Presentation on theme: "Process Safety Management: Some Lessons from Recent Incidents Presentation to the Introduction to Environmental, Health & Safety Workshop CSChE 2008."— Presentation transcript:
1 Process Safety Management: Some Lessons from Recent Incidents Presentation to the Introduction to Environmental, Health & Safety Workshop CSChE 2008 Conference Ottawa, ON, October 21, 2008Graham Creedy, P.Eng, FCIC, FEICSenior Manager, Responsible Care®Canadian Chemical Producers’ Association(613) ,
2 Origins of this Workshop Why Process Safety Management?Knowing (and meeting) the regulations is important; but is not enough – especially in CanadaNeed to Know:How to spot the hazardsWhy and How defences failHow to communicate
3 Personal safety hazards can sometimes be easy to spot; but major hazards are often not obvious Keep an open mind about hazards – do not assume that if it is important, someone else would have noted itKnow the basic hazard identification & risk assessment techniques and when to use themIf using a contractor for this, know enough to watch for competence
4 Why and How Defences Fail People often assume systems work as intended, despite warning signsExamples of good performance are cited as representing the whole, while poor ones are overlooked or soon forgottenFailure modes and effects analysis (FMEA) should include human and organizational aspects as well as equipment, physical and IT systems
5 Avonmouth, UK 1996Although not recent, it is a classic example of a latent failureHazard of material known, but lack of awareness of potential system failure mode leads to defective procedure design
6 Ghent, WV 2007Hazards well-known and supposedly covered by equipment and procedure designLatent errors in procedure execution allow actual practice to deviate from assumed
7 Danvers, MA 2006Hazards known, but defences compromised by apparently benign changeLatent error in procedure design creates vulnerability to likely execution error
8 Port Wentworth, GA 2007Hazard of material not obvious (despite history)Latent error allowed dust to accumulate, creating conditions for subsequent events
9 James Reason’s “Cheese Model” shows how the layers of protection intended to control hazards are not perfect, but are subject to holes that can increase over time if not monitored carefully. Eventually the holes are such that enough defences fail, leading to a major incident
10 The Process Safety Management Guide Summarizes CCPS approach in handy, short bookletAvailable as free download from CSChE’s PSM division website, in English and French (or as booklet, for nominal fee)Website:
11 A page from the “HISAT” Site Self-Assessment Tool, available on the PSM Division website
12 Understanding and sizing up the hazards The US Chemical Safety Board website has case studies and videos – great for understanding and “Could it happen here?”Center for Chemical Process Safety (CCPS) guideEasy to useDescribes hazard evaluation proceduresExplains when and how to use them
13 When communicating, remember the New Product Introduction Curve InnovatorsEarly AdoptersEarly MajorityLaggardsLate MajorityPercent adoptionCategories differ by ability and more importantly, motivationWhere is your org, and your boss, on this curve?
14 Dealing with a Safety (or Engineering) Problem Finding out who you’re dealing withWhere is the organization on the curve? (generally, and re the specific issue or problem)Where are the people you’re dealing with on the curve? (generally, and re the issue or problem)Finding out what to do“Benchmark” – don’t try to reinvent the wheel unless you’re sure there isn’t one already (or you’ve time and it’s fun to do so)Find out what others are doing about itRead the instructionsIdentify/define the issueIf it’s likely to be regulated, check with government agencies, trade associations, web, internetIf not regulated but likely good industry practice, check suppliers, other users of same material or item, other users of similar items, other industry contacts – but test the info!!! (cross-check, ask if it makes sense)Check standard reference works,(Lees, CCPS, etc)Doing itTry to think of all situations that are likely to occur (process, eqpt, people)“KISS”, keep it user-friendly, show basis for decisions if practical to do soFollow up afterwards to see how it’s working
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