PROCESS SAFETY FUNDAMENTALS Safe Operational Principles to avoid incidents with hazardous chemicals EPSC THE PROCESS SAFETY NETWORK i aCONTEXT Process Safety is about: the avoidance of Loss of Containment: of hazardous chemicals. For this three areas are considered relevant: Operational Excellence, Mechanical Incegrity and Engineering Design. EPSC is doing a lange study of the causes of incidents that classify as process safety incidents (according to ICCA or APL-7S4 standard), among their industrial members. The result, shown in Figure 1, shows that most cases originate in how the installation is operated. Losses are typically caused by operator handling or maintenance of the installation. This has led to the understanding that operational excellence on process saPety is of great importance. One of the questions is, what type oF incidents are we talking about and how could operation better prepare themselves to avoid these. Here the process saFety Fundamentals are defined that can play a role in strengthening process safety operational excellence on hazardous sites. To obtain this, Leadership and Competency on the critical operational and maintenance tasks is also essential. FIGURE 1. EPSC BENCHMARK RESULTS OF 2019 INCIDENT ROOT CAUSES (ON CA 1000 CLASSIFIED PROCESS SAFETY CASES) PROCESS SAFETY INCIDENT CAUSES. DESIGN 14% OPERATIONAL 51% INTEGRITY 35% PAGEZ al &The ePPectiveness of the integrity assurance processes are highly depen on demonstrated leadership by management at different: levels of the organization, but also by collective commitment demonstrated by the entire workForce. ing To avoid chemical releases so called “barriers” ane identified. These barriers can be hardware, human or organizational as shown in Figure 2. The scope of this booklet is limited to preventive and mitigating human barriers, and more speciPically the operating discipline principles that need to be respected rigorously to avoid process safety incidents and accidents. This rule based layer Forms a solid Foundation, on which the risk based methods can bulld, which are used to prevent the more complex process causes of incidents. FIGURE 2. FOCUS ON HUMAN BARRIERS Hordeare Horas PAGES =]SCOPE OF EPSC PROCESS SAFETY FUNDAMENTALS EPSC Process SaPety Fundamentals are a set of basic principles intended to support Frontline workers, supervisors and operational management. They draw attention to situations that: could lead to a release of a hazardous chemical with potential Por severe consequences and emphasize existing good practices to prevent such events. The EPSC Process Safety Fundamentals mention a number OF typical critical aspects that are not easy to do well and that: have resulted multiple serious incidents. Not all chemical saPety hazards are addressed. They can be used very well at industrial sites dealing with hazardous chemicals, in addition to the existing process saety management systems. Therefore, the EPSC PSFs do not replace existing safety management systems (including policies, safe systems For work, safety training programs, change management, critical task analysis & procedures etc.) but provide a tool to increase understanding on the items that often go wrong in the Field on the basis of a detailed discussion of the slides provided The current collection of EPSC Process Safety Fundamentals addresses 18 typical hazardous operational situations. Not all of these will be relevant: Por your site, and even you might Find missing ones. It's suggested to select the most relevant ones For your site and start to work on those. The EPSC PSF do not include new safe operation principles. Instead, they address well known basic principles but presented and visualized in a way that they can be used as tool enabling Front line workers to get: a better understanding of process safety in their day to day activities. EPSC PROCESS SAFETY FUNDAMENTALS & LIFE SAVING RULES. The EPSC Process Safety Fundamentals are intended as a complement to the Life Saving Rules adopted in many companies. However the context of the use of the EPSC PSF is quite difPerent From the intent of Life Saving Rules. Therefore, combining them in a single list is not recommended. A comparison of the use oF LiPe Saving Rules and EPSC Process Safety Fundamentals is given in the table at the next: page. PAGE — &LIFE SAVING PROCESS SAFETY RULES FUNDAMENTALS OBJECTIVE | Reduce number oF ‘Avoid loss of containment: oP injuries/Pavalities chemicals with potentially serious