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Continue Continue Exit Filter FINISH finish Definition definition Glossary Terms Menu Please rotate your device NEXT next Notes Notes Bio More info Captions pause play Send an email PREV previous Question List replay Additional Resources resources Restart Resume Search... search Search in: Search Results Back to top Slide Text SUBMIT ALL submit all SUBMIT submit volume key terms learner activity questions additional resources a guide of symbols used in this course element 2 management of process risk this element will look at the elements of a process safety management system and at risk management techniques used in the industry. it will also explain what a permit to work is used for, and how to select and manage contractors. learning outcomes at the end of the training, you will be able to: 2.1 outline the purpose and importance of establishing a process safety management system and its key elements. 2.2 outline common risk management techniques used in process industries. 2.3 outline asset management and maintenance strategies for process plant. 2.4 explain the role, purpose and features of a permit-to-work. 2.5 explain the key principles of safe shift handover. 2.6 explain the principles of selecting, assessing and managing contractors. 2.1 establishing a process safety management system. 2.2 risk management techniques used within the process industries. 2.3 asset management and maintenance strategies. 2.4 role, purpose and features of a permit-to-work system. 2.6 contractor management. 2.5 safe shift handover. element 2: management of process risk reasons for developing a psms key elements of psms (continued) strong leadership sets direction and determines culture. hazard analysis detailed understanding of process hazards and risks. moc understand consequences before changes are made. operation within design intent under all conditions including start-up and maintenance. competence management ongoing training. control of contractors control of selection and activities. asset integrity maintenance (planned and breakdown). emergency response foreseeable incidents, eg loss of containment. incident recording and investigation investigation to learn lessons. performance monitoring and management review leading and lagging indicators reviewed. review the process safety management systems your company have in place - how many of the elements from the table do you have in place? key elements of psms activity review the process safety management system at your organisation, how many of the elements do you have in place? learner activity think about this and complete the activity on the next slide before progressing. complete close close close close close close click the icon below to download your reflection as a document file and save this for your own records. download download download download download download review the psms at your organisation, howmany of the elements do you have in place? type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> key elements of psms - pdca plan policy. planning. do implementation andoperation. check checking and corrective action. act management review. continual improvement. licence to operate application made to regulators to run process. supply a ‘safety case’ during application: high hazards identified. major accident risks identified and controlled. risks controlled to alarp(as low as reasonably practicable). major accident prevention policy (mapp) what is mapp? your mapp document should set out your policy on the prevention of major accidents: in other words a statement of general intent which includes the aims and the principles you plan to adopt. the mapp document doesn't need to contain a detailed description of your safety management system, however, it should give sufficient detail to show you have systems in place to cover all the aspects required. a mapp document is similar in approach to a health and safety policy, but with two important additions: it must deal specifically with major accident hazards; and it must include measures to protect the environment. major accident prevention policy (mapp) contains: roles and responsibilities; identification of major accident hazards; operational control measures; emergency plans (on and off site); monitoring process; auditing process. key terms leading indicators proactive measurements of conditions that monitor process safety before something goes wrong and to see if things are operating as intended. lagging indicators reactive measures that look at failures, such as the number of injuries, near misses and spills which are reported, or excursions where plant is operated outside of the intended operational envelope. development and implementation of psis determine what can go wrong in the process and identify risk controls to prevent such incidents. establish lagging indicators to measure failure of these risk controls. establish critical actions for each risk control system and develop leading indicators to monitor whether these are working. monitor and review indicators. leading and lagging process safety performance indicators (psis) checks and balances to determine how well the site is managing process safety. effective indicators of process safety: activity consider how the 4 process safety indicators are used in your workplace to monitor process safety. are they leading and lagging indicators? what additional measures could be implemented to manage process safety in a more proactive manner? think about this and complete the activity on the next slide before progressing. learner activity complete close close close close close close click the icon below to download your reflection as a document file and save this for your own records. download download download download download download what additional measures could be implemented to manage process safety in a more proactive manner? type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> are they leading and lagging indicators? type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> write down 4 process safety indicators that are used in your workplace to monitor process safety. type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> key term auditing a systematic, objective, critical evaluation of how well an organisation’s management system is performing by examining evidence. auditing compliance audits: are proactive; check health and safety is managed; check controls are in place and working; identify areas for improvement which can then feed new health and safety plans – continual improvement. auditing compliance read the buncefield explosion and fire report or the buncefield explosion and fire case studies. think is there an effective process safety audit system to verify if the psm is effective and were they being used? auditing compliance findings from the buncefield explosion and fire report ‘effective auditing systems were not in place. auditing and monitoring arrangements focused on whether a system was in place; the audits did not test the quality of the systems and, most importantly, did not check whether they were being used or were effective.’ ‘management systems in place at hosl relating to tank filling were both deficient and not properly followed, despite the fact that the systems were independently audited.’ 2.1 establishing a process safety management system. 2.2 risk management techniques used within the process industries. 2.3 asset management and maintenance strategies. 2.4 role, purpose and features of a permit-to-work system. 2.6 contractor management. 2.5 safe shift handover. element 2: management of process risk activity what do you understand by the term “hazard”? how do we determine the level of risk? think about this and complete the activity on the next slide before progressing. learner activity correct close close close close close close burns or fatality, damage to process plant and equipment. electric shock and burns, fatality; explosion caused by unsuitable electrical equipment or static electricity igniting flammable vapours or dusts. loss of containment. fire, explosion, injury, fatalities. match the risks to the corresponding hazard incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct submit submit submit submit submit submit match the risks to the corresponding hazard burns or fatality, damage to process plant and equipment. electric shock and burns, fatality; explosion caused by unsuitable electrical equipment or static electricity igniting flammable vapours or dusts. loss of containment. fire, explosion, injury, fatalities. key terms hazard something that has the potential to cause harm. risk the likelihood that a hazard will cause harm, in a combination with the severity of injury, damage or loss that might foreseeably occur. purpose and use of risk assessment essential in the management of safety in workplaces. identifies hazards and evaluates risks by considering the likelihood and severity of harm occurring. risk controls are identified, which reduce the risk to an acceptable level. general risk assessments adapted from indg163: five steps to risk assessment basic risk assessment process follows the hse’s five-step approach: advanced risk assessments adapted from: offshore information sheet 3/2006 - guidance on risk assessment for offshore installations qualitative (q) determined as low, medium or high. semi-quantitative (sq) determined within ranges. quantitative (qra) fully calculated based on data. qualitative, semi-quantitative and quantitative risk assessments qualitative, semi-quantitative and quantitative risk assessments qualitative risk assessment (q) determined as low, medium or high. qualitative risk assessment involves making a formal judgement on the consequence and probability using: risk = severity x likelihood semi-quantitative risk assessment (sq) determined within ranges. quantitative risk assessment (qra) fully calculated based on data. quantitative risk assessment (qra) is most commonly used in the process industries to quantify the risks of ‘major hazards’. qra used in the offshore oil and gas industries, the transport of hazardous materials, the protection of the environment, mass transportation (rail) and the nuclear industry. barrier models there are barriers between hazard and loss. an incident only occurs when there is failure in each barrier. sometimes known as the ‘swiss cheese model’. when the holes line up there is an accident (ie the ‘hazard is realised’). the application of risk management tools most effective tools are initially considered at concept and design stage. before start-up, a more complete risk assessment should be carried out. additional controls may be needed during unusual process activities, eg start-up and shut-down. hazard realisation hazard realisation requires the assessor to look at worst-case scenarios. once these are understood, controls can be implemented in the form of ‘barriers’. these barriers can then be placed between the initiator (triggering event) and the potential consequences to either prevent or reduce the outcome. when drawn together, this is known as a ‘bow-tie’ diagram. bow tie model image from ‘offshore information sheet no. 3/2006 guidance on risk assessment for offshore installations, hse, 2006 identify the event you want to prevent: determine the initiating event that can cause it identify barriers that can prevent the release then further barriers to mitigate the consequences hazard and operability study (hazop) multidisciplinary team approach. breaks process into nodes (small chunks). agree parameters to be studied: eg flow, pressure, temperature, etc. agree guidewords to be used: eg more, less, no, reverse. combine guidewords with parameters to create ‘deviations’: more flow, less flow, no flow, etc. identify potential causes and controls. tabular format the hazop findings are recorded in a tabular format and retained as evidence of the study. example extract from a hazop of a domestic shower: hazard identification (hazid) multidisciplinary team approach. brainstorming process. may involve a walkthrough. identifies hazards to feed the risk assessment process. top-down study structured by keywords failure mode effect analysis (fmea) requires a multidisciplinary team to identify: failure modes (ways it can fail); effects (of the failure); severity (impact to the ‘customer’); cause (of the failure mode); occurrence (chance of it happening) detection (what is in place to spot it) determine risk priority (risk priority number: severity × occurrence × detection); recommended actions to be taken, by whom and by when. event tree analysis (eta) can be fully quantified: start with the initiating event. draw a “tree”. for each mitigating control draw potential success or failure as a “branch”. determine the probability of a “safe” outcome. what-if analysis assessor uses risk realisation to identify the true potential of the incident. for example, loss of containment of a flammable liquid could potentially result in fire, explosion, damage, injury and fatality, even if it does not in a particular incident. concept of alarp(as low as is reasonably practicable) cannot reduce all risk to zero. introduce controls to reduce risk to lowest level achievable without incurring disproportionate costs: some flexibility in how to achieve; balance risk vs cost/time/effort. guidance provides information on what is considered alarp. hierarchy of risk controls learn more about hierarchy of risk reduction measures at hse website: https://www.hse.gov.uk/rubber/risk-reduction.htm 2.1 establishing a process safety management system. 