Documente Academic
Documente Profesional
Documente Cultură
Human Involvement
Hansjrgen Labudde, SHE Training Manager - Europe
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
Conclusion
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Worldwide benchmark for industrial SHE $24 Billion in revenue 79,000 employees operating in 70 countries on 6 continents
Approx 66% of European sales are produced, refined or manufactured in the region
Injuries with more than 3 lost work days per 1000 employees per year
DuPont only 0,4
Environment
(SHE)
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
Conclusion
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
A Shift in Beliefs
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Shifting a Belief:
Things go wrong, accidents happen. Safety performance can be managed.
Shifting a Belief:
Fatalities and serious injuries are investigated because it is required by law. All accidents and incidents are investigated because we want to learn.
Shifting a Belief:
Safety performance is a question of luck. Safety performance can be managed.
Shifting a Belief:
Employees must be supervised so that they comply. Employees must be educated and empowered so that they perform.
Focus on people!
Lean organization. Tap the capabilities of all employees. Empower people ..
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Developing an Organization
Natural Instincts
Where
Supervision Reactive
Failures to perform
Independent
Interdependent
Management Commitment Condition of Employment Fear/Discipline Rules/Procedures Supervisor Control, Emphasis, and Goals Value All People Training
Personal Knowledge, Commitment, and Standards Internalization Personal Value Care for Self Practice, Habits Individual Recognition
Help Others Conform Others Keeper Networking Contributor Care for Others Organizational Pride
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
Conclusion
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Flixborough (6/74)
28 fatalities - $167MM Contaminated countryside 550+ fatalities - $26MM 3M+ fatalities - 200M affected 31 fatalities - 300 mi2 evacuated
Seveso (7/76) Mex. City (11/84) Bhopal (12/84) Chernob. Nuc. Plt. (4/86)
165 fatalities
23 fatalities - $797MM 17 fatalities - $14MM Multiple fatalities - $253MM $8MMM loss to economy 10 fatalities - $300MM 29 fatalities 20,000 homes damaged
10036
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
* Large property damage losses (17th edition); M&M Protection Consultants; 1166 Avenue of the Americas, NY, NY
Industrial Incidents
Unfortunately, that listing was only a partial (small) list of many incidents that have occurred in the energy and chemical industries worldwide.
So, whats the best answer?
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
The application of Management Systems to the IDENTIFICATION, UNDERSTANDING, and CONTROL of Process Hazards to prevent a major fire, explosion, or toxic release which could lead to a fatality or multiple lost workday cases.
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
1. Establishing a Safety Culture 2. Providing Management Leadership and Commitment 3. Implementing a comprehensive PS&RM Program 4. Achieving Operating Excellence through Operational Discipline
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
Conclusion
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
The
Step
1802
1815 1818
Damage $ 80 000 40 people killed Damage $ 120 000 Safety is a Management Responsibility
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
E. I. du Pont de Nemours
1811 rules
Safety is a line management Responsibility No employee may enter a new rebuilt mill until a member of top management has personally operated it
.adhere to the highest standards for the safe operations of facilities and the protection of the environment, our people, our customers, and the citizens of the communities in which we do business. Value the safety of our coworkers, our community and the need to return home safely to our families each day.
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Successful Fundamentals
1. All injuries, occupational illnesses, safety and environmental incidents are preventable. 2. Management is responsible for safety.
3. Safety is an individuals responsibility and a condition of employment. 4. Training is an essential element for safe workplaces. 5. Audits must be conducted.
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Successful Fundamentals
6. All deficiencies must be corrected promptly. 7. It is essential to investigate all injuries and incidents with injury potential. 8. Off the job safety is an important part of the safety effort. 9. It is good business to prevent injuries and illnesses.
10. People are the most important element of the Safety and Occupational Health Program.
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
The
Step
Management Leadership
in Process Safety
Principle
Management leadership and commitment form the foundation of efforts to improve process safety. Although leadership and initiative are needed throughout all levels of an organization, it is crucial that senior management provide visible support and encouragement.
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Key Responsibilities
Establishing the Safety Culture Establishing PSM policies/guidelines Committing resources Involving employees Establishing clear accountability Auditing for degree of compliance Personally participating in PSM activities
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
The
Step
Quality Assurance
TECHNOLOGY
FACILITIES
PERSONNEL
Technology
Process Technology
Standard
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Provide clear understanding of operating parameters and limits for safe operation
They explain the consequences of problems and the steps necessary to correct and or avoid them Developed and documented for each process g
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Changes may invalidate prior assessments All changes must be rigorously reviewed
Bhopal, India
Contributing Factors:
plant modification/change - HAZOP not recognizing safety critical systems and their operability design codes
Oppau, Germany
Contributing Factor:
Facilities
Quality Assurance Quality Assurance bridges the gap between design and installation:
fabrication delivery properly
Provides a final check for new or modified equipment to ensure the facilities are safe to operate
Std
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Mechanical Integrity Process related equipment that contains highly hazardous chemicals must be maintained from the time of design throughout the life of the facility. Mechanical integrity focuses on system integrity to contain hazardous materials.
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Mechanical Integrity
Deals with:
Maintenance Training
procedures
Quality
control
Equipment
Flixborough, England
Contributing Factors:
emergency plan
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Chernobyl, Ukraine
Contributing Factors:
Personnel
Trained employees are an absolute requirement, and be physically able, mentally alert and capable of using good judgment.
Training qualification must be documented.
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Contractors
For contractors working in and around highly hazardous material processes, or performing maintenance/repair on or near a covered process .
they are required to comply with same regulations and guidelines as industry /site!
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Investigations are essential to improve performance The objective is to find the contributing factors and implement corrective actions(s) The degree of the investigation will depend on severity or potential
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Management of Change - Personnel People are the essential ingredient: process experience knowledge and skill in managing Process Safety maintain minimum experience level and knowledge through personnel and organizational changes
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Planning and training for potential emergencies are essential for effective response
Auditing Auditing must be used to assure that all elements of Process Safety Management are being implemented properly.
Proper auditing must include positive and corrective feedback
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Pasadena, Texas
Contributing Factors:
Contributing Factors:
plant layout - the positioning of vessels emergency isolation survivability of critical systems emergency plan and site access
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Contributing Factors:
Quality Assurance
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
The
PERSONNEL
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
OD--What Is It?
Dedication and commitment by every member of the organization to carry out each task the right way every time.
Why is OD Important?
IT HELPS
1. 2. Change a paper PSRM program into a reality--an action program. Organizations achieve their goals, because improvement programs are implemented to their fullest.
3. 4.
5. 6.
Protect personnel from injury. Protect jobs by helping to prevent the loss of facilities. Ensure a quality product. Keep a business healthy
Copyright 2002 E. I. du Pont de Nemours and company. All rights reserved.
Quality Assurance
Agenda
Introduction
Shift in Beliefs The DuPont approach of Process Safety & Risk Management
CONCLUSION I
Good Safety
Good Business
CONCLUSION II