N - Legal

How do you manage

all these hazards and risks?

Origins of Process Safety

1817
UK Government sets up a Select Committee

To consider means of preventing

mischief of explosion on steamboats
to the danger or destruction of His
Majestys Subjects

Origins of Safety Management

1833
UK Factory Act
Factory Inspectors appointed
1882
Boiler Explosions Act

Safety legislation in US (& Canada)

1816-1848
3270 killed in US by boiler explosions

1838

First federal safety regulation, requiring semi-annual

visual inspection of steamboat boilers

Safety legislation in US (& Canada)

1852
2nd Boiler Safety Statute, requiring:
Annual pressure testing to 1.5 x design
Quality of boiler plates
Provision of safety valves
Licensing of engineers and pilots
Provision of fire hoses and lifeboats

Safety legislation in US
1852
Second boiler safety statute, requiring:
Annual pressure testing to 1.5 x design
Quality of boiler plates
Mechanical
Provision of safety valves
Integrity
Licensing of engineers and pilots
Provision of fire hoses and lifeboats

Safety legislation in US
1852
Second boiler safety statute, requiring:
Annual pressure testing to 1.5 x design
Quality of boiler plates
Protective
Provision of safety valves
Systems
Licensing of engineers and pilots
Provision of fire hoses and lifeboats

Safety legislation in US
1852
Second boiler safety statute, requiring:
Annual pressure testing to 1.5 x design
Quality of boiler plates
Provision of safety valves
Competency
Licensing of engineers and pilots
Provision of fire hoses and lifeboats

Safety legislation in US
1852
Second boiler safety statute, requiring:
Annual pressure testing to 1.5 x design
Quality of boiler plates
Emergency
Provision of safety valves
Response
Licensing of engineers and pilots
Provision of fire hoses and lifeboats

but boiler explosions continued

Mississippi
steamboat
Sultana,1865

Design capacity: 385 persons

Persons on board: over 2000
Boilers exploded mid-stream: over 1700 killed

And still continue to this day

Ford Dearborn, 1999 6 killed in boiler explosion

More disasters, more regulations

Flixborough UK 1974
28 fatalities

Phillips Pasadena US
1989, 23 fatalities

Piper Alpha UK,

1988, 167 fatalities

Major Process Safety Legislation

USA:
USA: OSHA
OSHAProcess
ProcessSafety
SafetyManagement,
Management,1992
1992
UK:
UK: Offshore
OffshoreInstallation
Installation(Safety
(SafetyCase)
Case)Regulations,
Regulations,1992
1992
UK:
UK: Offshore
OffshoreInstallation
Installation(Prevention
(Preventionof
ofFire
Fireand
andExplosion
Explosion
and
andEmergency
EmergencyResponse)
Response)Regulations
Regulations (PFEER),
(PFEER),1995
1995
USA:
USA: EPA
EPARisk
RiskManagement
ManagementProgram,
Program,1996
1996
European
EuropeanCommunity,
Community,Seveso
SevesoII
IIdirective,
directive,1996
1996
UK:
UK: Control
Controlof
ofMajor
MajorAccident
AccidentHazards
Hazards(COMAH)
(COMAH)
Regulations,
Regulations,1999
1999

Why are you here?

Process Safety
We make our money by handling and
converting large volumes of highly flammable,
explosive and acutely toxic chemicals.

This is our core business!

Process Safety
Is vital to
Securing our Business and Licence to Operate

Life Cycle Model

IDENTIFY
HAZARDS

DESIGN

BUILD

OPERATE

TRAINING

VERIFY

MoC

EMERGENCY
RESPONSE

MAINTAIN

INSPECT

Process Safety processes are cradle to grave

activities that encompasses the full life time cycle
of an operating facility and are based upon clear
identification of potential hazards associated with
such facilities and the risk management programmes
developed to control the hazards.

Life Cycle Model

Major Accident
Risk Reviews

Engineering
Technical
Practices

Process Hazard
Analysis
Process Safety
Standards

IDENTIFY
HAZARDS

PHSSER Process
Process Safety
Information

DESIGN

Documentation

Pre Start Up
Safety Reviews

Control of Work

CONSTRUCT

Operating
Procedures
Legislation
Operating
Envelopes
Lessons
Learned

Management of Change
VERIFY

OPERATE
Safety
Routines

Training & Competency

PSM KPI
Measures

Alarm
Management

Compliance
Audits

Protective Devices

EMERGENCY
RESPONSE

MAINTAIN

INSPECT

Incident
Investigation
Emergency
Exercises

Emergency
Plans

Maintenance
Procedures

Asset Care

Fabric Maintenance

Inspection
schedule
Pipework
Integrity

Process Safety Management (PSM)

A disciplined
framework for
managing the
integrity of
hazardous operating
systems

PSM Framework
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
Process Safety Audit

Leadership & Accountability

Executive support required for PSM program.
Management must identify clear expectations of
PSM, provide resources, and promote and enforce
the program within the company.
PSM should be in integral part of the business plan
with regular reviews.
Job descriptions of all workers must reflect PSM
responsibilities.
Worker participation is crucial.
Process Safety Leading indicators (KPIs) should
be selected.

PSM Comparison
Elements

OSHA PSM 1910.119

Leadership / Accountability
Process Safety Information

Process Safety Information

Process Risk Management

Process Hazard Analysis

BP IM Standard
Accountabilities

Hazard Evaluation and RA

Engineering Systems
Process & Mechanical Integrity

Mechanical Integrity

Facilities and Process Integrity

Protective Systems

Management of Change

Management of Change

Management of Change

Pre-Start up Safety Review

Pre-Start up Safety Review

Operating Procedures

Operating Procedures

Practices and Procedures

Training / Competence

Training

Competence

Employee Participation

Employee Participation

Contractor Management

Contractors

Safe Work Practices

Hot Work Permit

Emergency Preparedness

Emergency Planning &

Response

Emergency Response

Incident Investigation

Incident Investigation

Incident Investigation & Learning

Process Safety Knowledge

Trade Secrets

PSM Audit

Compliance Audits
Performance Mgmt & Learning

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BP IM Standard
BPs Integrity Management Standard is
intended to augment existing Group
standards and protocols that previously
existed.
IM Standard represents BPs short-term
Process Safety priorities.
IM Standard incorporates best of industry
practices.

IM Standard Elements
Integrity Management Standard = Immediate priorities for Process Safety
Accountabilities

Hazard Evaluation & Risk Mgmt

Facilities & Process Integrity
Management of Change

Protective Systems

IDENTIFY
MINIMISE / AVOID

PREVENT
CONTROL

Practices & Procedures

MITIGATE

RI
AR

Performance Mgmt & Learning

ER

Competence

MANAGE

Incident Investigation &

Learning

Emergency Response

Process Safety Management

Ten Second
Version

Process Safety Management

keep it in
the pipe

Process Safety Management

Integrity
Management
Standard

Process Safety Management

securing business
integrity

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