Guidance on Process Safety Performance Indicators

7/28/2019 Guidance on Process Safety Performance Indicators

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Guidance on Process SaetyPerormance Indicators


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01 INTRODUCTION

02 OBJECTIVE

02 SCOPE

03 CRITERIA

06 DATA REPORTING

08 PROCESS SAFETY PERFORMANCE

08 CONCLUSIONS

09 DEFINITIONS

09 REFERENCES

09 ABBREVIATIONS

Table o contents

Cefc - Guidance on Process Saety Perormance Indicators2nd Edition, May 2011


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Protection o people and the environmentis the most important objective o chemicalenterprises worldwide. An eective Process

Saety Management System that enablesthe identifcation, elimination, reduction andmitigation o risks resulting rom operations,is a pre-requisite.

Process and Plant Saety perormance can be

evaluated through the use o key perormanceindicators that measure and analyze ProcessSaety Incidents (PSI). Whilst the use o keyperormance indicators is common at individualcompany level, their application across industryis restricted because they are not harmonizedinto a universally shared management model

or Process Saety.

This guide contributes to developingplant and process saety metrics to

allow industry-wide cross reerencevia a common reporting system.

A recommended minimum data setwith shared criteria and denitionsis provided.

To ensure a consistent set o criteriaor internal and external reporting

o PSI, this guideline:

Describes the need and beneto implementing process saetyperormance indicators,

Denes the constraints or aneective internal system to captureall incidents, and

Provides criteria which characterize

an incident as a process saetyincident.



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The objective o the guideline isto describe a globally applicablereporting system by: Dening harmonized criteria

which qualiy incidents as ProcessSaety Incidents (PSI),

Giving guidance on methodsor the development and use

o Process Saety Indicators, Supporting their application by

a set o questions and answers.

The aim is to provide a reportingsystem so that saety perormancedata at global, regional and countrylevel is provided. This will allowsenior management to recognizethe actual level o perormance andidentiy trends so that unplannedand undesired process incidentscan be avoided, reduced or rectied.

Short-term and long-term incidentsare covered. Short-term Incidentshave short-term consequences, suchas release o an acute toxic substance.Long-term incidents have long-termconsequences, such as the releaseo a substance with a carcinogenicpotential or hazardous to theenvironment.

This guide ocuses on measuringPSI as a lagging indicator or processsaety perormance. Laggingindicators ollow behind overallactivity and include lost time rominjury requency rate or severity rate.They are not site specic and canbe adopted or a variety o situationsso they are useul or benchmarkingand trend analysis, enablingmanagement to draw conclusionsand drive continuous improvement.Leading indicators on the otherhand, monitor prevention and controlsystems and the level o preparednesso the organization. They include near

misses and the number o perormedinspections in time. They are toosite-specic or benchmarking ordeveloping globally applicable criteria.Thereore, although crucial manage-ment tools, they are not covered inthis guideline. It is company respon-sibility to adequately consider leadingindicators in order to ensure eective

process saety management.

02

Objective Scope



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The fowchart below summarizesthe process o determining whetheran incident qualies as a PSI.

03

Criteria


Figure 1: Determination o Process Saety Incident

Was a chemical substanceor a chemical process directlyinvolved in the damage caused?

Did the incident occur inproduction, distribution, storage,utilities, pilot plants laboratorieswithin the site boundaries o acompanies acility?

Was there a release o materialor energy (e.g. re, explosion,implosion) rom a chemicalprocess unit that resulted in...

Injury resulting in a LostTime Accicdent or a Fatality

or Hospitalisation (>24h)o any people on or o site?

Damage>$25,000 o

direct costs tothe company

Shelter inplace (e.g.

media release,evacuation)

GHS classifed

Health Hazards

Physical Hazards

Environmental Hazards

Acute Toxic1 2

1

Carcinogenic, Reproductive,Mutagenic

Thresholds (8h rule applies) 5 kg

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No

No

No No

No

Yes Yes

100 kg 2000 kg(recommended)

STOT single exposure

Does not meet the criteria ora Process Saety incident

Reportable ProcessSaety Incident

NotGHSClassifed

Substances

All OtherCategories

AllCategories

AllCategories

No


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1. Chemical substance or chemicalprocess involvement

A chemical substance processmust have been directly involvedin the damage caused. Termprocess is used broadly to includethe equipment and technologyneeded or chemical production -including reactors, tanks, piping,boilers, cooling towers andrerigeration systems.

2. Consequences above a minimumreporting thresholdSuch incidents qualiy as PSIi one or more o the ollowingcriteria are ullled:

Injury resulting in a Fatality,Hospitalization (>24h) or lost

workday o any people onor o site,

Release o energy (e.g. re,explosion) that causes a damagewith direct costs o > 25,000,

Release o chemical substancesdue to Loss o PrimaryContainment (LoPC) abovecertain thresholds,

Shelter in place (e.g. mediarelease evacuation).

