Operational discipline in practice

Abstract

A general guideline to improve operational discipline is required. Operational discipline can be improved with simple things such as floor level meeting (FLM), job cycle check (JCC), risk assessment (RA), daily safety audit (DSA), consequence analysis (CA), mechanical integrity (MI), incident investigation (II), management of change (MOC), behavior observation (BO), pre-start up safety reviews (PSSR), process hazard analysis (PHA), job risk assessment (JRA), quantitative risk assessment (QRA), and process safety management (PSM) implementation. This article presents risks identified from floor level meetings, steps for job cycle check and risk sensitivity and procedure for daily safety audit and behavior observation audit. Consequence analysis, pre-start up safety review and why tree analysis are discussed for improving operational discipline. Inclusion of consequence analysis in work instructions is discussed.Procedure for accident investigation is elaborated by investigating trainee unit shift engineer (USE) burning injury accident and why tree diagram is constructed and findings and recommendations are provided. PHA techniques (HAZOP, Failure Mode and Effect Analysis) methodology is presented to enhance operational discipline. This article is especially for those industries which are located in countries where PSM implementation is not mandatory and they are lacking in operational discipline.

Implementation guide for process safety management

“…These forms are shown in Figure 7. Incident investigation report form, floor level meeting form, consequence analysis form, job cycle check, mechanical integrity form, risk assessment work instruction wise, management of change form and daily safety audit form are presented in our earlier publication 18 which can be used as such or modified according to operations of a specific industry. Incident investigation report form 18 need to be completed after the incident and previous incidents may be investigated for learning and why tree analysis technique 19 may be used to identify which management systems failed during the incident.…”

“…Incident investigation report form, floor level meeting form, consequence analysis form, job cycle check, mechanical integrity form, risk assessment work instruction wise, management of change form and daily safety audit form are presented in our earlier publication 18 which can be used as such or modified according to operations of a specific industry. Incident investigation report form 18 need to be completed after the incident and previous incidents may be investigated for learning and why tree analysis technique 19 may be used to identify which management systems failed during the incident. Floor level meetings should be weekly and involve operators, engineers, senior engineers and in charges.…”

“…Floor level meetings should be weekly and involve operators, engineers, senior engineers and in charges. Consequence analysis 18 need to be performed once for all equipment at plant. Job cycle check forms need to be completed for all operational activities and should be consulted prior to performing operational job.…”

“…Management of change form should be completed prior to any change, permanent or temporary. Daily safety audit 18 should be performed daily and tentative schedule may be prepared for supervisors, engineers, senior engineers and in charges.…”

Integrated Hazard Identification (IHI): A Quick Accident Analysis and Quantification Method for Practitioners

“…An analysis of 400 operational incidents was reported by Rashid et al and concluded that process hazard analysis (PHA) has 16% share as a root cause or contributing factor in the considered incidents [8] . PHA role in enhancing operational discipline is discussed in another study [9] . In another work, Rashid et al has discussed significance of PHA, complications in performing PHA and hazardous scenarios which needs to be considered for conducting PHA [10] .…”