Guidelines for Risk Based Process Safety

List of Tables xxix List of Figures xxxi Acronyms and Abbreviations xxxiii Glossary xxxvii Acknowledgments xlvii Preface xlix Executive Summary li 1 INTRODUCTION 1 1.1 Purpose of These Guidelines 2 1.2 Background 6 1.3 Important Terminology 9 1.4 Management Systems Concepts 10 1.5 Risk Based Process Safety Elements 12 1.6 Relationship Between RBPS Elements and Work Activities 12 1.7 Application of these RBPS Guidelines 14 1.8 Organization of these Guidelines 16 1.9 References 17 2 OVERVIEW OF RISK BASED PROCESS SAFETY 19 2.1 Risk Based Process Safety System Design Strategies 22 2.2 Risk Based Process Safety Design and Improvement Criteria 24 2.3 Using Element Chapters to Design and Improve a Process Safety Management System 32 I COMMIT TO PROCESS SAFETY 37 3 PROCESS SAFETY CULTURE 39 3.1 Element Overview 40 3.2 Key Principles and Essential Features 45 3.3 Possible Work Activities 48 3.4 Examples of Ways to Improve Effectiveness 58 3.5 Element Metrics 62 3.6 Management Review 64 3.7 References 66 4 COMPLIANCE WITH STANDARDS 67 4 1 Element Overview 67 4.2 Key Principles and Essential Features 69 4.3 Possible Work Activities 74 4.4 Examples of Ways to Improve Effectiveness 81 4.5 Element Metrics 83 4.6 Management Review 84 4.7 References 86 5 PROCESS SAFETY COMPETENCY 89 5.1 Element Overview 90 5.2 Key Principles and Essential Features 93 5.3 Possible W ork Activities 100 5.4 Examples of Ways to Improve Effectiveness 111 5.5 Element Metrics 116 5.6 Management Review 119 5.7 References 121 6 WORKFORCE INVOLVEMENT 123 6.1 Element Overview 123 6.2 Key Principles and Essential Features 128 6.3 Possible Work Activities 131 6.4 Examples of Ways to Improve Effectiveness 136 6.5 Element Metrics 140 6.6 Management Review 142 6.7 References 143 7 STAKEHOLDER OUTREACH 145 7.1 Element Overview 146 7.2 Key Principles and Essential Features 148 7.3 Possible Work Activities 152 7.4 Examples of Ways to Improve Effectiveness 159 7.5 Element Metrics 161 7.6 Management Review 164 7.7 References 165 II UNDERSTAND HAZARDS AND RISK 167 8 PROCESS KNOWLEDGE MANAGEMENT 169 8.1 Element Overview 170 8.2 Key Principles and Essential Features 173 8.3 Possible Work Activities 186 8.4 Examples of Ways to Improve Effectiveness 196 8.5 Element Metrics 201 8.6 Management Review 204 8.7 References 206 9 HAZARD IDENTIFICATION AND RISK ANALYSIS 209 9.1 Element Overview 209 9.2 Key Principles and Essential Features 213 9.3 Possible Work Activities 221 9.4 Examples of Ways to Improve Effectiveness 229 9.5 Element Metrics 237 9.6 Management Review 240 9.7 References 242 III MANAGE RISK 10 OPERATING PROCEDURES 245 10.1 Element Overview 245 10.2 Key Principles and Essential Features 247 10.3 Possible Work Activities 260 10.4 Examples of Ways to Improve Effectiveness 273 10.5 Element Metrics 279 10.6 Management Review 282 10.7 References 283 11 SAFE WORK PRACTICES 285 11.1 Element Overview 285 11.2 Key Principles and Essential Features 288 11.3 Possible Work Activities 298 11.4 Examples of Ways to Improve Effectiveness 307 11.5 Element Metrics 312 11.6 Management Review 314 11.7 References 316 12 ASSET INTEGRITY AND RELIABILITY 317 12.1 Element Overview 318 12.2 Key Principles and Essential Features 320 12.3 Possible Work Activities 335 12.4 Examples of Ways to Improve Effectiveness 352 12.5 Element Metrics 359 12.6 Management Review 361 12.7 References 363 13 CONTRACTOR MANAGEMENT 365 13.1 Element Overview 365 13.2 Key Principles and Essential Features 368 13.3 Possible Work Activities 377 13.4 Examples of Ways to Improve Effectiveness 385 13.5 Element Metrics 390 13.6 Management Review 391 13.7 References 393 14 TRAINING AND PERFORMANCE ASSURANCE 395 14.1 Element Overview 395 14.2 Key Principles and Essential Features 398 14.3 Possible Work Activities 406 14.4 Examples of Ways to Improve Effectiveness 414 14.5 Element Metrics 417 14.6 Management Review 420 14.7 References 421 15 MANAGEMENT OF CHANGE 423 15.1 Element Overview 423 15.2 Key Principles and Essential Features 426 15.3 Possible Work Activities 431 15.4 Examples of Ways to Improve Effectiveness 440 15.5 Element Metrics 445 15.6 Management Review 447 15.7 References 448 16 OPERATIONAL READINESS 449 16.1 Element Overview 449 16.2 Key Principles and Essential Features 452 16.3 Possible Work Activities 456 16.4 Examples of Ways to Improve Effectiveness 462 16.5 Element Metrics 464 16.6 Management Review 465 16.7 References 