GUIDELINES FOR IMPLEMENTING PROCESS SAFETY MANAGEMENT SYSTEMS

The causes of catastrophic accidents in the process industries, now recognized as complex and interrelated, need to be matched by multi-faceted technical management systems. These principles apply to companies of any size and to a full range of industries beyond the chemical industry, such as pulp and paper, electronics, oil and gas. This book supplements the systematic approach to process safety management set out in previous CCPS publications -- A CHALLENGE TO COMMITMENT, GUIDELINES FOR TECHNICAL MANAGEMENT OF CHEMICAL PROCESS SAFETY, and PLANT GUIDELINES FOR TECHNICAL MANAGEMENT OF CHEMICAL PROCESS SAFETY.

The CENTER FOR CHEMICAL PROCESS SAFETY (CCPS), an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has been a world leader in developing and disseminatinginformation on process safety management and technology since 1985. CCPS has published over 80 books in its process safety guidelines and process safety concepts series. For more information, visit www.ccpsonline.org.

Preface.

Acknowledgments.

List of Tables, Figures, and Appendices.

1. Introduction.

1.1 Overview and Objective of This Book.

1.2 Scope.

1.2.1 What Kinds of Companies and Operations Are Covered?

1.2.2 What Information IS in This Book? What is Not?

1.3 How to Use This Book.

2. Get Management Commitment.

2.1 Why Get Management Commitment?

2.2 Getting Top-Level Commitment.

2.2.1 Selecting the Right Sponsor(s).

2.2.2 Selling the Need for PSM.

2.2.3 Selling the Need for Top-level Commitment.

2.3 Using Top-Level Commitment.

2.3.1 Setting Goals for PSM.

2.3.2 Communicating the Importance of PSM.

2.3.3 Providing Resources.

Appendix 2-1 Sample Document Presenting PSM to Senior Management.

3. Define Goals.

3.1 Introduction.

3.2 Select PSM Framework.

3.2.1 CCPS Model.

3.2.2 Other Models.

3.3 Establish a PSM Team.

3.3.1 Who Should Be on the Ream?

3.3.2 How Should This Team Work?

3.3.3 Soliciting Team Members’ Participation.

3.3.4 Scheduling and Organizing the First Meeting.

3.3.5 Conducting Team Meetings.

3.4 Define Company-Specific Attributes.

3.4.1 Characterize Company Management System Approach.

3.4.2 Define Supervision/Delegation Approach.

3.4.3 Define Documentation Approach.

3.4.4 Define Communication Approach.

4. Evaluate the Present Status.

4.1 Recognize the Objective.

4.2 Select an Evaluation Too.

4.2.1 Audits.

4.2.2 Surveys.

4.3 Perform the Evaluation.

4.4 Identify Gaps and Overlaps.

5. Develop a Plan.

5.1 Review the Preliminary Plan.

5.2 Select an Implementation Strategy.

5.2.1 Companywide Approach.

5.2.2 Facility-Specific Approach.

5.2.3 “Hybrid” Approach.

5.3 Define Priorities.

5.3.1 Priority Facilities.

5.3.2 Priority Elements.

5.3.3 Limitations on the Scope of the Plan.

5.4 Estimate Resource Needs and Schedule.

5.4.1 Develop a Program Plan.

5.4.2 Develop a Schedule.

5.4.3 Develop a Resource Plan.

5.5 Communicate and Get Approval of the Plan.

Appendix 5-1. Example Facility Ranking Process.

Appendix 5-2. Example of Management Presentation on PSM Plan.

6. Develop Specific Process Safety Management Systems.

6.1 Select and Approach.

6.1.1 Total Quality Management (TQM) Techniques.

6.1.2 Using Model Programs.

6.1.3 Business Process Redesign.

6.2 Select a Team.

6.3 Develop the System.

6.4 Recheck against Criteria.

7. Put the System into Practice.

7.1 Pilot Testing.

7.1.1 Factors to Consider in Pilot-Site Selection.

7.1.2 Gaining Local Support for the Pilot Test.

7.1.3 Implementing a Successful PSM Pilot.

7.1.4 Assessing Pilot Test Results.

7.2 Plan and Manage Installation.

7.2.1 Where to Begin Installation.

7.2.2 Who Should Manage Installation.

7.3 Sell the System.

7.3.1 Describe System Benefits.

7.3.2 Reinforce Buy-In from Management.

7.3.3 Reinforce Buy-In from Participants.

7.4 Design and Provide Training.

7.4.1 Training Managers.

7.4.2 Training Trainers.

7.4.3 Training Users.

7.4.4 Training Others (e.g., Contractors).

7.4.5 Training Methods and Tools.

Conclusion.

8. Measure and Monitor Installation.

8.1 Introduction.

8.2 Monitor Installation.

8.2.1 Plant-Level Monitoring.

8.2.2 Companywide Monitoring.

8.3 “Customer Feedback” and Follow-Up.

Conclusion.

9. Expanding Beyond Initial Scope.

9.1 Introduction.

9.2 Expanding Beyond Minimum Requirements.

9.3 Involve Other Activities.

9.4 Involve Other Functions.

9.5 Expand to Other Processes.

9.6 Expand Internationally.

9.6.1 Evaluate Local Needs.

9.6.2 Establish Priorities.

9.6.3 Match Systems to Local Needs.

Epilogue.

Case Study in Implementing Process Safety Management.

Background.

Introduction.

Getting Management Commitment.

Defining Goals.

Evaluating the Present Status.

Developing a Plan.

Developing Specific PSM Systems.

Putting the System into Practice.

Measuring and Monitoring.

Expanding Beyond Initial Scope.

Bibliography.

Index.