Process Safety Competency: Trends and Challenges. Hervé VAUDREY - DEKRA
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1 Process Safety Competency: Trends and Challenges Hervé VAUDREY - DEKRA
2 Stake of Process Safety Competency Graphically PS Knowledge GOOD Baby boomers leave Process Safety Knowledge vs Risk Newcomers join Some PS trainings delivered Some cost cutting ACCIDENT? PS Risk HIGH AVERAGE ALARP POOR LOW Time (years) Process Safety Knowledge Perceived Risk Real Risk Slide 2
3 STAKE OF PROCESS SAFETY COMPETENCY BY CASE STUDIES ILLUSTRATING FAILURES OF EMBEDDING ORGANIZATIONAL PROCESS SAFETY COMPETENCE
4 Case#1 : Flashpoint unknown or misused Sector: Chemicals Normal Process: Load 2000 liters of MEK in 6m3 mixer Heat to 60 C Load polyester resins sheets via manhole But flammable vapors, nuisances, Process change: Following success pilot test at ambient T, HSE decided to load sheets without heating Explosion at 1 st batch! Cause: Local incompetence T LIE : -9 C T LSE : 25 C
5 Case#2 : Thermal stability unknown Sector: Cosmetics/Healthcare The incident : 1 ton of product decomposed rapidly in a mixer filling the room with heavy & toxic fumes. Emergency plan & fortunately no injuries Likely cause : Ignition of the powder by spurious activation of explosion-suppressors (Hot spot in activation mechanism) Data: MIE 1J, Kst 50 bar.m/s but Tonset ~50 C Instrumentation installed in such a way that mixer was regulating 40 C On this particular incident : Lack & bad understanding of process safety data Wrong focus on dust-explosion rather than thermal stability Over-instrumented Cause: Organizational incompetence DEKRA
6 Case#3 : Dust explosion properties missing Sector: Pharmaceuticals (secondary) Process: Load pharma powder in hopper 15 years of experience! Incident Dust explosion Data : MIE < 1 mj Need to measure and understand dust flammability properties Cause: Competence
7 Process Safety Competence Failures A few extra stories At different levels Senior level (Verbatim): [Boss to Supervisor]: Why are we flaring today? [Supervisor to Boss]: This is the flare of our neighbor Engineer level: Dust explosion happened in a food dryer Not even 1 such scenario in the HAZOP review! Operator level: See:
8 Trends in Process Safety Competence Why PSC is getting attention? PSC is getting attention globally for reasons: Brain drain, New businesses, acquisitions, Regulator is helping (eg SEVESO or ATEX) Industry associations recommendations PSC is a chapter of CCPS PSM framework & Vision 2020 (Intentional Competency Development ) Companies realize how critical it is PS competence correlates with PS performance PSC seen as an Asset for a manufacturing company PSC Assurance is growing Several PS events are clearly related to PSC failures
9 Challenges and Barriers in PS Competence Our global survey results
10 Shift from Training to Competence building Our global survey results Plethora of providers Massive Internet information New learning delivery (vs death by PPT) Workshops & case studies Online courses / MOOC Serious games ènot training anymore but competence building with engagement of staff
11 PS Competence Building What is it? The right process safety skills For your needs / sector Embedded in the organization Different levels Different profiles/roles Sustainable ie Managed
12 PS Competence Solutions What are the best-in-class companies doing? Implement PSC-Management System See EPSC Report 35 and CCPS book from Jan In-house PS Academy/University Some core, some outsourced Measure PSC with metrics Leading for PS performance Corporate-wide PS Education programs Eg SIL, Hazards of P&T, Ignition sources, Fine-tuned with site specific examples/cases Embed widely inside their organization Not anymore 1 central expert, but a network of PS champions EPSC, Process Safety Competence, Report 35, 2013
13 Summary PS Competence more & more seen as critical Root cause for many PS Events Critical to glue PSM programs Correlates with PS performance All global companies face PS Competence challenges: How to embed, retain & sustain? Need: Shift to PS competence building via new learning solutions Sustained at different levels/profiles Mindful system/plan/investment Active corporate sponsor to make it happen High Process Safety Competence is an Asset for a Chemical Company Dr. H. Schwarz Corporate PS Head BASF
14 Want to know more about our Process Safety competence programs? Come to our booth or visit Contact:
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