mining fatalities, the number of these accidents remains high. Based on the number of fatalities per year, a persistent area of concern in mine safety continues to be equipment-related. The study was undertaken in order to more thoroughly characterize equipment-related mining fatalities and to perform an analysis of those that occurred over the last 11-years, from 1995 through 2005. Equipment-related fatalities obtained from the Mine Safety and Health Administration (MSHA) reports are used in this study. Results show that the proportion of total mine fatalities attributable to the equipment ranged from 37% to 88% per year. Among the MSHA equipment subcategories, the greatest proportion of fatalities is related to haul trucks (22.3%), belt conveyors (9.3%), front-end loaders (8.5%), and miscellaneous equipment (36.6%). The relationship between number of equipment-related fatalities and mining experience of the workforce was also examined. Study shows that workers with less than five years of appropriate mining experience constitute 44% of all fatalities that occurred during the period of 1995–2005.