467 17 CONDUCT OF OPERATIONS 469 17.1 Element Overview 469 17.2 Key Principles and Essential Features 471 17.3 Possible Work Activities 484 17.4 Examples of Ways to Improve Effectiveness 498 17.5 Element Metrics 502 17.6 Management Review 506 17.7.References 508 18 EMERGENCY MANAGEMENT 509 18.1 Element Overview 510 18.2 Key Principles and Essential Features 513 18.3 Possible Work Activities 526 18.4.Examples of Ways to Improve Effectiveness 541 18.5 Element Metrics 543 18.6 Management Review 545 18.7 References 547 IV LEARN FROM EXPERIENCE 549 19 INCIDENT INVESTIGATION 551 19.1 Element Overview 552 19.2 Key Principles and Essential Features 556 19.3Possible Work Activities 563 19.4 Examples of Ways to Improve Efficiency and Effectiveness 575 19.5 Element Metrics 580 19.6 Management Review 582 19.7 References 584 20 MEASUREMENT AND METRICS 585 20.1 Element Overview 585 20.2 Key Principles and Essential Features 588 20.3 Possible Work Activities 590 20.4 Examples of Ways to Improve Effectiveness 594 20.5 Element Metrics 595 20.6 Management Review 597 20.7 References 598 21 AUDITING 599 21.1 Element Overview 599 21.2 Key Principles and Essential Features 602 21.3 Possible Work Activities 615 21.4 Examples of Ways to Improve Effectiveness 622 21.5 Element Metrics 626 21.6 Management Review 628 21.7 References 629 22 MANAGEMENT REVIEW AND CONTINUOUS IMPROVEMENT 631 22.1 Element Overview 631 22.2 Key Principles and Essential Features 634 22.4 Examples of Ways to Improve Effectiveness 644 22.5 Element Metrics and Indications 646 22.6 Management Review 647 22.7 References 647 23 IMPLEMENTATION 649 23.1 Reasons to Implement a Risk-based Process Safety Management System 650 20.2 First Steps Toward Implementation 651 20.3 Start with RBPS Elements that Provide the Greatest Risk Benefit to Your Facility 653 20.4 Implementation Examples 656 20.5 Other Applications 680 20.6 Conclusions 681 20.7 References 682 24 THE FUTURE 683 Index 689 LIST OF TABLES TABLE S.l. Risk Based Process Safety Elements liv TABLE 1.1. Possible Causes of Process Safety Management Performance Stagnation 2 TABLE 1.2. RBPS Management System Accident Prevention Pillars 3 TABLE 1 3. CCPS Guidelines and Tools for Chemical Process Safety Management 7 TABLE 1.4. North American Industry Process Safety Management Initiatives 7 TABLE 1.5. Partial List of Worldwide Governmental Accident Prevention and Process Safety Management Initiatives 8 TABLE 1.6. Some Factors that Motivated the CCPS RBPS Project 9 TABLE 1.7. Important Issues to Address in a Process Safety Management System 11 TABLE 1.8. Comparison of RBPS Elements to Original CCPS PSM Elements 13 TABLE 1.9. Generic Work Breakdown Structure for the RBPS System 14 TABLE 2.1. Process Safety Accident Prevention Principles and Associated RBPS Elements 24 TABLE 2.2. Examples of How Risk Affects Implementation of RBPS Work Activities 31 TABLE 2 3. Advice on Using these Guidelines to Meet Specific User Needs 33 TABLE 3.1. Culture as a Determinant of Process Risk Control Attitudes and Practices 41 TABLE 4.1. Examples and Sources of Process Safety Related Standards, Codes, Regulations, and Laws 71 TABLE 6.1. UK HSE Workforce Involvement Suggestions 127 TABLE 8.1. Typical Types of Process Knowledge 176 TABLE 9.1. Example Issues that Can Be Addressed at Various Life Cycle Stages 233 TABLE 10.1. Procedure Formats 253 TABLE 11.1. Activities Typically Included in the Scope of the Safe Work Element 290 TABLE 13.1. Safety Program and Performance Information Useful in Evaluating Potential Contractors 372 TABLE 22.1. Example Schedule for Management Reviews 636 TABLE 23.1. RBPS Implementation Options for Upgrading Operating Procedures 659 TABLE 23.2. RBPS Implementation Options for Implementing the Conduct of Operations Element 665 TABLE 23.3. RBPS Implementation Options for Fixing a Deficient MOC System 671 TABLE 23.4. Using RBPS to Develop and Implement a New Process Safety Management System 678 LIST OF FIGURES FIGURE 2.1. Evolution of Process Safety and Accident/Loss Prevention Strategies 19 FIGURE 9.1. Levels of Hazard Evaluation and Risk Assessment 211 FIGURE 9.2. Typical Qualitative Risk Analysis Documentation Form 213 FIGURE 9.3. Example Risk Matrix 216 FIGURE 14.1. Training System Tasks 399 FIGURE 19.1. Incident Investigation Flowchart 553 FIGURE 19.2. Incident Investigation Levels of Analysis 555 FIGURE 23.1. A Risk-based Approach to Identifying Which RBPS Elements to Implement 655