Release o energyIn most cases the release o energy

(e.g. re, explosion) is detected rapidlyater the incident has occurred. Therelease o a chemical substance canhappen over an extended time periodwithout being recognized, especiallyin areas that cannot be checked byregular inspections.

To support the decision whether a re-

lease o a chemical substance is quali-ed as a PSI, the thresholds or LoPCas dened above reer to a time periodo 8 hours - approximately equivalentto a working shit.

A release to a fare or scrubber is stillconsidered to be within the primarycontainment as long as the mitigationsystem (e.g. scrubber, fare) is oper-

ated under normal conditions with-out any release above the thresholdsdened or normal operation.

A release to a secondary containment(e.g. waste water treatment or dike)will qualiy as a PSI because thesubstance is leaving the primaryprocess system.

Release o substances and mixturesThe thresholds should refect the

intrinsic hazard potential o thechemical substances. The GloballyHarmonized System (GHS) is usedto dene thresholds or hazardoussubstances and mixtures as ollows:

Substances: LoPC > 5 kg:

Cat 1 + 2 Acute Toxicity

Cat 1 Long Term Health Eects:Carcinogenicity (H350),Reproductive toxicity, Germcell mutagenicity (H340)

STOT ater single exposureand related to H370, category 1.

LoPC > 100 kg: All other GHS classied

substances.

LoPC > 2000 kg: All other not GHS classied

substances (recommendedor internal reporting).

I the material under considerationis a hazardous material that doesnot have a GHS classifcation yet,

use adequate/similar classifcation,or example the Hazard Classifcationrom the UN.


A release o energy or material qualies as a Process Saety Incident i it meets all three o the ollowing criteria:1. Chemical substance or chemical process involvement,2. Consequences above a minimum reporting threshold,3. Location.

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MixturesMixtures are treated as substanceswhen classication according to GHSis available. The ollowing principleshould be applied:

Mixing rule: Calculate the raction othreshold quantity release or eachcomponent. I the sum o the ractionsis greater than 100%, the release iscounted as a PSI. (This rule shall beapplied conservatively.)

Figure 2 summarizes how thresholdsor hazardous substances andmixtures are dened under GHS

3. LocationThe incident occurs in production,

distribution, storage, utilities, pilotplant or laboratory areas ocompany acilities. This includestank arms, ancillary support areas(e.g. boiler houses and waste watertreatment plants or warehouses),and distribution piping underresponsibility o the company.Transportation incidents are notcovered unless they occur duringloading and unloading procedureswhen connected/transerred tothe process.


NOTE: Agreed substance categorization is required orconsistency o reporting. CLP: Classifcation, Labeling andPackaging o Substances and Mixtures regulation

(EG 1272/2008) is used.

Figure 2: GHS Thresholds

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GHS classifed

Health Hazards

Physical Hazards

Environmental Hazards

Acute Toxic1 2

1

Carcinogenic, Reproductive,Mutagenic

Thresholds (8h rule applies)

5 kg 100 kg 2000 kg(recommended)

STOT single exposure

NotGHSClas

sifed

Substance

s

All OtherCategories

AllCategories

AllCategories


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Each company should implement asystem to ensure that all inormationdescribing PSI is reported internallyto a unction responsible or thePS indicators.

The data to be reported should ulllthe ollowing requirements:

SpecifcData should be specic or thecompany, i.e. hazardous processes,organization.

CompleteData should ulll internal andexternal requirements or thereporting o the process saetyperormance.

ComprehensibleData should enable the receptorto ollow the course o the incidentand the attributing actors.

To acilitate internal compliance andmotivation to report Process SaetyIncidents, the ollowing aspects o datacapture and reporting should also beconsidered:

DocumentationThe procedure or data captureshould be easy to use so as to

avoid unnecessary barriers toreporting incidents.

QualityThe use o a template or spreadsheet can enhance the qualityo data provision by structuringthe input o inormation andminimizing unstructured textwhich cannot be analyzedstatistically.

MotivationAn increasing demand orinormation may reduce thequality o the data providedas well as the willingness toprovide it. Sta are more likelyto report incidents in an open

atmosphere.

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Data Reporting



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Minimum Data SetThe minimum data set opposite isrecommended to ulll uture externalreporting requirements as well as thoserequired under Responsible Care.Company specic inormation can beadded to acilitate statistical evaluationwhere possible.

Additional inormation can be addedin order to comply with the prospectivestandard o the American PetroleumInstitute1.

1RP 754 - Recommended Practice or Process Saety Perormance Indicators

Recommended minimum data set Company identier (BU, Department, etc.) Incident identier (Incident title,

No., Incident description) Date and time Location (Country, site, plant)

o Type o incident Fire (yes/no) Explosion (yes/no)

Release o hazardoussubstances (yes/no)

Names CAS Number

GHS classication Optional UNDG Code Amount Physical state (gas, liquid, solid) Release path (air, soil, water) Consequences

o Human (employees, contractors,community members)

Fatalities (yes: number/no) LTA (yes: number / no) Hospitalization (yes: number/no)

o Damage Direct cost estimate

>

25,000 to the company Mode o operation, i.e.o Normal operationo Startupo Shutdowno Maintenanceo And others

O-site impact: An ocially declaredcommunity evacuation or shelter-

in-place (yes/no) Secondary containment in place (yes/no) Loss o secondary containment

(yes/no)

Additional inormation can bedened where necessary in orderto meet the particular need o thecompany or industry association.Reporting thresholds can be adaptedto the specic hazard portolio othe company (e.g. lower reportingthresholds or explosives, LPG)to ensure that LoPC with minor

consequences but high hazardpotential are captured.


