Guidelines for Risk Based Process Safety

Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology.  CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 80 books in its process safety guidelines and process safety concepts series.

"…a very comprehensive and thorough discussion of risk based process safety management systems…an invaluable reference source." (Journal of Loss Prevention in the Process Industries, January 2008) "This book is a very well-written, detailed analysis of industrial chemical plant safety. Following its guidelines, I am sure, will result in many fewer accidents in the future." (Journal of Hazardous Material, January 15, 2008)

• List of Tables xxixList of Figures xxxiAcronyms and Abbreviations xxxiiiGlossary xxxviiAcknowledgments xlviiPreface xlixExecutive Summary li1 INTRODUCTION 11.1 Purpose of These Guidelines 21.2 Background 61.3 Important Terminology 91.4 Management Systems Concepts 101.5 Risk Based Process Safety Elements 121.6 Relationship Between RBPS Elements and Work Activities 121.7 Application of these RBPS Guidelines 141.8 Organization of these Guidelines 161.9 References 172 OVERVIEW OF RISK BASED PROCESS SAFETY 192.1 Risk Based Process Safety System Design Strategies 222.2 Risk Based Process Safety Design and Improvement Criteria 242.3 Using Element Chapters to Design and Improve a Process Safety Management System 32I COMMIT TO PROCESS SAFETY 373 PROCESS SAFETY CULTURE 393.1 Element Overview 403.2 Key Principles and Essential Features 453.3 Possible Work Activities 483.4 Examples of Ways to Improve Effectiveness 583.5 Element Metrics 623.6 Management Review 643.7 References 664 COMPLIANCE WITH STANDARDS 674 1 Element Overview 674.2 Key Principles and Essential Features 694.3 Possible Work Activities 744.4 Examples of Ways to Improve Effectiveness 814.5 Element Metrics 834.6 Management Review 844.7 References 865 PROCESS SAFETY COMPETENCY 895.1 Element Overview 905.2 Key Principles and Essential Features 935.3 Possible W ork Activities 1005.4 Examples of Ways to Improve Effectiveness 1115.5 Element Metrics 1165.6 Management Review 1195.7 References 1216 WORKFORCE INVOLVEMENT 1236.1 Element Overview 1236.2 Key Principles and Essential Features 1286.3 Possible Work Activities 1316.4 Examples of Ways to Improve Effectiveness 1366.5 Element Metrics 1406.6 Management Review 1426.7 References 1437 STAKEHOLDER OUTREACH 1457.1 Element Overview 1467.2 Key Principles and Essential Features 1487.3 Possible Work Activities 1527.4 Examples of Ways to Improve Effectiveness 1597.5 Element Metrics 1617.6 Management Review 1647.7 References 165II UNDERSTAND HAZARDS AND RISK 1678 PROCESS KNOWLEDGE MANAGEMENT 1698.1 Element Overview 1708.2 Key Principles and Essential Features 1738.3 Possible Work Activities 1868.4 Examples of Ways to Improve Effectiveness 1968.5 Element Metrics 2018.6 Management Review 2048.7 References 2069 HAZARD IDENTIFICATION AND RISK ANALYSIS 2099.1 Element Overview 2099.2 Key Principles and Essential Features 2139.3 Possible Work Activities 2219.4 Examples of Ways to Improve Effectiveness 2299.5 Element Metrics 2379.6 Management Review 2409.7 References 242III MANAGE RISK10 OPERATING PROCEDURES 24510.1 Element Overview 24510.2 Key Principles and Essential Features 24710.3 Possible Work Activities 26010.4 Examples of Ways to Improve Effectiveness 27310.5 Element Metrics 27910.6 Management Review 28210.7 References 28311 SAFE WORK PRACTICES 28511.1 Element Overview 28511.2 Key Principles and Essential Features 28811.3 Possible Work Activities 29811.4 Examples of Ways to Improve Effectiveness 30711.5 Element Metrics 31211.6 Management Review 31411.7 References 31612 ASSET INTEGRITY AND RELIABILITY 31712.1 Element Overview 31812.2 Key Principles and Essential Features 32012.3 Possible Work Activities 33512.4 Examples of Ways to Improve Effectiveness 35212.5 Element Metrics 35912.6 Management Review 36112.7 References 36313 CONTRACTOR MANAGEMENT 36513.1 Element Overview 36513.2 Key Principles and Essential Features 36813.3 Possible Work Activities 37713.4 Examples of Ways to Improve Effectiveness 38513.5 Element Metrics 39013.6 Management Review 39113.7 References 39314 TRAINING AND PERFORMANCE ASSURANCE 39514.1 Element Overview 39514.2 Key Principles and Essential Features 39814.3 Possible Work Activities 40614.4 Examples of Ways to Improve Effectiveness 41414.5 Element Metrics 41714.6 Management Review 42014.7 References 42115 MANAGEMENT OF CHANGE 42315.1 Element Overview 42315.2 Key Principles and Essential Features 42615.3 Possible Work Activities 43115.4 Examples of Ways to Improve Effectiveness 44015.5 Element Metrics 