2.2 risk management techniques used within the process industries. 2.3 asset management and maintenance strategies. 2.4 role, purpose and features of a permit-to-work system. 2.6 contractor management. 2.5 safe shift handover. element 2: management of process risk asset integrity definition asset integrity can be defined as the ability of an asset to perform its required function effectively and efficiently whilst protecting health, safety and the environment. asset integrity management is the means of ensuring that the people, systems, processes and resources that deliver integrity are in place, in use and will perform when required over the whole lifecycle of the asset. integrity standards consideration of relevant standards at design stage. standards ensure safety and integrity. for example: en iso standards; welding standards; pressure ratings. activity an organisation doesn’t currently have a process to manage and maintain the integrity of plant and process equipment. what arguments could you use to convince the management that such a system is needed? think about this and complete the activity on the next slide before progressing. learner activity complete close close close close close close click the icon below to download your reflection as a document file and save this for your own records. download download download download download download sample answer continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> what arguments could you use to convince the management that such a system is needed? if assets are not maintained correctly, this can result in defects and failures that can have serious health and safety implications. for example: damaged, wearing or defective equipment can fail and cause leaks; equipment can fail, which can affect the performance of the process plant, eg failure of a hot oil system could cause the process to fail; loss of a cooling system could result in a runaway reaction; process plant will become ineffective and production will suffer; safety systems, such as fire suppression, may fail to operate correctly when required. it is far more effective to maintain equipment on a preventive basis, rather than allowing it to become worn to the point of breakdown, and so an effective asset integrity management programme is essential for any plant. scroll to view answer what arguments could you use to convince the management that such a system is needed? type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> key terms asset an item of equipment or an area of production plant asset integrity the ability of an asset to operate as intended effectively and efficiently over its entire lifespan whilst ensuring the health and safety of those exposed to it, including the environment. consequences of failing to manage the integrity of assets damaged, wearing or defective equipment can fail and cause leaks. equipment failure can impact plant safety and productivity. safety systems may fail to operate. breakdown maintenance is expensive and less effective than preventative maintenance. key term atex ‘atex’ is commonly used to refer to the two eu directives that control explosive atmospheres. it is from the french title of the 94/9/ec directive: appareils destinés à être utilises en atmosphères explosibles. atex-approved equipment that is suitable for use in an explosive atmosphere is given a symbol which is shown on the next slide. selection of equipment for the operating environment for example, in potentially flammable atmospheres where vapour or dust can result in fire or explosion, atex approved equipment must be used: considerations include: flammable atmospheres. wet conditions harsh environments (eg salty atmospheres); corrosive chemicals. 1. design designed to be safe. 2. procurement, construction installation and testing build completed correctly. 3. commissioning standards checked and signed off. 4. operations operate within design intent; maintenance and inspection. 5. modifications planned and assessed first. 6. decommissioning safe removal from operations. asset integrity through the lifecycle phases plant maintenance documentation maintenance records retained. some are legally required, eg the statutory records of pressure systems. can be paper or electronic, must be traceable. risk-based maintenance and inspection strategies three types breakdown maintenance. condition monitoring. planned preventive maintenance. must retain records for all! activity which maintenance activities are carried out in your organisation? how do they fit with the three maintenance types? think about this and complete the activity on the next slide before progressing. learner activity correct close close close close close close planned preventive condition monitoring breakdown maintenance use non-destructive testing to identify damage and irregularities in materials to obtain information about the current safety of process plant. monitor motors for noise levels to determine of the bearings are worn. replace a liquid level indicator that failed to work while in use. match the following statements to the correctmaintenance activities. incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct submit submit submit submit submit submit match the following statements to the correctmaintenance activities. replace a liquid level indicator that failed to work while in use. monitor motors for noise levels to determine of thebearings are worn. use non-destructive testing to identify damage and irregularities in materials to obtain information about the current safety of process plant. planned preventive condition monitoring breakdown maintenance correct close close close close close close planned preventive condition monitoring breakdown maintenance carry out preventive maintenance to safety critical equipment. use thermography (thermal imaging cameras) to detect hot spots on equipment that can indicate areas that may be overheating. replacing a safety valve that failed to work while in use. match the following statements to the correctmaintenance activities. incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct submit submit submit submit submit submit match the following statements to the correctmaintenance activities. replacing a safety valve that failed to work while in use. use thermography (thermal imaging cameras) to detect hot spots on equipment that can indicate areas that may be overheating. carry out preventive maintenance to safety critical equipment. planned preventive condition monitoring breakdown maintenance correct close close close close close close planned preventive condition monitoring breakdown maintenance a range of planned maintenance activities. cleaning, lubrication, oil