consequences For people, environment and assets HSE DOMAIN } Behaviors in Behaviors in operations involving occupational saRety } hazardous chemicals TARGET POPULATION Operation teams on hazardous sites (process operators, supervisors, operational management, contractors, maintenance technicians) NATURE AND Simple rules that are } More complex principles that APPLICABILITY } easy tounderstand { cannot always be Fully applied (eg. and apply in all in case of design issues) circumstances IMPLMENTATION Non-negotiable set | The aimis to identify situations OF requirements (LiFe } that ane not in line with the Saving Rules /Golden ; Process Safety Fundamentals Rules) and to start a discussion on how to proceed, while avoiding uncontrolled initiatives "to get the job done” ‘The deployment of the Process Safety Fundamentals is very different From the way that companies have implemented their Life Saving Rules. Life Saving Rules are introduced and managed as a set of non-negotiable simple requirements PRES Epstlwhile the Process Safety Fundamentals address more complex situations, where design and the practical situation need to be taken into account, to decide how tthe work can be executed safely. Therefore the PSF allow more Flexibility, that is they have to rely mone on advanced understanding and competency The intent of the PSFs is to emphasize some critical Pront-line tasks and behaviors that need to be Pully understood and supported by all operational leaders to enable successful process safety performance. The deployment Of the PSFs must allow a renewed Pocus on existing, good operating practices that we must get right every time. However, in practice, Pull application of the PSFs may not be easy or even not possible. It is also the aim of the PSFs to give Visibility to these dilemmas that Frontline operators may Face and to engage them in a discussion with involved operational management: on how to deal with these situations. In this context, Process SoPety Fundamentals are not intended to be seen as “another set of rules’, but nabher as an opportunity For discussion between front-line operators and operational management when difFiculties arise in the execution of some critical tasks. Im this context, the Process Safety Fundamentals provide an excellent tool For leaders to instill an open culture driving process safety excellence. Leaders should: * Drive safety From a position of care. Be visible in the Field. Have a regular dialogue on the PSFs. Help Front line safe to comPortably + surface dilemmas, operational issues, and weak signals. Have a high understanding of the compromising Factors in practical * situations. Once dilemmas are brought Forward, work with the Front line to resolve the issues. Show curiosity. Seek to understand and comply with the PSFs before allowing deviations. Recognize risk normalization in many oF our daily activities and address it The list of 18 EPSC Process Safety Fundamentals is not a comprehensive or exclusive list of all possible challenges that operators may Face in the Field. Therefore, other Process Safety Fundamentals may be developed and adopted by companies depending on the local contexts and needs. GUIDANCE CARDS In this booklet, guidance cards can be Found For each oF the 18 EPSC Process PACES: eeSaPety Fundamentals. These guidance cards give supporting information For the implementation of the PSFs. They give a description of the operation principles to be Followed, with a Focus on hazards, possible challenges in the Field and options to get it right. DEPLOYMENT OF THE PROCESS SAFETY FUNDAMENTALS The success of the deployment of the EPSC Process Safety Fundamentals is highly depending on the way in which they are rolled out. A description of possible steps is given below: Engagement Workshop To introduce the Process Safety Fundamentals, a workshop may be organized with key people in the operational chain to ensure their commitment and involvement, These people include representatives From Operations, Maintenance, Process Safety, Asset Integrity, The participation and commitment of senior leadership is vital For successful implementation of the PSFs. In the workshop, @ presentation can be given about: the PSF program and a discussion can be organized with Front line operators on how to efPectively implement the PSFs in the Field. A Formal plan For implementation of the PSFs, endorsed by all people involved, may be one of the deliverables of the workshop. Analysis and Promotion