Improving process safety by addressing the human element

Abstract

Celanese had several process safety incidents and near misses in 1996. Although there were several root causes, this article will address only one of them; human error. The system which was developed by Celanese to improve this human element is the conduct of operations system. The conduct of operations system has improved process safety performance of the human element by focusing on three operational areas: training, procedures, and general operations. Conduct of operations is a proactive approach to improve the current practices, improve the support systems and the behavior of the operator. The benefits include the following: Consistent application of training and procedures Reduction in human error, and Less process safety incidents This article will describe the need for and the content of conduct of operations system as implemented by Celanese. © 2009 American Institute of Chemical Engineers Process Saf Prog, 2009

Why process safety programs sometimes fail

“…The recommended process safety practices referenced in this article will reduce incidents associated with loss of containment but it will also improve production uptime, improved product quality, increase investor confidence, and generate higher profits—all the result of an improved process safety culture. The following Process Safety Progress articles provide additional information about process safety program performance [1–5].…”

Process Safety Management (PSM) for managing contractors in process plant

“…Many emphasize the importance of having a good safety program but do not describe how to achieve it (Haesle, Devlin, & Mccavit, 2009;Klein, 2005;J. Louvar, 2010).…”

Walk the Line

“…Do not assume that operators know these things. Clearly define the operator's responsibility and train for various OD tasks . In addition to those previously mentioned, other tasks related to energy control are discussed below and include (but are not limited to): Proper development of shift notes and making shift relief Reading and following operating instructions Practicing two‐way communication Developing comprehensive line labeling Learning how to complete an effective equipment evaluation round Returning equipment from maintenance Bypassing equipment Communication of abnormal operations …”