Professional Documents
Culture Documents
by Stephen Covey
#1 – Be Proactive
#2 – Begin with the End in Mind
#3 – Put First Things First
#4 – Think Win-Win
#5 – Seek First to Understand, Then to
be Understood
#6 – Synergize
#7 – Sharpen the Saw
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#2 – Begin With the End in Mind
- Why are Purdue Chem Engs required to take a class in process safety?
- Do other Chem Eng Depts require this?
- Where are we headed with this topic?
- We can fill in the details of what we will cover in the course once we
know where we are going, desired end point … and, why?
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Habit #2 on Personal Level:
- What matters most to you? What do you value?
- Vision of one’s life as a whole, your script, own uniqueness
- What do you want said about you at your funeral, by your family, co-workers…
- Is your ladder of ‘success’ leaning against the right wall?
- All things are created twice: (1) mentally and (2) physically
- Required of Leaders to be effective vs. Managers who focus on efficiency
- Is your script written by you or by others …?
- Development of personal mission statement 2
Film – ‘Spiral to Disaster’; Piper Alpha
Platform, North Sea
- When & where did this happen?
- How many lives were lost?
- How long did it take to destroy the platform?
- What was the role of a ‘permit to work’ in the disaster … and how many work
permits were there for the key valve?
- If only 2 were killed by initial oil fire, what led to the subsequent explosions,
fire and +100 fatalities?
- What were some of the design shortcomings that exasperated the incident /
consequence?
- What types of hazard or risk analyses might have reduced the magnitude of
the incident?
- How would you rate the decision making ability of the Offshore Installation
Manager (OIM) on the Claymore platform?
- To what extent did Emergency Response training help the survivors?
- Did the incident have any significant impacts on industry as a whole?
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Chapter # 1 –
Introduction to Process Safety
Purdue University
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Questions to be Addressed
• How is Process Safety different from Personnel Safety?
• How is process safety relevant to different types of operations
/ businesses?
• What is Safety Culture and why is leadership important?
• How can one measure the safety of one’s operation and
monitor performance over time?
• Can I benchmark our safety performance with other
operators & other industries?
• What factors should one consider to reduce hazards and
improve safety?
• What is ISD – Inherently Safer Design?
• How does ethics factor into this? How do I stay out of jail?
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WHAT’S THE DIFFERENCE?
PERSONNEL SAFETY ??
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BP Deepwater Horizon Incident, April 20, 2010
Explosion and subsequent fire in GOM on the Deepwater Horizon
semi-submersible Mobile Offshore Drilling Unit (MODU), with 11
fatalities, 16 injuries, ~ 4.9 million barrels of oil spilled & ~$62B.
http://previous.presstv.ir/photo/20111015/ramezani20111015132510717.jpg http://blogs.ft.com/energy-source/files/2010/12/macondo-explosion.jpg
http://www.upstreamonline.com/migration_catalog/article1195496.ece/ALTERNATES/article_main/Macondo+pelicans
5th victim passes away after Didion Corn Milling explosion
in Cambria, Wisc
The May 31, 2017 explosion sent 11 of 16 plant employees working at the time to
hospitals. The cause remains unknown and under investigation by OSHA & CSB. The
explosion destroyed much of the facility, with demolition and debris removal on-going.
The plant, which processes corn for ethanol and other uses, was cited in January 2011
for exposing its workers to dust explosion hazards and that plant filters lacked an
explosion protective system, according to OSHA records. The federal safety agency
ordered the mill to correct the problem by April 2011. The records show Didion paid a
$3,465 fine and the case was closed in
September 2013. OSHA hasn't cited the
plant for anything since.
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Texas fertilizer plant that exploded failed to report it was
storing volatile chemical used in the Oklahoma City
bombing at 1,350 times the safety levels; 2013
15 dead after horrific blast. Company failed to mention storing
up to 270 tons of ammonium nitrate in its risk management plan
with the EPA.
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Japanese Tsunami
Nuclear Power Plant
Incident - 2012
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Pipeline Incident – Sept 2010 … Notable incidents
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WHY TALK ABOUT SAFETY ??
- IS IT ALL ABOUT $$ ?