changes, adjustments, repairs, inspecting and replacing parts, and partial or complete overhauls. analyse oils to determine condition, contamination, and machine wear to uncover problems such as degradation, contamination & deterioration. repair the process pipeline that failed to work while in use. match the following statements to the correctmaintenance activities. incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct submit submit submit submit submit submit match the following statements to the correctmaintenance activities. repair the process pipeline that failed to work while in use. analyse oils to determine condition, contamination, and machine wear to uncover problems such as degradation, contamination & deterioration. a range of planned maintenance activities. cleaning, lubrication, oil changes, adjustments, repairs, inspecting and replacing parts, and partial or complete overhauls. planned preventive condition monitoring breakdown maintenance complete close close close close close close click the icon below to download your reflection as a document file and save this for your own records. download download download download download download maintenance activities type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> what preventive maintenance is carried out in your organisation? maintenance activities type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> what condition monitoring is carried out in your organisation? maintenance activities type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> what breakdown maintenance is carried out in your organisation? risk-based calibration of instrumentation an essential activity in the process industries the consequences of neglecting to maintain calibration can cause: failure to meet the quality system; safety risks for employees and customers; poor product quality and loss of reputation; failure to comply with legislation, causing the loss of the license to operate; unexpected downtime; economic losses. the accuracy of measurement instruments drift over time. users must check instruments periodically to see if they have drifted and make adjustments as necessary. process owners should take a risk based approach (sfarp) to establishing calibration and inspection criteria. risk-based calibration of instrumentation activity think of some examples of essential instrumentation in your workplace. would workers die or be injured if the instrument did not read correctly? (confined space entry) think about this and complete the activity on the next slide before progressing. learner activity complete close close close close close close click the icon below to download your reflection as a document file and save this for your own records. download download download download download download give some examples of essentialinstrumentation in your workplace. type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> would workers die or be injured if the instrument did not read correctly? (confined space entry) 2.1 establishing a process safety management system. 2.2 risk management techniques used within the process industries. 2.3 asset management and maintenance strategies. 2.4 role, purpose and features of a permit-to-work system. 2.6 contractor management. 2.5 safe shift handover. element 2: management of process risk activity watch this hse video regarding a hot work on an oil drum containing residual vapour. think can this incident be prevented? learner activity key term permit-to-work system a formal, documented procedure that forms part of a safe system of work. it is commonly used for high-risk work and it documents measures to reduce risks, such as isolations. it is used to ensure that the correct precautions are in place and that all those who need to know about the work are informed. purpose and effective use of a permit-to-work (ptw) used in high-risk activities. part of a safe system of work. communicates hazards and controls to user. links to: risk assessment and task/job safety analysis (used to identify hazards and plan precautions); method statement (describes how (step-by-step) the workwill be done safely). key features of a permit-to-work assesses and controls interfaces with adjacent plant and workers. usually contains: scope of work; duration of work (date and time the permit is valid to/from); identification of hazards; isolation of energy sources and/or process equipment (lock out / tag out ‘loto’) and other controls; links to other open permits; emergency controls and specific controls ie, gas testing; permit acceptance(including verification of their understanding of the risks and control measures) and permit cancellations requirements. interfaces with adjacent plant/ simultaneous operations permit issuer must consider potential impact of works on adjacent plant equipment, and vice versa. if the installation has duty and stand-by plant, then controls must be in place to ensure that these are not worked on simultaneously. can be achieved by issuing permits from a central issuing authority or location. interfaces with contractors permit-to-work process protects both contractors and workers, both should be issued with permits where appropriate. contractors may need to take addition measures, eg induction training. permits should always be issued by the organisation. types of permit-to-work types of permit include: isolation permit/general permit to work; hot work permit; cold work; electrical; confined space; working at height. activity is there a permit-to-work in use at your workplace? have a look at it and see how each of the sections we have discussed are included in the permit. learner activity benefits and limitations of electronic and paper based systems advantages in reducing the amount of paperwork associated with the permit process. before introducing electronic permit system operators must be sure that a suitable system (eg password-protected electronic signatures) is in place to: prevent unauthorised issue or acceptance; permits cannot be issued remotely without a site visit. systems in place to prevent permits already issued from being altered without the alterations being communicated to all concerned; facility for paper permits to be produced for display at the job site; training provided to ensure that operators assess the specific job and do not rely on ‘cutting and pasting’ from other permits; back-up systems available in case of a software failure or power outage. benefits and limitations of electronic and paper based systems circumstances when a ptwis not required not all work requires a permit, eg if the activities: are not on live process plant; do not require isolation or disconnection; do not fall under the other permit activity definitions (i.e. not hot work, confined space, etc.) another safe system of work may be more appropriate. 