We’ve been relying on Process Safety Management (PSM) frameworks for over 30 years:
- OSHA (29 CFR 1910.119) published in 1992
- CCPS (Risk Based Process Safety) published in 2007
- Energy Institute (PSM Framework) published in 2010
However, despite their widespread adoption (to underpin Design, Operations & Maintenance activities) plus better technology and bigger data, major accidents resulting from Loss of Containment of Hazardous Materials continue to occur.
What’s going wrong ?
These frameworks are often presented as either ‘Roman Arches‘:
Or ‘Greek Temples‘:
In reality, the Management of Processes (Plants) is a dynamic challenge which is better represented as a lifecycle than a static diagram.
Ian Travers has simplified the familiar 20 Elements into a more usable, operational structure as shown below:
“You’re My Only Hope”
Let’s refer to this as ‘STEWARDSHIP‘ to reinforce the principle that this is not the sole responsibility of senior roles (i.e. ‘Managers‘) to create and sustain safe assets & activities (i.e. ‘Manage‘). Everyone who contributes to and/or may be affected by process safety & process integrity has a part to play.
PSM Cards can be used at all levels from the Boardroom to the Control Room e.g. ‘players’ are dealt a card from the deck and have to briefly summarise their understanding of and contribution to the element on the card.
Here’s a summary of the key issues (click the Icons for relevant PSM elements) :
Leaders lack understanding & commitment.
Communication is poor & morale is low.
Leading & Lagging performance indicators are not (properly) measured or analysed.
Poor Basis of Design or no Basis of Safety.
Documents are inaccurate & inaccessible.
Training & accreditation is outdated.
Physical & mental exhaustion is common.
Hazard studies are incomplete & actions remain open.
Risk targets are inconsistent.
Equipment is not fit for purpose.
Protection is not fit for duty.
Process & equipment limits are not known or respected.
Maintenance is reactive.
Testing is irregular or incomplete.
Contractors & Suppliers are not vetted or supervised.
Emergency plans are unrehearsed.
First responders are unfamiliar with site.
Isolations are incomplete.
Adjacent activities are not monitored.
Close calls (Near Misses etc) are not recorded.
Incidents are not properly investigated or shared.
Temporary & permanent physical, functional & organisational changes are not assessed.
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