To coordinate the implementation of the Process Safety Fundamentals, the company may choose to nominate one or more stewards or champions. The role OF the stewardsicoaches includes the organization of sessions to give Further clarification to enable Front line workers to understand the scope and objectives OF the PSF program. These sessions can also be used For discussions on possible Pront-line dilemmas in the application of the selected PSFs. The content of tthe EPSC PSF guidance sheets can be used as a tool in the discussions. In the discussion it helps if the people that work in the Field, can openly share all the cases, where one had deviated From best practices. The type and number of PSFs to be included in the program may vary. One or more of the EPSC Process Safety Fundamentals may be selected. However other PSFs may be included, based on specific local process safety challenges and supported by a thorough analysis of its internal incident and leading indicator data related to actual or potential high consequence process safety events. One option could be to initially select a minimum set of PSFs to be promoted during a pilot phase over a one-year program, allowing a better estimate of the a we EPSCrequired eFort in terms of budget and resources allocation For a Full-scale deployment over the Following years. Roll-Out Please Find in Table 2, some suggestions that can help you to role-out the process saPety Fundamentals within your company. PRACTICE PURPOSE ons 1.1 Individual, team or site gop analysis, with improvement action plan 1.2 360 degree Feedback Identify strengths and areas For improvement, using invernet survey, card-sort or paper- based questionnaire. For manager or supervisor behaviors in the ‘area oF Process Safety Fundamentals, inked to development. PI ren olka uen knead 21 Awareness campaigns 22 Setting behavioral expectations 23 Interactive exercises 2.4 HSE days Explain PSFs and why they are important, Ongoing sharing of the PSFs with the Front-line workforce, making rePenence to neal events that: have occurred at site level, but also taking into account lessons learned and other available material From the industry Emphasize behaviors expected in relation to tthe Process Safety Fundamentals. Fon simple ways of explaining the Process Safety Fundamentals in an interactive and engaging way. Communication of Process Safety Fundamentals to workForce during themed HSE days / events. PACES aw eePRACTICE 25 Toolbox talks 26 Posters 27 Videos 28 Booklets BUILDING INTO HR PRO 31 Employee selection (all levels) 32 Management: development: 3.3. Supervisor development PURPOSE, Communication of Process Safety Fundamentals to workFonce by supervisors. Posters can be a powerPul communication tool providing strong relevant images that can be displayed at strategic positions. A well-chosen image can often convey a meaning more powerfully than words alone. Meaningful videos can result in greater ‘attention to, and retention oF information. They increase audience understanding, trigger emotions and encourage participant questions. A short video could be developed For each of the PSFs, to explain the its importance and the roles played by employees in preventing undesired process safety events. A pocket-sized booklet: covering the PSFs can be a helpful resource to maintain awareness of PSFs and also be used to prompt process saPety discussion, For example during toolbox talks, or during operational site visits by managers and supervisors. Use Process SaPety Fundamentals as criteria For selection. Develop manager engagement in application oF Process Safety Fundamentals. Develop supervisor engagement in application oF Process Safety Fundamentals. PAGES a &PRACTICE 34 Coaching 35 Enhancement of personal HSE action plans PURPOSE, Develop behaviors related to Process SaPety Fundamentals. ‘Add respect of Process Safety Fundamentals vo personal HSE action plans. 