THE TEN COMMANDMENTS OF RISK BASED PROCESS SAFETY—INTRO
Instruction of many “Foundations of Risk Based Process Safety (RBPS)” courses has resulted in the realization that the volume of material presented in RBPS training could be overwhelming. The need for a simplified tool to ensure critical points are understood and actions follow upon the “Ten Commandments of Risk Based Process Safety” were developed to leave with the participants to highlight the concepts of the course. It is important to understand the breadth of each “commandment,” for full integration and application. The ultimate intention is that each item will serve as a stimulus for taking action upon returning to your workplace 1, 2.
THE TEN COMMANDMENTS OF RISK BASED PROCESS SAFETY
Each commandment is listed below with an explanation of the relative concept.
I. Thou shalt always honor thy container
Businesses that are diligent about keeping chemicals and energy in their respective containers in order to eliminate unplanned releases, significantly reduce the likelihood of a process safety incident. In order to create a low likelihood of a process safety incident the following are required; proper operating procedures, a strong mechanical integrity program, appropriate training and routine observations.
It is also very important to include all containers in a process. Many significant incidents occur with finished materials storage tanks, raw material storage tanks, and others. Transportation containers need to also be included in your process safety management activities. A transportation incident can result in a process safety incident which may severely damage not only a company's reputation but can also affect the lives of others, especially those in the surrounding communities. Due diligence is necessary when ensuring that the appropriate containers are used and inspected, and that all transportation rules and guidelines are followed.
II. Thou shalt always maintain a sense of vulnerability
Complacency equals incidents. The potential for a process safety incident is always present. This concept needs to be a critical part of the mindset of every employee and every contractor. In order to keep this active in any organization it requires consistency in practice from everyone in the organization. Safety awareness is not the job of just one or two people. It needs to be on the minds of every employee. The thought that it can't happen here, or that it has never happened before need to be dispelled.
III. Thou shalt eliminate normalization of deviation
Normalization of deviation is accepting operations which are outside of set limits. One example is when the temperature limits on a reaction is set at 75 degrees C, plus or minus 2 degrees C. Over time the process is allowed to run consistently at 76 degrees C, then 77 degrees C, and then at 78 degrees C. This condition of constantly running at higher than the original set limit has reached a level of acceptability. Over time, it has the potential of further exceeding the original limit if no action is taken. At some point it may reach a temperature where a process safety incident is experienced. Designing a process without strict adherence to design standards is another area where normalization of deviation tends to exist. If a deviation is necessary in any circumstance, steps need to be taken such as management of change, supervisory approval and subsequent documentation to change the previously set limits. Advancements in technology as well as knowledge from experience (either on-site or from field experts) will dictate whether a deviation is acceptable or not. One individual should not determine whether a deviation is allowable. A deviation needs to be researched and based upon sound industry practice.
IV. Thou shalt know thy chemistry
It is extremely important to know and understand the chemistry of everything under your control. This knowledge includes: side reactions, operating limits and why these limits are what they are, stability, reactivity, and other properties. T...
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[ 4.0 ms ] story [ 82.8 ms ] threadTHE TEN COMMANDMENTS OF RISK BASED PROCESS SAFETY Each commandment is listed below with an explanation of the relative concept.
I. Thou shalt always honor thy container Businesses that are diligent about keeping chemicals and energy in their respective containers in order to eliminate unplanned releases, significantly reduce the likelihood of a process safety incident. In order to create a low likelihood of a process safety incident the following are required; proper operating procedures, a strong mechanical integrity program, appropriate training and routine observations.
It is also very important to include all containers in a process. Many significant incidents occur with finished materials storage tanks, raw material storage tanks, and others. Transportation containers need to also be included in your process safety management activities. A transportation incident can result in a process safety incident which may severely damage not only a company's reputation but can also affect the lives of others, especially those in the surrounding communities. Due diligence is necessary when ensuring that the appropriate containers are used and inspected, and that all transportation rules and guidelines are followed.
II. Thou shalt always maintain a sense of vulnerability Complacency equals incidents. The potential for a process safety incident is always present. This concept needs to be a critical part of the mindset of every employee and every contractor. In order to keep this active in any organization it requires consistency in practice from everyone in the organization. Safety awareness is not the job of just one or two people. It needs to be on the minds of every employee. The thought that it can't happen here, or that it has never happened before need to be dispelled.
III. Thou shalt eliminate normalization of deviation Normalization of deviation is accepting operations which are outside of set limits. One example is when the temperature limits on a reaction is set at 75 degrees C, plus or minus 2 degrees C. Over time the process is allowed to run consistently at 76 degrees C, then 77 degrees C, and then at 78 degrees C. This condition of constantly running at higher than the original set limit has reached a level of acceptability. Over time, it has the potential of further exceeding the original limit if no action is taken. At some point it may reach a temperature where a process safety incident is experienced. Designing a process without strict adherence to design standards is another area where normalization of deviation tends to exist. If a deviation is necessary in any circumstance, steps need to be taken such as management of change, supervisory approval and subsequent documentation to change the previously set limits. Advancements in technology as well as knowledge from experience (either on-site or from field experts) will dictate whether a deviation is acceptable or not. One individual should not determine whether a deviation is allowable. A deviation needs to be researched and based upon sound industry practice.
IV. Thou shalt know thy chemistry It is extremely important to know and understand the chemistry of everything under your control. This knowledge includes: side reactions, operating limits and why these limits are what they are, stability, reactivity, and other properties. T...