2.1 establishing a process safety management system. 2.2 risk management techniques used within the process industries. 2.3 asset management and maintenance strategies. 2.4 role, purpose and features of a permit-to-work system. 2.6 contractor management. 2.5 safe shift handover. element 2: management of process risk importance of shift handover importance of safe shift handover transfer of critical information to the incoming shift. failure to do so can have devastating consequences as in piper alpha. two-way communication and joint responsibility joint responsibility of both outgoing and incoming shift leaders. needs time to be done properly. competence workers carrying out shift handovers must: have the right level of technical knowledge, expertise; be able to communicate effectively. review the piper alpha disaster or case study. think is there safe shift handover? the piper alpha disaster in 1988 was caused, in a large part, by the failure to hand information over from one shift to another. in an hse publication, it was said that “there was a breakdown in communications and the permit-to-work system at shift changeover and safety procedures were not practised sufficiently”. this all too tragically illustrated the importance of ensuring that safety critical information is reliably passed from one shift to another. importance of shift handover shift handover requirements shift handover must be: given the highest priority; conducted face to face; done using accurate verbal and written communication (handover logs are useful); based on information needs of incoming staff; given as much time as necessary to allow for questioning, explanation and clarification. typical information shared at shift handover the main issues communicated include: operational status of the plant; emergency situations or incidents; any safety issues; maintenance activities underway/planned; permit-to-work details, especially those still open; operational issues for the incoming shift (eg production plans); planned receipt of hazardous material deliveries; any drills or exercises planned; physical demonstration of plant state. 2.1 establishing a process safety management system. 2.2 risk management techniques used within the process industries. 2.3 asset management and maintenance strategies. 2.4 role, purpose and features of a permit-to-work system. 2.6 contractor management. 2.5 safe shift handover. element 2: management of process risk scale of contractor use within the process industries a ‘contractor’ is an individual or organisation paid to deliver a service without being directly employed. widely used in the process industries for: additional manpower and labour; specialist skills, eg designers, welders, etc. activity identify examples of contractors you encounter in your workplace. think about this and complete the activity on the next slide before progressing. learner activity complete close close close close close close click the icon below to download your reflection as a document file and save this for your own records. download download download download download download give examples of contractors you encounter in your workplace. type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> activity identify factors that could be considered when selecting a contractor and assessing their suitability for use on site. (these might usefully be in a contractor approval checklist). think about this and complete the activity on the next slide before progressing. learner activity complete close close close close close close click the icon below to download your reflection as a document file and save this for your own records. download download download download download download sample answer continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> example factors that could be considered when selecting a contractor: experience in the type of work; trained in specific safety requirements of the environment; suitability of the organisation’s health and safety policy; quality of their risk assessments; suitability of method statements; accident history, including near-miss reporting; enforcement history and prosecutions; health and safety performance monitoring; qualifications of all workers (including managers); membership of a professional body or trade association; selection and management of subcontractors; insurance cover; liaison with clients; references from previous clients. scroll to view answer what factors could be considered when selecting a contractor and assessing their suitability? type your text here… continue >>> continue >>> continue >>> continue >>> continue >>> continue >>> contractor selection assessed for suitability using criteria including: experience in the type of work; trained in specific safety requirements of the environment; suitability of the organisation’s health and safety policy; quality of their risk assessments; suitability of method statements; accident history, including near-miss reporting; (continued) contractor selection enforcement history and prosecutions; health and safety performance monitoring; qualifications of all workers (including managers); membership of a professional body or trade association; selection and management of subcontractors; insurance cover; liaison with clients; references from previous clients. periodic review of contractor safety performance essential to ensure: working to agreed standards. compliance with documentation. the review may include: site inspections; safety tours; meetings to review performance. contractor induction client to advise workers on site-specific hazards and procedures, including: ppe requirements; permit-to-work requirements; accident reporting procedures; near miss and hazard reporting. sign in/out procedures; emergency procedures; site rules; specific site hazards; contractor supervision ownership of contractor activities: include contractors in process risk assessments and safe systems of work. clearly identified person responsible for approval and day-to-day contractor management. contractors should know who theirclient contact is. auditing contractor performance handover to client hand back of plant and equipment. handover of building or installations arising from project. information handed over includes: operation and maintenance manuals; pipework and instrumentation diagrams; updated layout plans, including location of services; design specifications; as-built drawings. siting of contractor accommodation process operators evaluate all newly sited structures under moc and include in the overall pha. temporary accommodation should be based on exclusion zones for areas where explosions are possible. all occupied trailers should be located outside of