Course Objective

To teach basic concepts of Process Safety.

To provide a basic knowledge and understanding of
process hazards in operating plants and field operations.
To illustrate the value of industrial accident case
studies in managing process safety.
To describe how Process Safety can be managed

Subjects covered?

Why Process Safety

What has gone wrong
What are Hazards
How does it Fail
What is Risk
How you we Assess & Manage Risk
What are the Risk Controls
How to Engineer for Safety
How to Operate
Human Factors
Management of Change
Legal requirements
How we manage Process Safety
Review of Texas City Accident

Process Safety
Process Safety is a disciplined framework for
managing the integrity of hazardous operating
systems and processes by applying good design
principles engineering and operating
practices.
It deals with the prevention and control of
incidents that have the potential to release
hazardous materials or energy. Such incidents
can cause toxic effects, fire or explosion and
could ultimately result in serious injuries,
property damage, lost production and
environmental impact.

Process Safety Management

Leadership / Accountability
Process Safety Information
Process Risk Management
Engineering Systems
Process & Mechanical Integrity
Management of Change
Pre-Startup Safety Review
Operating Procedures

Training / Competence
Employee Participation
Contractor Management
Safe Work Practices
Emergency Preparedness
Incident Investigation
Process Safety Knowledge
PSM Audit

Process Safety Framework

Concept
Design

Residual
Risk

Detailed
Design

Selecting Technology,
Process and Location
Inherently Safer Design
Intensification
Substitution
Attenuation
Simplification

Risk Reduction Measures

Prevention
Control
Mitigation
Reliability / Availability
Passive
Active
Administrative

Residual
Risk

Layers of
Protection

Plant

Process

People

Operation

Process Safety
Management +

PSM Framework
PSM frameworks have not been fully successful in
some organizations because of:

Lack of senior management commitment

Financial constraints
Not all staff engaged in PSM
Lack of specialized resources
Activities too prescriptive - compliance driven
Organization blinded by past success
PSM not integrated with other business initiatives
Link between PSM and operational hazards not obvious
- i.e. food and drug industry

Managers Quiz
A competent plant manager should be able to answer these questions:
What are the principal process hazards on the site?
Where are the highest exposures to these hazards?
How vulnerable is the plant to a major process upset?
How vulnerable is the operation to a power failure,
instrument malfunction, procedural error or mechanical failure?
What controls or contingency plans are in place to deal
with these scenarios?
What is the worst case loss scenario for the entire facility?
What conditions are necessary to cause such a loss?
What is being done to prevent such a loss from occurring?
What is the most prevalent type of loss (process safety incident)
at the facility?
What is the equivalent dollar value of this
type of loss on an annual basis?

Useful links
Q&A on safetyCLIPS http://oe.bpweb.bp.com/eclips/Eclips.asp?SearchAll=&ForumID=42
Process Safety website (QSB, PS booklets, PS awareness packs, PSMEs, etc.):
http://refiningprocesssafety.bpweb.bp.com/global/
Fire Engineering intranet: http://fireengineering.bpweb.bp.com/
Lessons Learned Database:
http://safetylessons.bpweb.bp.com/default.aspx
Safety and Operations: http://hsse.bpweb.bp.com/
Engineering Technical Practices (ETPs): http://etplib.bpweb.bp.com/
Engineering Technical Portal (External Standards):
http://technical_practices.bpweb.bp.com/

Safety & Operations - Top Priorities

Key Messages
Line management is accountable for

safety

Develop and implement individual

action plans to achieve the six

imperatives (opposite)

Imperatives:
1. Complete Texas City response actions
temporary buildings and blow-down
systems
2. Major Accident Risk assessment and
action plan
3. Integrity Management and Control of
Work Group Standards
Implementation
4. Compliance with applicable laws and
regulations
5. Close out Audit Actions
6. Staff training and development in
safety and operations

Where necessary, further

investments will be made

Process Safety

securing business
integrity

Goodbye
IDENTIFY

PREVENT

PSM
COP
MITIGATE

CONTROL