4. BUILDING INTO HSE PROCESSES & SYSTEMS 41 HSE improvement campaigns 42 During auditing 43 Reward and recognition 44 Post-incident review 45 Near-miss analysis Executive Safety Tools 46 Executive Saety Tools AT Contractor selection & management Linking Process Safety Fundamentals to specific campaigns (e.g. certain types of injury or incidents). Inclusion of Process SaPety Fundamentals during traditional HSE audits. Linking to demonstration of excellent: application of Process Safety Fundamentals. Following an incident, using the Process Safety Fundamentals to embed post-incident learning. Identieying trends in application of Process Safety Fundamentals in a series of nean-misses. Simple practices which senior executives can use to promote Process Safety Fundamentals. Engage contractors in demonstrating and reinPorcing the right behaviors related to Process Safety Fundamentals. PAGE 1 aw eePRACTICE 48 Integration in contractual agreements a oy 51 Risk assessment 52 Employee involvement 5.3 SaPety moments 54 Site visits and inspection program 55 Recognition and interventions PRACTICES PURPOSE The PSFs adopted inside the Company can be referenced in Tender documentation, not necessarily as a stand-alone document, but: identifying the most suitable way to ensure Contractors working on Company's sites are Fully aware that PSFs are part of Company policies/procedures. Encourage / maintain mindFulness. Get everyone involved in respecting Process ‘SoPety Fundamentals. Encourage / maintain mindfulness. Dedicated site visits can be conducted by supervisors and managers to support implementation of the PSFs; dilemmas raised by Front line workers can then be addressed to Facility continuous improvement in process ‘saPety performance. Inclusion of the PSFs in site hazard observation cards enabling dilemmas Paced by Frontline workers in trying to implement: PSFs, to be raised. And an award or recognition program For the best card of the month. Another ‘option is the inclusion of the PSFs in the pre- job Tool-Box-Talks materials, helping to increase understanding of the required controls to be ‘applied before starting work. PAGE 1 a &MONITORING AND FOLLOW-UP Management system activities include monitoring and Follow-up. In the case of Process Safety Fundamentals (as part of process management), some time be needed to measure the cutcome of the implementation of PSFs (in terms oF reduction of the number of Process Safety Events related to operating integrity). A more immediate step change will be more likely visible in terms of increased front-line awareness, competence and engagement in process safety FIGURE 1. INTEGRITY MANAGEMENT AREAS. orm ese 2 o oe EPSC18 TOPICS FOR PROCESS SAFETY EXCELLENCE 1, APPLY DOUBLE ISOLATION EMPTY AND DE-ENERGIZE BEFORE LINE-BREAKING 3. MONITOR AN OPEN DRAIN 4, MANAGE OVERRIDES OF SAFETY CRITICAL SYSTEMS LINE-BREAKING INCIDENTS 5. WALK THE LINE 6. VERIFY LEAK TIGHTNESS AFTER MAINTENANCE WORK 7. AVOID WORKING BEHIND A SINGLE VALVE 8. VERIFY THE CONDITION OF FLEXIBLE HOSES, 9, OPERATE WITHIN SAFE LIMITS 10. CONTROL UTILITY SYSTEMS CONNECTED TO A PROCESS: 11, REPORT DEFICIENCIES ON SAFETY CRITICAL EQUIPMENT 12. UNPLUGGING OF EQUIPMENT 13. STAY OUT OF THE LINE OF FIRE 14. CONTROL (UN)LOADING 15. CHECK ATMOSPHERE IN FIRE BOX BEFORE IGNITING THE BURNERS 16. AVOID SPLASH LOADING 17, AVOID RUN-AWAYREACTION 18. REPORT PROCESS SAFETY INCIDENTS PAGE 1 a &EPSC PROCESS SAFETY FUNDAMENTALS €: Apply Double Isolation Empty and De-enengize Monitor an open drain before Line-breaking SYSTEM OVERRIDE = = 7: Manage Overrides of Walk the line Verify leak tightness Safety Critical Systems after maintenance work . w" Avoid working behind Verify the condition Operate within a single valve of Plexible hoses safe limits PAGE 14 aw eePICTOGRAMS D i ei - {_—_ 3 Control utility Report deficiencies Control unplugging oF systems ‘on Safety critical equipment: f 9? o— “ io # Lae ‘Stay out of Control (Un)loading Check atmosphere the Line of Fire. in Fire box before igniting the burners | aes Avoid Splash Loading Avoid run-away reaction Reports Process SaPety IncidentsGUIDANCE ON USING THE PROCESS SAFETY FUNDAMENTALS These are saPe operating principles related to hazardous chemicals to avoid spills, Fire, explosion, exposure, or business interruption. To establish Process SaPety Excellence on chemical sites by enhancing ‘awareness on typical hazardous operations and discussing the relevant details. Understanding the challenges in the Field and the good practices that help to get things right. Select: a limited number of PSF relevant For your operation to start; eventually expand in next: steps with additional more specific PSE Use the PSF slide to start the discussion. It is the discussion that provides the understanding of where you really are and what can be improved! Establish clear agreement: & procedures on the discussed PSF To get in the positive process safety mood, Feel Free to use this video made by Shell: https:/Mmwwyoubube.comiwatch?v=l9FudydckGgOPTIONS TO GET IT RIGHT Olean