Process Safety Management

Alternatively named ‘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. Everyone who contributes to and/or may be affected by process safety & process integrity has a part to play.

Unlike LoC or Ignition cards, these are not based around Events. The 13 ‘Stewardship’ or PSM elements are assigned to the 13 playing cards in each of the 4 suits starting from the 2 up to 10 then J, K, Q and Ace.

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.

Process Safety Stewardship Model (13 elements)

Playing cards illustrate and summarise the elements of Process Safety Management (PSM) systems including OSHAProcess Safety Management“, CCPSRisk Based Process Safety” framework and the Energy InstituteHigh Level Framework for Process Safety Management

OSHA
CCPS
Energy Institute

Supporting guidance makes due reference to key Leading & Lagging Process Safety Performance Indicators (PSPI) from industry sources including IOGP 456 “Process safety – recommended practice on key performance indicators” , API 754Process Safety Performance Indicators For The Refining And Petrochemical Industries” , HSG 254 “Developing process safety indicators: A step-by-step guide for chemical and major hazard industries“ and the IChemE Safety Centre “Lead Process Safety Metrics – selecting, tracking and learning“:

IOGP
API
HSE
IChemE Safety Centre

This deck can be summarised as a framework which is “All for one and one for all” i.e. inclusive and informative with a simple core of:

  • How Dangerous is it ?
    • Determine the Hazards, Events & Risks
  • Make it Safe !
    • Fit for purpose
      • Implement appropriate protection measures (designed to be big enough, fast enough, and strong enough)
  • Keep it Safe !
    • Fit for Duty
      • Ensure operations activity does not disable the protection
      • Ensure permanent modifications do not delete the protection
      • Ensure temporary modifications do not defeat the protection
    • Fit for Service
      • Ensure maintenance inactivity does not allow the protection to degrade.

Images © Process Safety Integrity 2020

Leadership, Culture and Communication

Corporate concepts to facilitate stewardship by empowering and engaging all stakeholders at all stages of the lifecycle.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Employee participation
CCPS
• Process safety culture
• Stakeholder outreach

EI
• Leadership commitment and responsibility
• Workforce involvement
• Communication with stakeholder

Continuous Improvement

Acquiring, analysing, and acting upon relevant leading and lagging process safety performance indicators in conjunction with planned and unplanned (ad-hoc) audits and surveys at all stages of the lifecycle.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Compliance audits
CCPS
• Measurement and metrics
• Auditing
• Management review and continuous improvement

EI
• Audit, assurance, management review and intervention

Information Management

The right process safety information (e.g. drawings, documents, calculations, settings & standards) is available to the right people at the right time.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Process safety information
CCPS
• Process knowledge management
EI
• Documents, records, and knowledge management

Capability Management

Usually referred to as competence but not just limited to mental proficiency e.g. training it includes physical ability e.g. considering work, fatigue and health management (particularly during COVID-19) of all personal at all stages of the lifecycle.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Employee training
CCPS
• Process safety competency
• Workforce involvement
• Training and performance analysis

EI
• Employee selection, placement and competency and health assurance

Process Hazard Analysis

HAZID, HAZOP, PHA etc. are conducted and founded on the corporate appetite for risk and statutory risk criteria.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Process hazard analysis
CCPS
• Hazard identification and risk analysis
EI
• Hazard identification and risk assessment

Process and Plant Design

Strive for inherent safety (ERIC PD principles) where practical, otherwise using RAGAGEP (recognized and generally accepted good engineering practices) and other good and best industry practices to ensure that assets and their protection is properly engineered, installed and commissioned.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• n/a
CCPS
• Compliance with standards
EI
• Identification and compliance with legislation and industry standards
• Standards and practices

Operational Integrity

Ensuring that the process is kept within design conditions and that state transitions (e.g. Startup, Rundown etc) are properly assessed and appropriately manually and/or automatically controlled.

Operating procedures include standard, temporary, abnormal/alarm or emergency/evacuation.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Operating procedures
• Pre-startup safety review

CCPS
• Conduct of operations
• Operating procedures
• Operational readiness

EI
• Management of operational interfaces
• Operating manuals and procedures
• Process and operational status monitoring and handover
• Operational readiness and process start-up

Asset and Protection Integrity

Ensuring that the process containment (primary, secondary and tertiary) is intact and that protection measures (barriers) are fit for service including Human, Active Hardware, Passive Hardware and Continuous Hardware.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Mechanical integrity
CCPS
• Asset integrity and reliability
EI
• Inspection and maintenance
• Management of safety critical devices

3rd Party Management

Usually focusses on contractors, this should include everyone outside the organisation who provides products and/or services to achieve and/or sustain safe processes.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Contractors
CCPS
• Contractor management
EI
• Contractor and supplier, selection and management

Emergency Planning and Response

Includes preparation (plus rehearsal) and the execution of the emergency response not just the management of the situation if/when it occurs.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Emergency planning and response
CCPS
• Emergency management
EI
• Emergency preparedness

Control of Work

Commonly known as a ‘Permit to Work’ system (or PTW), to avoid the misinterpretation that the permit (paper or electronic) is the only element in a ‘Safe System of Work’, the term ‘Control of Work’ is used (whether the hazards are flammable or not i.e. not limited to Hot Work).

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Hot work permit
CCPS
• Safe work practices
EI
• Work control, permit to work and task risk management

Event Investigation

Most commonly this is referred to as ‘Incident Investigation’ however the term ‘event’ is used to include the following:

• Near misses, near hits, close calls or dangerous occurrences.
• Loss of containment/control that did or did not result in the consequence ~ an Accident or Incident.
• Failure of a safety critical element (including human response e.g. alarm) on demand or test.
• Spurious operation/activation of a safety critical element.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Incident investigation
CCPS
• Incident investigation
EI
• Incident reporting and investigation

Management of Change

Evaluation of the potential impact of organisational/personnel, regulatory and/or technical changes (permanent or temporary, physical/hardware or logical/software) on Threats, Barriers or Consequences.

This summarises and/or aligns with the following familiar PSM elements:

OSHA
• Management of change
CCPS
• Management of change
EI
• Management of change and project management


For more information on PSM cards, options & pricing, please contact us.