How can you tell where the next accident is coming from? How can you monitor the safety of your plant? It all comes from the concept of Process Safety Indicators and an understanding of Process Safety Management Systems.
Process Safety Management Framework
Our work on Process Safety Management Framework is in line with the Energy Institute Framework for Process Safety Management EI 3197:
In 2010 the EI’s Process Safety Committee identified a benefit in promoting a common high-level framework for PSM across the energy industry sectors. The first edition of the High level framework for process safety management provided a simple and systematic approach suitable for organisations large and small across the energy industry sectors, defining the key items that organisations need to get right to assure the integrity of their operations incorporating technical, maintenance, operational, and human and organisational factors.
This framework provides a consistent approach that should help high hazards organisations seeking efficient development and implementation approaches to achieve effective PSM. The framework is geared more towards the management of process safety during the post-design phase of an asset, rather than the design itself, which is well served with international standards and codes of practice. That said, the primary aim of the framework is to preserve the design intent of a major hazards asset.
PSMS
OTECSA have carried out process safety management system review projects for hazardous facilities process plants. This includes for our clients COMAH sites and complex distillery sites. Although the companies all operate from decentralised operating sites, process safety management systems should be embedded at a corporate level.
One of the key issues that contributed to the Texas City refinery disaster was weaknesses in the Process Safety Management System (PSMS). There is therefore a clear focus from the regulatory bodies on high hazard sites to be on top of your PSMS.
While the challenges, threats and opportunities with each client are unique, the systems we are designing all have the key elements of policy, objectives and targets, monitoring and measurement and continual improvement at their core.
In our reviews we recognised that one size will never fit all. We recognise good practice from the high hazard industries we work with and deliver fit for purpose solutions tailored to the culture of the clients we support.
Process Safety Indicators – Leading and Lagging
One common theme we identify is lack of historical data-analysis of these data sets provides an essential ‘early warning system’ to identify high risk areas for focus.
The HSE publication “HSG 254 Developing Process Safety Indicators” is a good place to start with its 6 step guide to performance measurement.
This includes the identification of leading indicators:
Leading indicators require a routine systematic check that key actions or activities are undertaken as intended
And lagging indicators:
Lagging indicators show when a desired safety outcome has failed, or has not been achieved.”
Data Capture
We encourage clients to ensure data is captured including key indicators such as:
- Near misses
- Safety Observations
- Safety Audit Results and Performance
- Management of Change (Plant Modification) Statistics
- Incident Investigation Status
- Status of Risk Assessments such as HAZOP, LOPA
- Safety Critical Equipment Status
It all comes back to ensuring your systems are robust enough to indicate the potential system weaknesses before catastrophic failure while ensuring the workforce is engaged with the process. No one wants to be the next Texas City.
A work force that is confident that the leadership team support PSM will tend to do the right thing.