Process Safety Management.

Format:

Book

Author/Creator:

Sutton, Ian.

Language:

English

Subjects (All):

Industrial safety.

Risk management.

Physical Description:

1 online resource (860 pages)

Edition:

1st ed.

Place of Publication:

Chantilly : Elsevier, 2025.

Summary:

Process Safety Management offers comprehensive and practical guidance for developing and implementing process safety in design, operations, and maintenance of existing facilities by the concepts of process safety management (PSM) through detailed definitions, examples, historic perspectives and case-studies related to process safety.

Contents:

Front Cover

Process Safety Management

Copyright

Contents

Preface

1 - The Process Safety Discipline

Standard Examples

Example #1: Process Flow

Example #2: Shell and Tube Heat Exchanger

Example #3: Tank Bund Wall

Defining Process Safety Management

Justification for Process Safety

Other Types of Safety

Prescriptive/Nonprescriptive

Risk-Based Management

Safety Layers

Compliance

Complicated and Complex Problems

Process Safety Management Elements

The "Most Important" Element

Order of Implementation

Systems

High-Consequence Incidents

Flixborough, U.K. (1974)

Three Mile Island, United States (1979)

Bhopal, India (1984)

Piper Alpha, U.K. (1988)

Deepwater Horizon, U.S. (2010)

Fukushima-Daiichi, Japan (2011), U.S. (2010)

Safe Limits

Incompatible Chemicals

Operating, Safe and Emergency Limits

Finding the Safe Limits

Set Point Values

Working With People

Health, Safety &amp

Environmental (HSE) Programs

Safety

Environmental

Health

Measuring Progress

Other Management Programs

Nuclear Power

ISO 9000/14001

Six Sigma

Just in Time/Lean Management

Supply Chain Management

Operational Excellence

The Process and Energy Industries

Chemicals and Petrochemicals

Oil Refineries

Offshore Oil and Gas

Lack of Escape Routes

Persons on Board (POB)

Extensive Use of Contractors

Cyclones/Hurricanes

Downers and Leaners

Blowouts

Dropped Objects

Helicopters

Ship Collision/Mooring Failure

Pipelines

Process Boundaries

The Meer Decision

Meaning of the Word "Process"

OSHA Update #8. Defining the Limits of a PSM-Covered Process

Reference

2 - Risk Analysis and Management

Components of Risk

Hazards

Consequences

Predicted Frequency.

Quality of the Results

Safeguards

Presence of Persons

Large Facilities

Overall Risk

Subjective Nature of Risk

Degree of Control

Familiarity with the Hazard

Direct Benefit

Personal Impact

Natural versus Man-Made Risks

Recency of Events

Perception of the Consequence Term

Comprehension Time

Randomness

Black Swan Events

Law of Unintended Consequences

Acceptable Risk

As Low as Reasonably Practicable Risk (ALARP)

De Minimis Risk

Citations/Case Law

Risk Matrices

Consequence Matrix

Worker Safety

Public Safety and Health

Environmental Impact

Economic Loss

Frequency Matrix

Risk Matrix

A-(Red) Very High

B-(Orange) High

C-(Yellow) Moderate

D-(Green) Low

Other Categories

Limitations of Risk Matrices

Low-Hanging Fruit

Prepare for the Worst Case

Expensive Good Ideas

Indexing Methods

Level 1: Normal Operations

Level 2: Procedural Safeguards

Level 3: Safety Systems

Passive Safety Systems

Active Safety Systems

Administrative Safety Systems

Level 4: Mechanical Safeguards

Level 5: Passive Safeguards

Level 6: Emergency Response

Risk Management

References

3 - Regulations and Standards

A Standards Hierarchy

The Regulator's Dilemma

OSHA's Process Safety Regulation

Application and Scope

Definitions

Chemical Threshold Quantities

Low Concentrations

Flammable Materials

The Chevron Doctrine

The OSHA Update

The EPA's Risk Management Program

Safety and Environmental Management System (SEMS)

UK HSE/COMAH

Safety Cases

Codes and Standards

Engineering Standards

Company Standards

Trade Secrets

4 - Process Safety Culture

Culture Themes

Maintain a Sense of Vulnerability

Normalization of Deviance

Risk Assessments

Independent Role for Safety.

Open Communication

Elements of Culture

Leadership Commitment

Employee Participation

Continuous Learning

Continuous Improvement

Accountability and Blame

Confidential Reporting

Shortcuts

Unrealistic Stretch Goals

Production Creep

Production Records

Initiative Overload

Excessive Cost Reduction

Reduction of "Non-Essentials"

Reductions in the Work Force

Flattened Organizations

Aging Infrastructure

Outsourcing

Not Enough Time for Detailed Work

Organizational Spread

Belief that "It Cannot Happen Here"

