There are four aspects of Process Safety: Hazards, Risk, Human factors, and Training. These factors all affect the process safety of a manufacturing facility. To ensure that all of these are properly addressed, companies must conduct a pre-start-up safety review. The pre-start-up safety review determines whether all safety, emergency, and operating procedures are in compliance with the PHA. Inspections of major process equipment and units must be conducted based on recognized good engineering practices.
Hazards
Process safety refers to a framework for handling hazardous properties, such as chemicals and biological agents. It draws on wholesome design principles, engineering, and operating and maintenance exercises to control and prevent hazardous discharges. Process safety is commonly used in the oil and gas industry, where major incidents can occur from accidental releases or deterioration of assets. Typically, a process hazard can occur when the processing plant has an out-of-control chemical reaction.
In addition to training employees about safety standards and procedures, a company must also take proactive measures to ensure that non-technical crews, including the painter, scaffolder, safety health officer, and catering crew, understand the importance of a culture of safety and health. They must be trained about the basics of the production system, as well as a specific major hazard in their current operation. Taking preventive action is the best way to ensure that processes are run safely.
The hazards in process safety vary widely in each workplace. Some industries are more prone to risks than others. Companies with high-risk chemical products, such as ethylene oxide, must implement the Process Safety Management of Highly Hazardous Chemicals (PSMHHC) standard to address the potential consequences of a release. Process hazard analysis is a critical component of process safety management, as it enables employers to identify, evaluate, and manage the risks of a complex operating process.
The PSM Rule specifies several steps in the PSM implementation. The most important of these steps is process hazard analysis (PHA), which requires systematic identification of potential hazards and accident scenarios. The PSM Rule provides various methods for conducting PrHAs, including process hazard analysis. Each method should be chosen based on the process being analyzed. The PSM rule requires that this PHA is in place prior to startup of the process, and that it be reviewed at least every 5 years.
Risk
Process safety refers to the management of risks associated with workplace activities. Although process safety incidents may not occur often, they can be catastrophic, requiring a different approach than traditional workplace accidents. Process safety may also be referred to as process control, process hazard analysis, advanced process control, and asset integrity. This article describes some of the basic steps in the assessment/management of process safety. These steps include:
First, it is important to understand the risks that may occur in the production of a product or service. This involves identifying the risks, providing appropriate layers of protection, and learning from incidents. To illustrate the processes that help prevent process safety incidents, consider the Swiss cheese model. James Reason created this model to illustrate how processes are integrated to reduce risk and mitigate it. It illustrates how each layer of the process safety barrier contributes to safety, and how it affects the entire process.
As the demand for energy, commodities, and chemicals continues to rise, so do the hazards associated with processing them. Increasing complexity of processing plants creates new hazards, but risk-management efforts must balance the increased risks with the potential economic benefit. The problem is that accidents keep occurring, albeit with varying degrees of severity. A study by Khan and Abbasi, for example, found that if process safety fails to prevent or mitigate the risks, these accidents can lead to multiple fatalities and extensive downtime. Further, these accidents can garner unwanted media coverage, so any potential financial losses must be evaluated carefully.
Documentation is a key component of process safety. Employees must be involved in the process safety planning and implementation. Documentation should be readily available and provide baseline information for hazard analysis. The documentation should be sufficient to support ongoing operations and audit purposes. Using a solution like Sphera’s Advanced Risk Assessment solution can simplify this process and make it more effective. Not only does Sphera provide access to knowledge libraries, but it also allows teams to collaborate, distribute, and trace documentation.
Human factors
This course examines the relationship between human factors and process safety and how they can be integrated into safety management practices. It explores contemporary human factors methodologies, the return on investment and value-added aspects of human performance, and the preservation of human well-being, the environment, and company assets. It also covers a case study of a classic incident highlighting the human factors elements involved. While the two disciplines have very different purposes, they share a common goal: minimizing human errors and preventing accidents. The course also addresses the challenges of silosism in safety management and provides practical methods for reducing risks.