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Safety Culture
• Varies across industries and companies within an industry
• UK Health & Safety Executive defines as: ‘the product of individual &
group values, attitudes and perceptions, competencies, and patterns
of behavior that determine the commitment to, and the style and
proficiency of an organization’s health & safety management.’
• Some known characteristics:
– Top management is actively & visibly engaged in safety
– Open communication at all levels of the organization
– Consistency in placing safety before production
– Everyone’s responsibilities and accountabilities regarding safety
are clearly defined and understood
– Workers are not only concerned with their work behaviors but are
empowered to intervene in co-workers unsafe acts
– Safety is second nature; zero tolerance for disregard of safety
related management systems, procedures, etc
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ExxonMobil’s Views
• ‘Safety of our workforce is a moral imperative,’ Lee Raymond former CEO,
ExxonMobil
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CSB Investigative Report Vol 3; Drilling Rig
Explosion and Fire at Macondo … , April 2010
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‘Best-in-Class’ Safety Culture Attributes
1. Leadership
2. Culture & values
3. Goals, policies & initiatives
4. Organization & structure
5. Employee engagement and behaviors
6. Resource allocation & performance management
7. Systems, standards & processes
8. Metrics & reporting
9. A continually learning organization
10. Verification and audit
‘Framework For Creating a Best-in-Class Safety Culture’, Mannan, M. S., Mentzer, R.A., and
Zhang, J., J. of Loss Prevention in the Process Industries; 26 (6), pp 1423-1432, 2013 25
Measurement of Safety
• How to measure safety? Important factors?
• Metrics are needed to assess the effectiveness of
safety programs
• Hazards – physical or chemical condition having
potential to cause damage to people, property or
environment
• Risk – a function of likelihood & magnitude
• Understanding of risk, real & perceived, is needed
for assessment of alternative designs, modifications
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Safety Pyramid
1-2 Fatalities
• Look at the picture above and you can see where this driver broke through the guardrail,
on the right side of the culvert, where the people are standing on the road, pointing.
• The pick-up was traveling about 75 mph from right to left when it crashed through the
guardrail.
• It flipped end-over-end, bounced off and across the culvert outlet, and landed right side
up on the left side of the culvert, facing the opposite direction from which the driver was
traveling.
• The 22-year-old driver and his 18-year-old passenger were unhurt except for minor cuts
and bruises.
• Now look at the second picture below...
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Construction had the highest count of fatal injures in 2016, but the agriculture,
forestry, fishing and hunting sector had the highest fatal work injury rate.
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Source: Bureau of Labor Statistics, 2018
Safety Metrics – Fatality Rate
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US OSHA Recordkeeping System
• Purpose:
• To require employers to record and report work-related injuries,
illnesses & fatalities.
– OSHA system
• Routine first-aid treatments are not counted, EG – BandAids, cleaning
wound, non-prescription medication, etc
• Based on cases requiring medical treatment, plus fatalities
• Scope of medical treatment specifically defined resulting in OSHA
‘recordable’ incidents
• ‘Lost-time’ incidents are those where injured person couldn’t return to
normal duties the following day
• Injuries are counted that result in loss of consciousness, days away from
work, restriction of work & temporary transfer to another job
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OSHA Incident Rate (cont’d)
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Running With The Bulls
• Estimate OSHA injury rate
• Run lasts only a few minutes from start to stadium
for bull fight, but let’s assume each of the ~2,000
contestants is there for an hour
• Reportedly 50 – 100 are injured each year, with 50
being hospitalized in 2013, but let’s assume the
widely reported 2017 # of ten (mostly <dumb> Americans)
• 10 runners injured x 2 x 10**5 / (2,000 runners x 1 hr / runner)
= 10,000
• Within industry a good OSHA recordable rate < 1 40
Monitoring TRIR & LTIR Trends
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OSHA Metric Calculations
• You work for a firm with 200 employees. Through
the first half of the year they had 2 first aid
incidents and one incident requiring medical
treatment. What is their OSHA TRIR? Should they
be satisfied?
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Process Incident Definition
A process incident is the sudden unintended
release of or exposure to a hazardous substance,
which results in or might reasonably have resulted
in, deaths, injuries, significant property or
environmental damage, evacuation or sheltering in
place.
VS.
