Risk Base Process Safety (RBPS)

According to
CCPS-Guidelines

BY
Dr. Mohamed Abdelaziz
Lead PSM Consultant
 1
1. Process Safety Culture

2
2. Compliance with Standards

3
3. Process Safety Competency

I - COMMIT TO
4
4. Workforce Involvement

PROCESS SAFETY
5. Stakeholder Outreach

5
6
6. Process Knowledge Management

RISK
7
7. Hazard Identification and Risk Analysis

II- UNDERSTAND
HAZARDS AND
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8. Operating Procedures

9
9. Safe Work Practices

10. Asset Integrity and Reliability

10

11. Contractor Management

11

12. Training and Performance Assurance

12

13. Management of Change

13

III - MANAGE RISK

14. Operational Readiness

14

15. Conduct of Operations

PROCESS SAFETY MANAGEMENT SYSTEM

15

16. Emergency Management

16
17

17. Incident Investigation

Risk Based Process Safety Management Structure

18. Measurement and Metrics

18

FROM
IV - LEARN

19. Auditing
19

EXPERIENCE
10

Management Review and Continuous Improvement

20
 AIChE CCPS Risk Based PSM System Elements

20 Elements
• Manage Risk
• Commit to Process Safety 8. Operating Procedures
1. Process Safety Culture 9. Safe Work Practices & PTW
10.Asset Integrity & Reliability
2. Compliance with Standards
11.Contractor Management
3. Process Safety Competency 12.Training & Performance Assurance
4. Workforce Involvement 13.Management of Change (MOC)
14.Operational Readiness (PSSR)
5. Stakeholder Outreach
15.Conduct of Operations
• Understanding Hazards & Risks 16.Emergency Management
6. Process Knowledge Management • Learn from Experience
7. Hazard Identification & Risk Management 3
17.Incident Investigation
18.Measures & Metrics
19.Auditing
20.Management Review & continuous
Improvement
 What is PSM?

• A blend of engineering and management skills focused on

preventing catastrophic accidents and near misses, particularly
structural collapse, explosions, fires and toxic gas releases
associated with loss of containment of energy or dangerous
substances such as chemicals and petroleum products

CCPS/AIChE
 What is PSM?
• A management system that is focused on prevention ,
mitigation , response and restoration from catastrophic
releases of chemicals or energy from a facility
RBPS
• The application of management principles and systems to
the identification, understanding and control of process
hazards to prevent process safety incidents
 What is PSM?

• Managing the integrity of hazardous operating systems

and processes by applying good design principles,
engineering, and operating and maintenance practices
 What is PSM?

• The proactive and systematic identification,

evaluation, and mitigation or prevention of
chemical releases that could occur as a result of
failures in process, procedures, or equipment.

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 When should PSM applied?

• PSM applies to most industrial processes containing

≥ 10,000 pounds (4535.9 kg) of hazardous material

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 Major Accident Hazard (MAH) &
Process Safety Incident/Event
• An unplanned or uncontrolled LOPC of any material including non- toxic
or non-flammable materials from a process, or
an undesired event or condition that could have resulted in a LOPC
which can lead to severe or catastrophic consequences.

The definition of major accident specifically excludes “occupational accidents”,

which could also have severe or catastrophic consequences
 Decades of learning from disasters

3000 fatalities
500 fatalities and
MIC
terminal
destroyed Release
28 fatalities and
36 injured Rupture of 8 inch 167 fatalities and
LPG pipeline platform destroyed.
Vapor cloud explosion Leakage from pump
( Explosion during start up) discharge relief valve
Bhopal Gas
18 fatalities and Incident- 1984
81 injured
Loss – Human &

Mexico
LPG Leakage – (1984)
Sampling/ water draining Flixborough (1974)
Piper Alpha 1988
Property

Feyzin,
France - 1966 Emergency
Preparedness
Operating Management MOC , Staffing Work permit system
Assert
Procedure Of Change Multiple Failures PTW , Hazard
Integrity
communication

Years of learning

10
 Decades of learning from disasters

Leakage occurred during

maint. work on valve . Over filling overfilling of a

Fatalities 23. Over 130 of column. large storage tank
injured
Loss – Human & Property
Fatalities15. and
170 injured
Catastrophic failure
of heat exchangers Jaipur
Pasadena 1989 Buncefield Terminal
2 fatalities and (2009)
(2005)
8 injured

BP Texas (2005)

Esso Longford (1998)

Operating
Maintenance Discipline Operating
practices Contractor Safety
Hazard
Discipline
Analysis
Assert Integrity

Years of learning
11
 Causes of Major Property Losses in the Oil Refining and
Petrochemical Industries

Mechanical Failure

Operational Error

Process Upset

Natural Hazard

Design Error

Sabotage/Arson

Others/Unknown

0 10 20 30 40 50
Percent of Losses

1
2
 Equipment Involved in Major Property Losses in the
Oil Refining & Petrochemical Industries

