High Level Framework for Process Safety management
The High Level Framework for Process Safety management from UK Energy Institute
This is an important document within the context of this course, please study it carefully.
Incidents that define Process Safety
For more detail on these incidents, excluding the BP Gulf of Mexico incident, you should read:
Incidents that define Process Safety’ by J Atherton and F Gil (2008), John Wiley and Sons Inc ISBN 0470122048.
Selection of Hazard Evaluation Techniques
The ability to ensure process safety at a facility is influenced by many things: for example, employing appropriate technology in design and construction, anticipating the effects of external circumstances, understanding and dealing with human behavior, getting high reporting of near misses to learn from incidents, and having effective management systems.
The Health and Safety Executive publication “Five steps to risk assessment”
This leaflet aims to help you assess health and safety risks in the workplace.
The “Swiss Cheese” model
For more detail on these The "Swiss Cheese", you should read:
The “Swiss Cheese” model developed by James Reason and Dante Orlandella (see Human Error by James Reason ISBN-10: 0521314194 ISBN-13: 978-0521314190)
Health and Safety Executive
For further details see the Health and Safety Executive website
For a communication targeted at the general public, particularly those who live around major hazard sites, see this document (Major Hazard Sites and Safety Reports – What You Need to Know)
ALARP
Further information on ALARP can be obtained from this Health and Safety Executive web site
Investigating accidents and incidents
A workbook for employers, unions, safety representatives and safety professionals
Further Research
The following incidents discussed in “Incidents that Define Process Safety” highlight the importance of effective learning from incidents and near misses. They did not occur within the process industry, but nevertheless, in each case a failure to learn from previous incidents led to major incidents and loss of life.
It’s important to remember that it is not just high-hazard process industries that have the potential for serious incidents. This also applies, for example, to rail, sea and air travel.
• The loss of the Space Shuttle “Columbia” over Texas, USA February 1 2003 (page 211)
• The capsize of the Herald of Free Enterprise, Zeebrugge, Belgium March 6 1987 (page 220)
• Air France Concorde Crash, Paris, France July 25 2000 (page 227)
Industrial Operators handbook
View the Industrial Operators handbook
Further Research
As further support material for this section, you should read about the following incidents, which are discussed in “Incidents that Define Process Safety”, and again highlight the importance of effective inspection and maintenance.
- HF Release at Marathon Oil Refinery, Texas City, USA October 30 1987 (page 101)
- Oil Refinery Explosion and Fire at Texaco Milford Haven July 24 1994 (page 105)
- FCCU Explosion at Total La Mede, France, November 9 1992 (page 112)
Further Research
Other relevant material is available on the Health and Safety Executive web site. In particular students should study Revitalising Procedures available. The following incidents discussed in “Incidents that Define Process Safety” highlight the importance of effective operating practices and procedures>
Hydrocracker Effluent Pipe Rupture, Tosco, Avon Refinery California USA January 21 1997 (page 244)
BP Texas City Isomerisation Unit Explosion, Texas, USA March 23 2005 (page 251)
The essential attributes of an effective operating procedure system are defined in Element 8: ‘Operating Manuals and Procedures’ of the Energy Institute High Level Framework for Effective Process Safety Management.
Further Research
Other relevant is material is available on the Health and Safety Executive web site. In particular students should study Human Factors: Organisational Change
and Plant Modification/Change Procedures.
The following incidents, discussed in “Incidents that Define Process Safety”, highlight the importance of effective management of change.
Chernobyl, USSR – How a Safety Enhancement Experiment turned into a world scale disaster, April 26 1986 (page 195)
Dutch State Mines Nypro Plant, Flixborough UK June 1 1974 (page 202)
Permit to Work process
The following incidents, discussed in “Incidents that Define Process Safety”, also highlight the importance of an effective Permit to Work system.
Phillips Pasadena, Texas, October 23 1989 (page 272)
Piper Alpha Platform, UK, North Sea July 6 1988 (page 277)
PDF - Guidance on permit-to-work systems
Further reading on the Take 5 concept
This is a handy resource on the Take 5 Concept.