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Trailing or Lagging Indicators
• Measurement of incidents; with intent to analyze
and take steps to reduce risks and hazards
• Most safety indicators historically tend to be
lagging
• Limited usefulness since they apply after the
incident
• Also, one obtains fewer data for use in improving safety
performance as safety improves
• Examples of lagging indicators:
• Number of safety related on the job incidents
• Trend in process safety incidents – loss of containment,
fires, $$ damage, vapor releases, etc
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Leading Indicators
• A measure of activities to reduce risk prior to occurrence of
an incident
• Unfortunately, not as widely used as lagging indicators
• Examples of leading indicators:
- Number of near misses reported
- Trend in implementation of prevention programs,
employee safety training, etc
- Followup on items identified from risk
assessments (%)
- Deferred maintenance, % of items
- Faults detected by inspections and testing 46
Process vs. Personnel Safety Metrics
• Personnel Safety
– # injuries, illnesses & fatalities
– FAR; OSHA TRIR & LTIR; etc
– Processes well developed for lagging indicators; evolved over last ~20 yrs for
leading indicators
• Process Safety
– Businesses have historically measured volume of oil spilled, chemical releases, fires,
hazard loss $$, etc
– Industry standardization with API RP 754 ‘Process Safety Performance Indicators’
• Tiers 1 & 2 primarily provide lagging indicators; measure loss of primary
containment resulting in serious injuries, significant fire / explosion, community
evacuation, etc
• Tiers 3 & 4 leading indicators; % completion of process safety audit followup,
training, work permit compliance, etc
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Process Safety Performance Indicators for the Refining and
Petrochemical Industries
• Tiers of the pyramid represent a
continuum of leading and lagging
process safety indicators
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Consequence of Using Wrong Indicator
- Process vs. Personnel Safety
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Voluntary or Involuntary Risk
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Safety in the Chemical Industry
• Risk is generally less than perceived by public, and
often out of context with readily accepted everyday
voluntary risks
• Chemical industry is held to a higher than average
safety standard
• Continuous
improvement toward
an accident free
workplace is
necessary for
credibility and public
trust
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American Chemical Council – Responsible Care
Losses in Industry
• Transportation leading cause of workplace fatalities;
primarily motor-vehicle (Crowl, Figure 1-4, p.13)
• Most common chemical plant incidents: fires,
explosions and toxic releases
• Largest causes of chemical plant losses (Crowl,
Figure 1-7, p.16):
– mechanical failure – 53% (often maintenance related)
– operator error a distance 2nd @18%; on-site leading
directly to incident vs. mechanical error due to
improper maintenance
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Historic Loss Trends for Refining and Upstream Oil & Gas
Consistent with trend of larger & more complex plants and processes
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ISD In Practice
• Seek to minimize risk: ISD during the process lifecycle
- recognition of the hazards posed by
the process
- continual effort to analyze the risks and
to reduce or control them to the lowest
levels practical
- considering the balance of other
objectives of the business in doing so
• Involves such practical applications
as:
- substituting more benign chemicals at
the development stage,
- minimizing risk in the transportation of
chemicals,
- using safer processing methods at the
manufacturing stage, and
- inherent safety during commissioning a
manufacturing plant 60
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ETHICS - ‘Cobalt (car) owners died because
GM refused to replace a small, defective
part in its executives …’
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Ethics – your most important attribute
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Code of Engineering Ethics (Crowl, Table 1-1, p. 5)
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Terminology Overview
- Commonly Used Terms
• PPE
• PSM
• RMP
• OSHA
• CSB
• Gas treating – remove sulfur compounds & CO2 from gas stream
• Gas processing – to recover NGLs from gas stream
• Condensate – generally liquid condensed from produced gas, but can also
refer to water condensed from vapor
• NGL- natural gas liquids … ethane, propane, butanes, +C5
• LPG – liquefied petroleum gas … primarily propane & butane
• LNG – liquefied natural gas … primarily methane chilled to -260 F
Upstream
- ExxonMobil
How are Fuels Produced? - (2)
Downstream
597 students also: 1-32 and - Later this semester we will discuss the Bhopal incident resulting from the release of large
quantities of a very toxic substance resulting in +2,000 fatalities, where they could have designed the process without it.
What two ISD principles should have been employed to prevent or mitigate the consequences of the incident?
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