Guidelines for Risk Based Process Safety provides guidelines for industries that manufacture, consume, or handle chemicals, by focusing on new ways to design, correct, or improve process safety management practices. This new framework for thinking about process safety builds upon the original process safety management ideas published in the early 1990s, integrates industry lessons learned over the intervening years, utilizes applicable "total quality" principles (i.e., plan, do, check, act), and organizes it in a way that will be useful to all organizations - even those with relatively lower hazard activities - throughout the life-cycle of a company.
Table of Contents:
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
About the Author :
Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 80 books in its process safety guidelines and process safety concepts series.
Review :
"…a very comprehensive and thorough discussion of risk based process safety management systems…an invaluable reference source." (Journal of Loss Prevention in the Process Industries, January 2008) "This book is a very well-written, detailed analysis of industrial chemical plant safety. Following its guidelines, I am sure, will result in many fewer accidents in the future." (Journal of Hazardous Material, January 15, 2008)
