process safety management leadership challenges dutta.pdf · process safety management &...
TRANSCRIPT
Process Safety Management
&
Leadership Challenges
Hirak Dutta Executive Director-OISD
Maintenance Integrity
Operational Integrity
Design Integrity
Asset Integrity
Process Safety Management
Process Safety Management
Accidents do not happen just like
that…
Prior to any major accident there are always warning signs which, had they been responded to, would have averted the incident.
But they weren’t.
They were ignored.
Very often there is a whole culture of denial operating to suppress these warning signals.
Professor Andrew Hopkins
Warning signals
Process equipment not functioning as intended.
Frequent process excursions outside the safe operating envelope.
Continuing Operation with impaired safeguards.
Critical safety systems kept in bypassed mode or not functioning as intended or not tested.
Frequent process upsets.
Tolerance to failure to follow company’s systems and procedures.
Failure to learn from previous incidents.
Minor incidents not being reported.
Repeat findings occur in the subsequent audits.
Flixborough (1974)
Mexico (1984)
7
Ignoring
Warning Signals
Piper Alpha 1988
Jaipur Terminal(2009) Buncefield (2005)
GAIL (2014)
Process Safety Management
Process Safety must always be kept in focus like HSE.
Good Personal Safety is not equal to Process Safety.
Hazards are easy to spot on site walkouts but process safety requires technical knowledge & understanding of process and analytical techniques & understanding human behaviour.
Effective process safety provides deep understanding of hazards & safeguards to control risks - terminate, treat, transfer or tolerate.
PSM is a state of mind and requires a continuous commitment.
There had been general improvement in understanding of independent protection layers & PSM issues but implementation of PSM is weak.
What are the
Leadership Challenges?
Process Safety Management
Need leaders who can live with a chronic sense of unease.
Leaders who can spot the warning signals of complacency creeping in.
Leaders who are willing to sit with peers, subordinates and understand the process safety issues.
Leaders who are willing to go out on plant visits and conduct safety tours, audits or inspections?
Leaders who actively work to remove barriers to the reporting of ‘Bad News ’ & promote an open culture for communicating process safety issues.
Process Safety Management
Leaders who include process safety on the agenda for all Board Meetings.
Leaders who prioritize long term process safety assurance over & above short term budget restrictions and profitability.
Leaders who ensure that incentive scheme don’t encourage production at the expense of process safety?
Systems & procedures will work if properly explained, well communicated, understood by everyone and monitored by Senior Management
Leaders who move away from individual to institutional approach.
Process Safety Management
Chronic sense of Unease
• Memory fades • People do not remember • People change & move on • Accidents continue to
happen
High reliability organizations lack any sense of complacency – Yesterday’s good safety record does not
guarantee accident won’t happen.
Process Safety Management
Strong
response to weak signals
• Set threshold for intervening very low
• Doesn’t seem right – likely to stop operations
• Investigate
High reliability organizations accept a much higher level of false alarms.
Process Safety Management
Four (04) basic principles:
Human errors are inevitable,
Blaming an error suppressing systemic deficiencies,
Even minor errors are due to failure of the system,
Accident investigation & error prevention go hand in hand.
Process Safety Management
Process Safety as an all-inclusive effort: Ensure everybody has adequate knowledge on
Process Safety,
Include root cause analysis & lessons learned,
Institutionalize the learning process, Proactive asset management,
Update layers of protections,
Focus on Leading indicators,
Comprehensive hazard assessment.
Process Safety Management
Two Mantras for success:
Listen to the plant
And
Listen to people
Safety
Corner Stones of Safety
Employee Engagement
Managing Asset Integrity
Risk Assessment & Hazard Study
Adherence to System & Procedures Accident Incident Analysis
Management of Change
Thank You
Questions???