vulnerable areas, (even if they are moved beyond the facility’s boundary). housing of contractors consideration given to the safe location of contractors on site: facilities and amenities required. located away from high-hazard areas. correct close close close close close close event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). learning check - quiz q1. process organisations have in place a wide range of mitigation measures designed to reduce the consequences of a major incident. which risk management technique is especially suited to assess the effectiveness of these mitigation measures? incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct q1. process organisations have in place a wide range of mitigation measures designed to reduce the consequences of a major incident. which risk management technique is especially suited to assess the effectiveness of these mitigation measures? failure mode effects analysis (fmea). failure mode effects analysis (fmea). failure mode effects analysis (fmea). failure mode effects analysis (fmea). failure mode effects analysis (fmea). failure mode effects analysis (fmea). event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). event tree analysis (eta). risk assessment (ra). risk assessment (ra). risk assessment (ra). risk assessment (ra). risk assessment (ra). risk assessment (ra). hazard identification (hazid). hazard identification (hazid). hazard identification (hazid). hazard identification (hazid). hazard identification (hazid). hazard identification (hazid). quiz submit submit submit submit submit submit correct close close close close close close greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. learning check - quiz q2 which of the following is an example of planned preventive maintenance? incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct q2. which of the following is an example of planned preventive maintenance? daily visual inspections of process plant. daily visual inspections of process plant. daily visual inspections of process plant. daily visual inspections of process plant. daily visual inspections of process plant. daily visual inspections of process plant. greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. greasing of pump bearings. regular sampling of product. regular sampling of product. regular sampling of product. regular sampling of product. regular sampling of product. regular sampling of product. testing of stack emissions. testing of stack emissions. testing of stack emissions. testing of stack emissions. testing of stack emissions. testing of stack emissions. quiz submit submit submit submit submit submit correct close close close close close close objective objective objective objective objective objective learning check - quiz q3 quantitative risk assessment differs from qualitative risk assessment because it is more: incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct q3. quantitative risk assessment differs from qualitative risk assessment because it is more: adaptive. adaptive. adaptive. adaptive. adaptive. adaptive. objective. objective. objective. objective. objective. objective. subjective. subjective. subjective. subjective. subjective. subjective. detective. detective. detective. detective. detective. detective. quiz submit submit submit submit submit submit correct close close close close close close face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. learning check - quiz q4 a preferred method of conducting a shift handover is: incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct q4. a preferred method of conducting a shift handover is: face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. face to face using verbal and written communication. by telephone using verbal communication. by telephone using verbal communication. by telephone using verbal communication. by telephone using verbal communication. by telephone using verbal communication. by telephone using verbal communication. via a log book using written communication. via a log book using written communication. via a log book using written communication. via a log book using written communication. via a log book using written communication. via a log book using written communication. by radio using verbal communication. by radio using verbal communication. by radio using verbal communication. by radio using verbal communication. by radio using verbal communication. by radio using verbal communication. quiz submit submit submit submit submit submit correct close close close close close close evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others learning check - quiz q5 which of the following is the most important consideration when selecting contractors? incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct q5. which of the following is the most important consideration when selecting contractors? proving that they have no previous or pending enforcement actions proving that they have no previous or pending enforcement actions proving that they have no previous or pending enforcement actions proving that they have no previous or pending enforcement actions proving that they have no previous or pending enforcement actions proving that they have no previous or pending enforcement actions providing method statements, risk assessments and safety policies providing method statements, risk assessments and safety policies providing method statements, risk assessments and safety policies providing method statements, risk assessments and safety policies providing method statements, risk assessments and safety policies providing method statements, risk assessments and safety policies evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others evidence of previous safe working and understanding their impact on others membership of a professional body and adequate insurance cover for the work membership of a professional body and adequate insurance cover for the work membership of a professional body and adequate insurance cover for the work membership of a professional body and adequate insurance cover for the work membership of a professional body and adequate insurance cover for the work membership of a professional body and adequate insurance cover for the work quiz submit submit submit submit submit submit q6. consider the scenario below and answer the question on the next slide. two separate work permits had been issued for the maintenance work on a pump. one was for repair of the pump and one was for removal and servicing of the pressure relief valve on the discharge side of the pump. the pump repair had been completed but the servicing of the pressure relief valve had not been completed by the end of the shift. in place of the pressure relief valve a ‘blank’ had been loosely installed. during