An approach to help a company reduce duplication of its management efforts as it improves its process safety performance is described in the CCPS book “Guidelines for Integrating Management Systems and Metrics to Improve Process Safety,” scheduled to be published in 2015. This article provides an overview for the book, describing how a company can identify and prioritize its process safety‐related risks across its separate safety, health, environmental, quality, and security groups (SHEQ&S), helping ensure that decisions made at any level in the company, whether corporate, regional, or local, do not increase its overall risk. An example showing some metrics affecting process safety performance across the SHEQ&S groups is provided to help the reader apply this approach to their organization. The Guideline addresses the risk reduction efforts and complex interaction between these groups, focusing on process safety‐related metrics that cross the different SHEQ&S group boundaries. This book combines the Plan, Do, Check, Act management life cycle approach, the Bow Tie barrier analysis risk reduction approach, the Risk‐Based Process Safety concepts and applies recent advances for identifying and implementing process safety‐related metrics. The bottom line: A company can improve its overall process safety performance using process safety‐related metrics in an integrated SHEQ&S management system. © 2014 American Institute of Chemical Engineers Process Saf Prog 34: 259–266, 2015
Companies often have multiple ‘sister’ plants in different locations, sometimes scattered around the globe. Generally, these companies are striving for similarly low risk among all these sister plants, even though they may have been built at different times, using evolving technology, and often have different capacities. In the pursuit of achieving acceptably low risk at all the chemical plants within a company, Process Safety specialists tend to put each under the PHA ‘microscope’ separately. FMC has several businesses that operate multiple “sister” plants, and has found that there are substantial benefits to be gained by also comparing the hazards at similar plants. © 2009 American Institute of Chemical Engineers Process Saf Prog, 2010
Current modifications will dramatically reduce the complexity of the East Leman Unit production platforms. They include by-passing all the major processing facilities on the platforms and installing new utility packages to support an unmanned operation. This has enabled the frequency of platform visits and the cost of future maintenance to be minimised.
Like most U.S. chemical companies, you probably know where your security-sensitive inventories are located within your sites and have assured yourself that you have taken reasonable precautions to reduce the risk of their being used in a terrorist attack. What about when you ship them? How secure are the various parts of your value chain-offsite storage and transportation of your products, raw materials, intermediates, and wastes, and processing of ordering and invoicing transactions? Value chain security focuses on tampering and misuse of materials handled outside the plant boundaries.At FMC, we took a three-stage approach to identifying and dealing with potential security issues posed by materials in transit. Stage 1 was a quick review to determine which of our products, intermediates, or raw materials might be potentially useful to terrorists. In Stage 2 we looked for specific security-emergency scenarios that might involve those chemicals, estimated the risk of those scenarios, and made recommendations to reduce the vulnerability to terrorist attack. In Stage 3 we are implementing the plans we developed.FMC's approach has successfully focused our efforts and used familiar techniques to break down complex Value Chains into manageable sections and then to identify the possible scenarios and (relative) risks at each section. We were able to do this with minimal travel costs. This paper describes the general organization of FMC's value chain security efforts and our analysis technique, and discusses lessons (including a few surprises) that we have learned from the analyses.
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