You don t improve what you don t measure

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1 You don t improve what you don t measure Paul Delanoy Process Safety Technology Leader The Dow Chemical Company Presented to: IChemE meeting and workshop on Process Safety Performance Indicators 1 1

2 What are the CCPS Metrics? Centre for Chemical Process Safety (CCPS) Process Safety Leading and Lagging Metrics CPS_metrics% pdf 2 2

3 Project Team 3M ABS Consulting AcuTech Air Products Albemarle Bayer Material Science LLC BP Braskem CCPS ChevronPhillips Chemical Contra Costa County Health Dept Dow Chemical DuPont Eli Lilly EPA ExxonMobil Honeywell Specialty Materials Husky Oil INEOS Olefins & Polymers Lyondell Mary Kay O Connor Process Safety Center at Texas A&M Monsanto Nalco NOVA OSHA PPG Industries, Inc. Reliance Industries Rohm and Haas Shell SIS-Tech Solutia Suncor UK Health & Safety Executive United Steelworkers, USW Valero Wharton Risk Management and Decision Processes Center Organisations involved in harmonization American Chemistry Council (ACC) American Petroleum Institute (API) National Petrochemical and Refiners Association (NPRA) European Process Safety Centre (EPSC) Conservation of Clean Air and Water in Europe (CONCAWE) 3 3

4 How do the CCPS Metrics work? Lagging Metric: Criteria: Process Safety Incident (PSI) Any releases of material or energy from a process unit resulting in: Employee/contractor lost time injury(s), or Fire or Explosion resulting in $25,000 of direct cost to the company, or Chemical release from the primary containment (i.e., vessel or pipe)*, greater than chemical release threshold quantities** * Excluding releases to designed control device specifically designed for that event (e.g., flare, scrubber, or PSV designed per API 521 or equivalent) ** Threshold quantities are linked to the UN Dangerous Goods criteria 4 4

5 Process Safety Total Incident Rate (PSTIR): Total count of all Process Safety incidents x 200,000 Total employee and contractor work hours 5 5

6 Process Safety Incident Severity The PSSR is calculated using a scoring grid as outlined below: Severity Level Human Health Fire, Explosion & Overpressure Chemical Impact Community or Environmental Impact N.A Process Safety Incident Severity Rate (PSISR) The result is then scaled to the man hours worked as with the previous measurement Total severity score for all PS incidents x 200,000 Total employee & contractor work hours 6 6

7 Process Safety Incident Severity Rate (PSISR) Continued: 7 7

8 CCPS Recommendation CCPS recommends that all companies and trade associations collect and report the three lagging metrics: Total Count of Process Safety Incidents (PSIC) Process Safety Total Incident Rate (PSTIR): Process Safety Incident Severity Rate (PSISR) While the metrics may not be perfect, CCPS recommends that they be used for 2-3 years to establish a base of experience before improvements are considered 8 8

9 Leading Indicators Mechanical Integrity % Inspections done/inspections due % safety critical equipment in failed state/total operating time Action Items Follow-up % past due action items/total action items Management of Change % MOC s satisfying MOC policy % changes that used the MOC procedure prior to making the change by audit % start-ups following changes where no safety problems were encountered Operator Competency % operators trained on schedule % compliance with Training Competency Assessment % failure to follow procedures/safe working practices by audit Safety Culture By survey 9 9

10 Process Safety Near Miss Reporting Process Safety Near Miss: Any significant release of a hazardous substance that does not meet the threshold for a Process Safety Incident lagging metric, or A challenge to a safety system, where: Challenges to a safety system can be divided into the following categories: - Pressure Relief Device (PRD) challenge, - Safety Instrumented System (SIS) challenge, or - Process deviation or excursion

11 Support for the CCPS Metrics The CCPS Metrics are already supported by a large number of companies and organisations: The American Chemistry Council - The ACC has 135 member companies representing most of the US Chemical Industry The American Petroleum Institute -Trade association that represents all aspects of America s oil and natural gas industry Already some companies outside the USA have adopted the CCPS metrics and many more companies and organisations are considering doing so

12 Why the Dow Chemical Company has adopted the CCPS Metrics: The advantages of adopting a a uniform set of metrics within the chemical industry are mostly associated with benchmarking: Most important is the ability of a company to be able to benchmark their own performance. - How does your company s Process Safety performance compare to others? - Is your company s performance improving as fast as the rest of the industry? - How does your company s Process Safety performance compare to the companies that are having significant incidents? The member companies of the American Chemistry Council will be publishing Process Safety lagging metrics. Initially only the count of incidents and the aggregate of the severity rate metric will be made public, but all three metrics will be available to member companies. Eventually, we would assume that all three metrics will be published

13 The CCPS Metrics appear to be the logical choice of indicator: The metrics are the product of careful development The metrics are already widely accepted Data on these metrics will be available from all ACC member companies Developing alternative global metrics will take considerable time and effort Alternative metrics will dilute the efforts to achieve a global measurement 13 13

14 What next? We are hoping that more companies and organisations will support the CCPS metrics. The more widespread the use of the metrics the greater their value will become. Currently this is largely a US initiative we would like to see it become a global resource. The full guideline is available at:

Process Safety Metrics

Global Process Safety Metrics Driving Consistency and Improvement Tim Overton Chief Process Safety Engineer The Dow Chemical Company (Chair: CCPS Metric Project) Presented to: AICHE Spring Meeting/CCPS