Although the oil and gas industry has not traditionally been a heavy user of human factors in safety management, it has made significant strides in the literature. For example, the Energy Institute has published more than 50 documents on human factors, ranging from Briefing Notes to detailed guidance. The IOGP has also published numerous reports and videos aimed at embedding human factors concepts into operational procedures and organizational practices. Ultimately, human factors and process safety work hand-in-hand to improve safety and efficiency.
A lack of formally qualified human-factors professionals is a key barrier to effective human-factors management. However, it is important to promote role-specific HF awareness throughout the organization. For example, in exploration and production, companies might conclude that human error is the cause of an incident without drilling deeper into the root cause of the incident. Instead, they should use the incident as an opportunity to understand the root cause and improve systems.
Training
Although process safety is often associated with the oil and gas industry, it can also be applicable to other industries. While PSM initially originated in the oil and gas industry, its principles are applicable to any industry. The word “process” is associated with accidents, including the accidental loss of energy. If you’re looking for an efficient way to improve safety in your facility, CCPS’s RBPS Approach can help. These courses are highly interactive, with discussion and workshop sessions that allow for easy sharing of knowledge and experiences.
Process safety involves the prevention of unintended releases of hazardous materials and energy. It requires a comprehensive assessment of the entire process, including design, technology, and other elements. It begins with a rigorous examination of work operations, identifying hazards, and controlling processes. It also considers the effects on the community. A chemical release could result in anything from a single complaint to the death of a community member. Taking this into account will help prevent the risk of accidents, avoiding unnecessary losses, and ensuring a safe workplace.
PSM is an important component of the safety management system. The ultimate goal of PSM is to prevent major accidents associated with highly hazardous chemicals. This includes gasses, liquids, and toxic or reactive substances. A successful PSM program can protect employees, customers, and the environment from chemical exposures caused by faulty processes and procedures. Whether you’re a manufacturing plant, chemical factory, or offshore oil and gas platform, PSM training will help prevent accidents.
Compared to occupational safety, process safety training involves more extensive technical training. Process safety expenses include new process equipment, ongoing maintenance, and complete redesign of processes. If process safety failures are not addressed properly, these incidents can lead to the permanent shutdown of a plant. Because of this, the investment required for process safety training is significantly higher than those for occupational safety. The risk of a chemical or nuclear disaster is far greater than the risk of a small accident.
Management of change
If you are responsible for managing the change process in your plant, you may have heard of the term “management of change” (MOC). But what is it and why is it so important? To put it simply, it refers to the process of making changes to a process without creating additional hazards or increasing existing risks. This process consists of a number of steps, including the assessment of risks, the review and authorization process, and notification of affected personnel.
One of the primary concerns in managing organizational change is the safety of workers. Changing core processes poses a much higher risk to a company’s workforce than it does during routine production. These changes may even threaten a worker’s life or health. Those risks are amplified if the company is dealing with hazardous materials or energy. A MOC helps to define change and make it easier to implement. Oftentimes, a sudden change in procedures causes confusion and contributes to process breakdowns.
In order to implement a management of change plan, employers must define written procedures for every process. These procedures must cover all process chemicals, technology, equipment, procedures, and facilities. They must also notify employees about any changes, train affected employees, and update documents impacted by the change. Some changes are exempt from MOC due to emergency response. This procedure requires that all changes are reviewed by qualified personnel. During the review process, individuals who are responsible for process safety must provide the necessary information to initiate the change.
The first step in implementing a management of change plan is identifying the risks of the proposed changes. This process is critical for identifying hazards, identifying mitigation measures, and ensuring worker and environmental protection. MOC also includes the review of proposed changes to existing operating procedures. Managing changes during the transitional period will increase the safety of the company and its employees. There are five key elements to a management of change plan, and these can affect any number of business aspects.