Lack of Direct Experience

Good Occupational Safety Performance

Lack of Imaginative Thinking

Failure to Learn from Near Misses

Failure to Draw on Experience Elsewhere

Overconfidence Based on Rule Compliance

Team Player Culture

Fear of Litigation

Mergers, Acquisitions and Divestitures

OSHA Update #11. Employee Participation and Stop Work Authority

Guidance

Stop Work Authority

5 - Process Safety Information

Regulations

OSHA

SEMS

Flowsheets

Block Flow Diagrams

Process Flow Diagrams

Materials of Construction Table

Piping and Instrument Diagrams (P&amp

IDs)

Equipment and Line Designations

Instrument Designations

Updating P&amp

IDs

Design Stages

Iconic Flow Diagrams

Maps/Plot Plans

One-line Diagrams

Personal Schematics

Equipment Data Sheets

Maximum Allowable Working Pressure

Safety Data Sheets

Safety Critical Items

Safety Instrumentation

Priority 1

Priority 2

Priority 3

Alarms, Trips and Interlocks

Safety Instrumented Systems

Hazardous Chemicals

Hydrogen Sulfide

Chlorine

Sulfur Dioxide

Management of Information

OSHA Updates

OSHA Update #4. Reactive Chemical Hazards

OSHA Update #5. Highly Hazardous Chemicals.

OSHA Update #6. Explosives and Blasting Agents

OSHA Update #13. Updating Collected Information

6 - Hazards Analysis

Methodology

Periodic Analyses

Analysis Report

Hazards Analysis Process

Step 1. Identify the Hazards

Step 2. Risk Rank

Step 3. Eliminate or Substitute the Hazard

Step 4. Remove the People

Step 5. Reduce the Consequence

Step 6. Reduce the Likelihood

Step 7. Install Safeguards

Types of Hazard Analysis

Creative/Imaginative Techniques

Experience-Based

Logical/Rational

Organization of a Hazards Analysis

Charge/Scope Letter

Objective

Physical Scope

Method(s) to be Used

Assigned Personnel

Risk Management Guidance

Schedule and Reporting

Basic Assumptions

Utilities/Skid-Mounted Units

Abandoned and Unused Equipment

Preparations

Meeting Protocol

Location of the Meeting

Projection of Notes

Documentation Requirements

P&amp

ID Reviews

Security of the Information

Time Required

Kick-Off and Close-Out Meetings

Walk Abouts

The Team

Leader/Facilitator

Casual Remarks

"If we had Unlimited Money"

Generalizations

Team Management

Knowledge of Actual Incidents

Lawyer-Like Behavior

Persona

Personal Preparation

The Scribe

Operations/Maintenance Expert

Process and Instrument Experts

Specialists

Use of Sophisticated Language

The Hazard and Operability Method (HAZOP)

Step 1. Node Selection and Purpose

Step 2. Process Guideword/Safe Limits

Step 3. Identification of Hazards and their Causes

Step 4. "Announcement" of the Hazard

Step 5. Consequences

Step 6. Identification of Safeguards

Step 7. Predicted Frequency of Occurrence of the Hazard

Step 8. Risk Rank

Step 9. Findings

Step 10. Next Process Guideword/Node.

HAZID/Major Hazards Screening

Checklists

Checklist Categories

Structure of a Checklist

The What-If Method

Node/Functional Area Review

Equipment and Function Review

Ignition Source Controls

Instrumentation and Control Systems

Operations Response

Process Upsets

Siting

Utility Systems

Batch Processes

Operating Procedures

Layout Reviews

What-If/Checklist

Failure Modes and Effects Analysis (FMEA)

Primary, Secondary and Command Failures

Catastrophic, Degraded and Incipient Failures

Real Failures/Necessary Replacements

Qualitative Fault Tree Analysis

LOPA

IPLs

Specific

Independent

Dependable

Auditable

LOPA Organization

Single Scenarios

Implementing LOPA

Bow-Tie Analysis

Cause and Effect Charts

Revalidation Hazards Analyses

Thought Experiments

Results of the Analysis

Recommendations

Action Items

Risk Register

Finding Number and Date

Hazard

Source

Consequence(s)/Likelihood/Risk

Follow-Up

The Hazards Analysis Report

Completeness of the Notes

Cross-Reference

Anonymity

Findings Terminology

Completeness and Appearance

"Non-findings"

Report Distribution

Communication with the Public

Table of Contents

Disclaimer

Executive Summary

Objectives of the Analysis

Summary of Findings

Method Used

Risk Ranking

Regulations and Standards

Attachments

Publishing the Report

Step 1. Notes Clean-Up

Step 2. Team Review

Step 3. Draft Report

Step 4. Client/Management Review

Step 5. Final Report

Step 6. Risk Register

Legal Issues

Special Issues

Need to Act on Findings

Informal Notes

Internal Communication

Leadership Qualification

Special Types of Hazards Analysis

Interface Hazards Analysis

Temporary and Transient Operations

Transportation.

Decommissioning/Demolition.

Notes:

Description based on publisher supplied metadata and other sources.

Part of the metadata in this record was created by AI, based on the text of the resource.

Other Format:

Print version: Sutton, Ian Process Safety Management

ISBN:

9780443340284

OCLC:

1551920171