High Level Framework for Process Safety management
Linking theory and practice
The essential attributes of effective control of work and task risk management systems are defined in Element 17: “Work Control, Permit to Work and Task Risk Management” in the Energy Institute ‘High Level Framework for Effective Process Safety Management’
Link to Process Safety Management and COMAH regulations
Process Safety incidents can lead to loss of life and major environmental damage. The following incidents discussed in “Incidents that Define Process Safety” highlight how Process Safety failures can cause significant environmental damage.
ICMESA Seveso Italy, Toxic Cloud Release July 10 1976 (page 295)
Sandoz SA Warehouse Fire, Bale, Switzerland November 1 1986 (page 300).
Permit to Work
The General Permit to Work.
Macondo Investigation reports
Volume 1 - Macondo-specific incident events: Relevant background on deepwater drilling and temporary abandonment
Volume 2 - Technical findings on the Deepwater Horizon blowout preventer (BOP) with an emphasis on the effective management of safety critical elements
Regulators Response to Buncefield
Press Release from HSE 16th February 2011
Managing Process Safety – Four Pillars
The Energy Institute and Centre for Chemical Process Safety (CCPS) both identify four accident prevention pillars striving towards the same goal – Safe Process Operations.
Advice and Definitions
Process Safety Management list of definitions
REVIEW OF HAZARD IDENTIFICATION TECHNIQUES
The objective of this project was to gain an overview of the hazard identification techniques commonly used at sites that will fall within the COMAH Regulations [COMAH 1999].
HAZOP - Hazard Identification Techniques
A hazard and operability study (HAZOP) is a structured and systematic examination of a planned or exisitng process or operation in order to identify and evaluate problems that may represent risks to personnel or equipment, or prevent efficient operation.
Gov.uk Emergency preparedness
COMAH – Control of Major Accident Hazards 2015
Control of Major Accident Hazards Regulations 2015
ER preparedness
Watch this video and detail in the relevant areas of the form.
Case Study
Case study, Fire and Community Evacuation in Apex, North Carolina
Investigation Report
Pesticide Chemical Runaway Reaction Pressure Vessel Explosion
Loss of Containment
A key concept in Process Safety Management is the prevention of loss of containment.
COMAH – Control of Major Accident Hazards 2015
COMAH – Control of Major Accident Hazards 2015
HID Regulatory Model
Safety Management in Major Hazard Industries
Implementing Control
Implementing control should focus on determining control through the elements of Prevention and Mitigation of the major hazards using the risk profile as a guide to the strength and depth of barriers required.
Plant Process and People
Effective process safety management is essential to the prevention and mitigation of major accident hazards.
Latent and Active Failure
Human Factors view of accident causation.
Accident Causes
Types of Adverse Event
Investigation Report Sterigenics
Sterigenics Ontarino, California, August 19, 2004
Investigation Report
Vinyl Chloride Monomer Explosion
Investigation Report
Pesticide Chemical Runaway Reaction Pressure Vessel Explosion
A guide to Major Accident Hazards Regulations
This guidance is for anyone who has duties under the COMAH Regulations 2015.
COMAH - Guidance
This section provides guidance and information under the COMAH regulations:
Major accident prevention policies for lower-tier COMAH establishments
The Control of Major Accident Hazards Regulations 1999 (COMAH) are the most far-reaching set of regulations to apply to 'major hazard' premises for many years.
Website - High Level Framework for Process Safety management
PDF - CSB - TN Metal Dust Flash Fires and Hydrogen Explosion
PDF - CSB - West Virginia Methyl Chloride Release
PDF - HSE - Investigating accidents and incidents
Incident Types
Investigation should focus on all types of incidents, including Process and Occupational incidents.
Investigation Process
Approach to Accident Investigation.
Developing process safety indicators
A step-by-step guide for chemical and major hazard industries
Risk Evaluation Techniques
There are a number of different Risk Evaluation Techniques.