Piping Systems
Tanks
Reactors Drums

Pumps/Compressors

Heat Exchangers
Towers Heaters

Boilers

Others

Unknown

0 5 10 15 20 25 30 35

Percent of Losses

1
3
 Frequency and Cost of Major Property Losses in the Oil
Refining and Petrochemical Industries 1960 to 1990

100 5
Number
Cost
80 4

BILLIONS OF DOLLARS $
60
Number of 3
Losses
40 2

20 1

0 0
1962-71 1972-81 1982-91

1
4
 The Bradley Curve and Four Stages of Mind-sets
Safety Excellence Requires A Culture Shift
Involvement / Ownership by All Employees

Reactive Dependent Independent Interdependent

• Safety by Natural Instinct • Management Commitment • Personal Knowledge, • Help Others Conform
• Compliance is the Goal • Condition of Employment Commitment, & Standards • Others’ Keeper
• Delegated to Safety • Fear/Discipline • Internalization • Networking Contributor
Manager • Rules/Procedures • Personal Value • Care for Others
• Lack of Management • Supervisor Control, • Care for Self • Organizational Pride
Involvement Emphasis, and Goals • Practice, Habits
• Value All People • Individual Recognition
• Training
 Why developing a PSMS?

I- Moral reasons
– Avoidance of incidents and disasters.!
II- Legal/Compliance reasons
– legal requirement. !!
– corporate requirement (company standards).
III- Financial reasons. !!!
– Avoids losses associated with disasters.
What did these incidents all have
in common?

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 A Breakdown or Lack of

Process Safety Management System

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 A Risk-Based Process Safety Management System

Goal: To design, implement, correct, and improve process safety

management activities based on consideration of the risk exposures.

• A risk-based process safety management system allocates resources for

specific business processes, implementation tactics and activities
commensurate with the process safety risk exposures.

• Risk-based analysis and decision making need to be core competencies.

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 Process Safety vs Occupational/Personal Safety

Frequency
(Probability)

Personal Safety
Frequently Happened & Less Severity Consequence (Severity)
e.g. slips, trips and falls
Process Safety
High Severity & low Probability
e.g. Fires, Explosions and Toxic Releases
Multi Fatalities & Massive Damage
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 Occupational Safety Process Safety
Look at ISO-45001 Major Accident Hazard (MAH)
Look at PSMS
prevention of injuries prevention or mitigation of catastrophic
failures; for major hazard industry due to
large amounts of dangerous chemicals &
dust
Slips, trips, falls, chemical contact, safe driving, Fires, explosions, toxic gas releases significant loss
electricity, flammable material not associated with of life, property or environmental
MAH, contact with high temp. or hazardous
substances, fire/open flame, work at height, confined
space, asphyxiate, security
High Frequency, Low Severity. (easy to predict) Low Frequency (difficult to predict), High Severity

Safegaurds: PPE, PTW, machine gaurding, fire Safegaurds: plant technical control (SRV, Interlock,
precautions, alarms,
equipment checks, managing slips and trips. maint., inspection, training, procedures) and robust PSMS
 Principles of Commit To Process safety

1. leadership teams be Aware of the hazards, risk, consequences and LOD to

make right decision (delaying maintenance Or cutting critical staff)
2. Board level visibility and promotion of positive process safety culture such
as leading by example (wearing PPE), carrying out site visits, following site
rules, asking questions, supporting the risk assessment process. !
3. Process safety objectives
4. provision of adequate resources (human, facilities, financial). !!
5. Process safety responsibilities For critical positions. !!!
6. Accounting for all individuals with PSM responsibility. !!!!
7. Continuous improvement (after incident, audit, legalrequirement,
change)
 AIChE CCPS Risk Based PSM System Elements

• Manage Risk
20 Elements 8. Operating Procedures
9. Safe Work Practices & PTW
• Commit to Process Safety 10.Asset Integrity & Reliability
1. Process Safety Culture 11.Contractor Management
12.Training & Performance Assurance
2. Compliance with Standards 13.Management of Change (MOC)
3. Process Safety Competency 14.Operational Readiness (PSSR)
4. Workforce Involvement 15.Conduct of Operations
16.Emergency Management
5. Stakeholder Outreach • Learn from Experience
• Understanding Hazards & Risks 23
17.Incident Investigation
6. Process Knowledge Management 18.Measures & Metrics
19.Auditing
7. Hazard Identification & Risk
20.Management Review & continuous
Management 21.Improvement
 1. Process Safety Culture

• Many incidents are due to inadequate leadership and poor

organizational structure while we still focus on physical controls,
engineering solutions and design improvements

If you do not believe the messenger, you will not believe the
message
 WHAT IS PROCESS SAFETY CULTURE
The group values and behaviors that determine the
manner in which process safety is managed

 "How we do things,"
 "How we behave when no one is watching."
 Ways To Understand organization’s process safety culture

 Analyzing audit results, which can reveal the degree of the care in
conduct of process safety activities.
 Analyzing incident root cause trends to identify systemic issues.
 Making random observations of work practices and attention to
safety.
 Analyzing employee safety attitude and management leadership
and commitment (survey).
 indications of a weak process safety culture.