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PSI reporting is the rst step to getan overview o the process saetyperormance o a chemical company.The inormation provided can onlybe compared within the same entity(e.g. country, site or plant) i thesize o the respective entity hasnot changed signicantly over theobserved time period.

In order to acilitate a benchmark odierent sites, companies or countries,the number o process saety incidentsmust be normalized to achieve a rate(Process Saety Event Rate: PSE).The value to be used or normalizationshould have an intrinsic and meaningulrelationship to the probability o

process saety incidents. As a rststep the Number o PSI per 1 millionworking hours can be used.

To avoid inconsistencies, it isrecommended that the same valueis used or calculating LTAR (LostTime Accident Rate) and PSE within

a company.

The successul implementation o aPSI reporting system to evaluate saetyperormance within a company shouldinclude the ollowing considerations:

The reporting system is implementedtop down rom the managementboard to the operator,

The benet o reporting incidents

is clearly communicated to theresponsible management along theline down to the plant management,

Misuse o the PSE should be avoided: A small site within a company

having only one PSI can have amuch higher PSE than the mediumvalue o a company. This does notrefect a poor perormance o the

small site automatically. Senior management should be

encouraged to communicate PSI,thereore the reporting o incidentsshould not jeopardize their jobperormance evaluation orbonus system.

Process saety incidents and work placeaccidents are caused, in most cases, byhuman error or deciencies within theorganization. Enabling the managementand operators to improve the systemrequires an open atmosphere o reportingthese deviations.

Process and plant saety can besignicantly enhanced through theimplementation o an eective ProcessManagement System. At presenthowever, a universally sharedmanagement model or processsaety does not exist, partly becausethere are ew i any harmonized keyperormance indicators that can

measure process saety incidentsacross industry in order to providebenchmarking and trend analysis.

In order to ll this gap, this guidehas provided:

The basis to a commonreporting system,

A recommended minimum data set, Shared criteria and denitions.

It is hoped that this guide will acilitateindustry-wide cross reerence as a rststep towards developing universallyapplicable process saety metrics.

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Process Saety Perormance Conclusions



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Loss o Primary Containment (LoPC)LoPC is an unplanned or uncontrolledrelease o material or energy rom primarycontainment. A tank, vessel, pipe, truck,rail car or equipment intended to serveas the primary container or used orprocessing or transer o material.

Lost Time Accident Rate (LTAR)

Lost Time Accident Rate is the numbero accidents causing an absence romwork, with reerence to a dened base(e.g. 1 million working hours, or 200,000working hours). It is used in OccupationalHealth and Saety, and it is oten linked toLTIR (Lost Time Injury Frequency Rate).

Release o energy

A release o energy (temperature,pressure) that results in: Fire (any combustion like smoldering,

charring, smoking or an open re).The presence o fame is not relevantor the combustion,

Major pressure changes like a blastwave (e.g., detonations, defagrations)

or implosion.

Release o materialA release o chemical substancesthat reaches or exceeds the reportingthreshold in eight hours or less. Releases via Pressure Relie Device

(PRD) are reported as long asthe release exceeds the thresholdlimits in this guide,

Release to emission control device:

Releases to a properly designed andoperating emissions control device,such as a fare, scrubber, etc.do not have to be reported.

Secondary Containment (LoSC)Any containment which serves asa barrier to limit the consequencesdue to the LoPC.

API:RP 754 Process Saety PerormanceIndicators or the Refning andPetrochemical IndustryCCPS:Process Saety Leading and lagging MetricsHSE:Developing Process Saety Indicators

EPSC:EPSC Reports and Presentations

Abbreviations

API American Petroleum InstituteCCPS Center or Chemical Process Saety

GHS Global Harmonized SystemLOPC Loss o Primary ContainmentLTAR Lost Time Accident RatePRD Pressure Relie DevicePSE Process Saety EventPSI Process Saety IncidentSTOT Specifc Target Organic Toxicity

Acknowledgements:Cec Issue Team Process & Plant Saety

Defnitions Reerences


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[email protected]

d

esign:www.landmarks.be

Cefc - The European Chemical Industry Council

Cec is the Brussels-based organisation representing national chemical ederations and chemical companies in Europe.Cec represents, directly or indirectly, around 27,000 large, medium and small companies in Europe, which employ about

1.2 million people and account or more than 29% o world chemicals production.

Cec - May 2011Dpot Lgal D/3158/2011/1

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