44515.6 Management Review 44715.7 References 44816 OPERATIONAL READINESS 44916.1 Element Overview 44916.2 Key Principles and Essential Features 45216.3 Possible Work Activities 45616.4 Examples of Ways to Improve Effectiveness 46216.5 Element Metrics 46416.6 Management Review 46516.7 References 46717 CONDUCT OF OPERATIONS 46917.1 Element Overview 46917.2 Key Principles and Essential Features 47117.3 Possible Work Activities 48417.4 Examples of Ways to Improve Effectiveness 49817.5 Element Metrics 50217.6 Management Review 50617.7.References 50818 EMERGENCY MANAGEMENT 50918.1 Element Overview 51018.2 Key Principles and Essential Features 51318.3 Possible Work Activities 52618.4.Examples of Ways to Improve Effectiveness 54118.5 Element Metrics 54318.6 Management Review 54518.7 References 547IV LEARN FROM EXPERIENCE 54919 INCIDENT INVESTIGATION 55119.1 Element Overview 55219.2 Key Principles and Essential Features 55619.3Possible Work Activities 56319.4 Examples of Ways to Improve Efficiency and Effectiveness 57519.5 Element Metrics 58019.6 Management Review 58219.7 References 58420 MEASUREMENT AND METRICS 58520.1 Element Overview 58520.2 Key Principles and Essential Features 58820.3 Possible Work Activities 59020.4 Examples of Ways to Improve Effectiveness 59420.5 Element Metrics 59520.6 Management Review 59720.7 References 59821 AUDITING 59921.1 Element Overview 59921.2 Key Principles and Essential Features 60221.3 Possible Work Activities 61521.4 Examples of Ways to Improve Effectiveness 62221.5 Element Metrics 62621.6 Management Review 62821.7 References 62922 MANAGEMENT REVIEW AND CONTINUOUS IMPROVEMENT 63122.1 Element Overview 63122.2 Key Principles and Essential Features 63422.4 Examples of Ways to Improve Effectiveness 64422.5 Element Metrics and Indications 64622.6 Management Review 64722.7 References 64723 IMPLEMENTATION 64923.1 Reasons to Implement a Risk-based Process Safety Management System 65020.2 First Steps Toward Implementation 65120.3 Start with RBPS Elements that Provide the Greatest Risk Benefit to Your Facility 65320.4 Implementation Examples 65620.5 Other Applications 68020.6 Conclusions 68120.7 References 68224 THE FUTURE 683Index 689LIST OF TABLESTABLE S.l. Risk Based Process Safety Elements livTABLE 1.1. Possible Causes of Process Safety Management Performance Stagnation 2TABLE 1.2. RBPS Management System Accident Prevention Pillars 3TABLE 1 3. CCPS Guidelines and Tools for Chemical Process Safety Management 7TABLE 1.4. North American Industry Process Safety Management Initiatives 7TABLE 1.5. Partial List of Worldwide Governmental Accident Prevention and Process Safety Management Initiatives 8TABLE 1.6. Some Factors that Motivated the CCPS RBPS Project 9TABLE 1.7. Important Issues to Address in a Process Safety Management System 11TABLE 1.8. Comparison of RBPS Elements to Original CCPS PSM Elements 13TABLE 1.9. Generic Work Breakdown Structure for the RBPS System 14TABLE 2.1. Process Safety Accident Prevention Principles and Associated RBPS Elements 24TABLE 2.2. Examples of How Risk Affects Implementation of RBPS Work Activities 31TABLE 2 3. Advice on Using these Guidelines to Meet Specific User Needs 33TABLE 3.1. Culture as a Determinant of Process Risk Control Attitudes and Practices 41TABLE 4.1. Examples and Sources of Process Safety Related Standards, Codes, Regulations, and Laws 71TABLE 6.1. UK HSE Workforce Involvement Suggestions 127TABLE 8.1. Typical Types of Process Knowledge 176TABLE 9.1. Example Issues that Can Be Addressed at Various Life Cycle Stages 233TABLE 10.1. Procedure Formats 253TABLE 11.1. Activities Typically Included in the Scope of the Safe Work Element 290TABLE 13.1. Safety Program and Performance Information Useful in Evaluating Potential Contractors 372TABLE 22.1. Example Schedule for Management Reviews 636TABLE 23.1. RBPS Implementation Options for Upgrading Operating Procedures 659TABLE 23.2. RBPS Implementation Options for Implementing the Conduct of Operations Element 665TABLE 23.3. RBPS Implementation Options for Fixing a Deficient MOC System 671TABLE 23.4. Using RBPS to Develop and Implement a New Process Safety Management System 678LIST OF FIGURESFIGURE 2.1. Evolution of Process Safety and Accident/Loss Prevention Strategies 19FIGURE 9.1. Levels of Hazard Evaluation and Risk Assessment 211FIGURE 9.2. Typical Qualitative Risk Analysis Documentation Form 213FIGURE 9.3. Example Risk Matrix 216FIGURE 14.1. Training System Tasks 399FIGURE 19.1. Incident Investigation Flowchart 553FIGURE 19.2. Incident Investigation Levels of Analysis 555FIGURE 23.1. A Risk-based Approach to Identifying Which RBPS Elements to Implement 655