"It's not my job,“

"I only do what I'm told to do,"

"We'll take shortcuts if necessary to get the job done," or

"This process safety stuff is costing too much money"

 Sound Culture

• Integrates safe operations into the organization's core values.

• focus on potential failures and controls

• provide resources proportional to the perceived risk.

• learning from past experience to prevent future problems.

• continuously improve performance.

• Employees are involved in identifying Hazards without management involvement.

 2. COMPLIANCE WITH STANDARDS & REGULATIONS

Is the standard mandatory or not?

What is the difference between code & standard?
Best practice  standard (API, ASME, ANSI, NFPA)  law (eg. OSHA PSM)

Comply With Standards Helps A Company To:

 Operate and maintain a safe facility
 Minimize legal liability.
 Conform with insurance company (Optimized the Insurance Coast)
 COMPLIANCE WITH STANDARDS & REGULATIONS

Code: accepted rules that tell you what you need to do

Standards: provide the “how to” executing codes

Specifications: outline the requirements of a specific company or product.

Regulations: which can incorporate codes and standards, are mandated by a

government body and required, by law, to be complied with.
 Standards

Should provide access to applicable standards, codes and regulations

that affect PSM.
 What Is Standards ?

• Standard is a set of technical definitions and guidelines

• or a “how-to” instructions for designers and manufacturers.
• Standard serves as a common language for defining quality
and establishing safety criteria for the product.
• E.g. ASTM, API, ISO
 Why standard required?

• Standard Built confidence about product quality , cost

of production will reduce as you can produce in bulk
for global markets.
 What is the Code?

• A CODE is a standard adopted by governmental bodies and become

legally enforceable, or when it has been incorporated into a business
contract.

• ASME Codes are legally enforceable in many US states. Whereas, in the

other part of the world they are not legally enforceable but such
countries have their own similar codes.
 What is the Code?

• requirements will only be mandatory if The Code

is adopted as law by a regulatory body
• Otherwise, Code will serve as generally accepted
guidelines for design, fabrication, construction,
and installation,
• e,.g. ASME Boiler and Pressure Vessel Code, BS,
DIN etc.
 Why Code required?

• Code Provides a set of rules that specify the

minimum acceptable level of safety &
Quality for manufactured, fabricated, or
constructed goods.

• Codes also refer out to standards or

specifications for the specific details on
additional requirements that are not specified in
the Code
 What is a Specification?

• Specifications provide specific/additional requirements for the

materials, components or services that are beyond the code or
standard requirements generated by private companies

• For Example, if you want A106 Gr B pipe with Maximum

carbon of 0.23% against standard requirements of 0.3% Max,
you have to specify your requirement in your specification or
Purchase Order.
 Why Specification required?

• allow purchaser to include special

requirements as per design and service
condition
• Must meet requirements
– Examples- Product specification, Shell
DEP & EIL Specification
Difference Between Code, Standard, and
Specification in Piping.
 3. Process Knowledge Management
(Or Process Safety Information PSI)

PSM information is necessary for learning and safe operation

and maintenance of process plant and should be:
• Documented (paper or electronic format),
• Reliable;
• Current; and
• Easily available. !
 Internal Sources of PSI

• SDS ; • process control systems;

• process & equipment design basis; • relief system design; !
• drawings and calculations • fire detection and protection plans.
• SOPs with SOE ; • technical documents
• inspection, audit and investigation • specs for design, fabrication,
reports; and installation
• maintenance records; • operation and maintenance manuals
 External Sources of process
safety information

Information to the organisation:

• UK (HSE);
• US (OSHA);
• Trade associations/professional bodies eg (UK-IChemE), AIChE.
• (BS);
• European standards;
• (ILO);
process safety information contains

A. Process Chemical Hazards.

B. Process Technology.
C. Process Equipment.
 A- Process Chemical Hazards
Information Shall Consist of at least the following:
1. Toxicity information
2. Permissible Exposure Limits (PEL)
3. Physical Data
4. Reactivity Data
5. Corrosivity Data, and
6. Thermal and chemical stability data, and hazardous effects of
inadvertent mixing of different materials.

Safety Data Sheets

https://www.osha.gov/Publications/OSHA3514.html
 B- Process Technology.

• BFD / or simplified PFD,

• Process chemistry, Unit Operation
• Maximum intended inventory (HC),
• Safe Operating Envelope (SOE)
• Evaluation of the consequences of deviations.
 C- Process Equipment
• Materials of construction,
• P&IDs
• Relief system design and design basis,
• Ventilation system design,
• Design codes and standards employed,
• Material and energy balances
• Safety systems (e.g., interlocks, detection, or suppression
systems SIS)