shift handover, the maintenance work and return to service of the pump was discussed, but no mention was made of the servicing work being carried out on its pressure relief valve. the pump was then started, allowing flammable liquids to leak from the ‘blank’. this vapour cloud ignited, causing a fire. quiz correct close close close close close close a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. learning check - quiz q6 think about the scenario on the previous slide. which of the following actions during shift handover would have been most effective in preventing this accident? incorrect that is incorrect. please try again. try again try again try again try again try again try again incorrect you did not select the correct response. see answer see answer see answer see answer see answer see answer incorrect correct that's right! you selected the correct response. continue continue continue continue continue continue correct q6. think about the scenario on the previous slide. which of the following actions during shift handover would have been most effective in preventing this accident? verbal communication in a quiet place between incoming and outgoing workers. verbal communication in a quiet place between incoming and outgoing workers. verbal communication in a quiet place between incoming and outgoing workers. verbal communication in a quiet place between incoming and outgoing workers. verbal communication in a quiet place between incoming and outgoing workers. verbal communication in a quiet place between incoming and outgoing workers. confirmation of permits signed off as completed confirmation of permits signed off as completed confirmation of permits signed off as completed confirmation of permits signed off as completed confirmation of permits signed off as completed confirmation of permits signed off as completed discussion of the recorded process checks undertaken by the outgoing workers. discussion of the recorded process checks undertaken by the outgoing workers. discussion of the recorded process checks undertaken by the outgoing workers. discussion of the recorded process checks undertaken by the outgoing workers. discussion of the recorded process checks undertaken by the outgoing workers. discussion of the recorded process checks undertaken by the outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. a physical demonstration of the plant state between incoming and outgoing workers. quiz submit submit submit submit submit submit element 2: summary 2.1 establishing a process safety management system. 2.2 risk management techniques used within the process industries. 2.3 asset management and maintenance strategies. 2.4 role, purpose and features of a permit-to-work system. 2.5 safe shift handover. 2.6 contractor management. end of element 2 <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>In practice, the PDCA model means having the above components in place.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>In practice, the PDCA model means having the above components in place.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>ALARP – as low as reasonably practicable</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Sandy: Additional resource https://www.hse.gov.uk/comah/background/comah15.htm#:~:text=COMAH%20aims%20to%20prevent%20and,seriously%20as%20those%20to%20people.</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'></textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>MAJOR ACCIDENT PREVENTION POLICY (MAPP) AND SAFETY MANAGEMENT SYSTEM (SMS) ASPECTS OF SAFETY REPORT ASSESSMENT</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>https://www.hse.gov.uk/comah/sram/docs/s11.pdf</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Diagram: Main stages in the risk assessment process </textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Identify the event you want to prevent:</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>• Determine the initiating event that can cause it</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>• Identify barriers that can prevent the release</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>• Then further barriers to mitigate the consequences</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'></textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>Image based on offshore information sheet No. 3/2006 Guidance on risk assessment for offshore installations, HSE, 2006</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>(www.hse.gov.uk/offshore/sheet32006.pdf)</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Can be fully quantified:</textformat><textformat leading='0' tabstops='[0, 37, 48, 96, 144]'>•Start with the initiating event.</textformat><textformat leading='0' tabstops='[0, 37, 48, 96, 144]'>•Draw a “tree”.</textformat><textformat leading='0' tabstops='[0, 37, 48, 96, 144]'>•For each mitigating control draw potential success or failure as a “branch”.</textformat><textformat leading='0' tabstops='[0, 37, 48, 96, 144]'>•Determine the probability of a “safe” outcome.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Breakdown maintenance is expensive and less effective than preventative maintenance as there is already a loss.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Tutor notes: ‘ATEX’ is commonly used to refer to the two EU directives which control explosive atmospheres. It is from the French title of the 94/9/EC directive: Appareils destinés à être utilisés en ATmosphères EXplosibles, and ATEX-approved equipment which is suitable for use in an explosive atmosphere is given the above symbol.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Here get the group to think about what they do and give examples. Thermography to identify hot spots on electrical panels is condition monitoring, planned overhaul of a safety valve is planned maintenance, etc.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Here get the group to think about what they do and give examples. Thermography to identify hot spots on electrical panels is condition monitoring, planned overhaul of a safety valve is planned maintenance, etc.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Here get the group to think about what they do and give examples. Thermography to identify hot spots on electrical panels is condition monitoring, planned overhaul of a safety valve is planned maintenance, etc.</textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Example high-risk activities include: </textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>Hot-work</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>Work on complex plant</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>Confined space working</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>Work on high voltage electrical systems</textformat><textformat leading='0' tabstops='[0, 48, 96, 144]'>Excavations near buried services. </textformat></html> <html><textformat leading='0' tabstops='[0, 48, 96, 144]'>Permit acceptance and cancellations is inclusive of issue; receipt; clearance/return to service; cancellation. </textformat></html> ALARP means that the risk hasn’t just been reduced, but is now at the lowest level that can be achieved without incurring disproportionate costs (costs can be financial, time, effort and inconvenience). An item of equipment or an area of production plant. The ability of an asset to perform its required function effectively and efficiently whilst protecting health, safety and the environment. Controls that can be put in place between the initiator (the triggering event) to either prevent if from happening or to mitigate the outcome. Also see Bow-Tie model and Hazard realisation. Used with ‘hazard realisation’. As the hazard realisation is worked through then ‘barriers’ can be identified that can be placed between the initiator (the triggering event) to either prevent it from happening or to mitigate the outcome (also known as layers of protection or defence. When these are drawn together this is known as a bow-tie. Hazardous places are classified in terms of zones on the basis of the frequency and duration of the occurrence of an explosive atmosphere: Zones 0-2 relate to gas/vapours/mists and Zones 20-22 to dusts. The ability to undertake responsibilities and to perform activities to a relevant standard, as necessary, to ensure process safety and prevent major accidents. Competence is a combination of knowledge skills and experience and requires a willingness and reliability that work activities will be undertaken in accordance with agreed standards, rules and procedures. A contractor is anyone you get in to work for you who is not an employee. A reaction is called endothermic if energy (heat) is absorbed during the reaction. Used to evaluate the mitigation measures that will operate after an event. The process starts with an initiating event and works forward in time to see what protective measure will operate. Each control will either be a success or a failure and, in this way, branches are built up on tree. A reaction is called exothermic if energy (heat) is released during the reaction. One or more deliberate points of weakness are included in process plant; it they are of suitable size and in the right place, they will safely vent an explosion with the plant. A substance has the risk of exploding in the right mixture with oxygen and if sufficient energy is available. A study often used to brainstorm how a component or a system might fail, the potential effects/consequences of those failures, existing safeguards against those failure modes and whether more should be in place. The property of a substance (usually gas or liquid (or the vapour above the liquid)) to ignite when sufficient energy is applied in the form of heat. The minimum temperature at which a liquid, under specific test conditions, gives off sufficient flammable vapour to ignite momentarily on the application of an ignition source. An advanced risk assessment. It is a very thorough analysis of a process to identify ways in which the process could deviate from its design intention in order that controls can be developed. It is usually chaired by an independent HAZOP leader and involves a multidisciplinary team of designers, engineers, safety professionals, operators and other specialists. A brainstorming activity to identify hazards before changes are made to existing processes and plant (sometimes called a walk-through). In hazard realisation, the assessor looks at ‘the worst-case scenario’ to understand the potential consequences of the hazard so that controls can be implemented in the form of barriers. Reactive measures that look at failures such as the number of injuries, near misses and spills which are reported, or excursions where plant is operated outside of the intended operational envelope. Proactive measurements of conditions that monitor process safety management before something goes wrong and to see if things are operating as intended. The minimum concentration of vapour in air below which propagation of a flame will not occur in the presence of an ignition source. Also referred to as the lowerflammable limit or lower explosive limit. The property of a substance to readily accept electrons from another substance. A formal recorded process used to control work which is identified as potentially hazardous. It is also a means of communication between site/installation management, plant supervisors and operators and those who carry out the hazardous work. Any activity involving a highly hazardous chemical including use, storage, manufacturing, handling, or the on-site movement of such chemicals, or combination of these activities. Any group of vessels that are interconnected, & Separate vessels which are located such that a highly hazardous chemical could be involved in a potential release. The above all considered a single process. A blend of engineering and management skills focused on preventing catastrophic accidents and near misses, particularly structural collapse, explosions, fires and toxic releases associated with loss of containment of energy or dangerous substances such as chemicals and petroleum products. These engineering and management skills exceed those required for managing workplace safety (Adapted from Centre for Chemical Process Safety of the American Institute of Chemical Engineers) The limits of the operating conditions under which a process can take place safely. Typically, process limits are established by setting upper and lower levels for a range of parameters. A document step-by-step instruction on how to conduct specific parts of the operating process. It sets out the way a certain task or activity is done so that mistakes which might lead to a situation where the safe operating envelope could be breached are avoided. The overall purpose of the SOP is to identify and maintain the operating parameters such as pressure limits, temperature range, flow rates etc at the required safe level. The terms used to describe the transfer of information between a shift who are leaving work and incoming new shift. A reaction that is out of control because the rate of heat generation by an exothermic chemical reaction exceeds the rate of cooling available. The maximum concentration of vapour in air above which the propagation of a flame will not occur. Also referred to as the upper flammable limit or the upper explosion limit. In ‘what-if analysis of risk realisation, the assessor asks, 'what-if' and then digs deeper to look at the true potential of an incident.