Lessons learned from Process Safety
Management
A Practical Guide to Defense in Depth
NEAL LANGERMAN
Advanced Chemical Safety
San Diego, California, USA
Defense in depth
LAYER OF PROTECTION
Alfred Nobel
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Chicago Pile 1
Three Levels of control (protection)
Enrico Fermi
1. Manual control rod
2. Motor-driven control rod activated
by neutron activity
3. Gravity driven control rod, activated
by man with axe
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Defense in depth
Layers of Protection === Defense in Depth
Every defense has weaknesses
Chemical enterprise learned from failures
Share some lessons learned with the Nuclear Power
enterprise
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Defense in depth
PROCESS SAFETY MANAGEMENT
A guide to defense in depth
Applicability
Basic chemical engineering principals
Regulatory, but broad applicability
US OSHA 29 CFR 1910.119
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Technical sections of 1910.119 = Layers of Protection
Process Hazard Analysis
Process Safety Analysis
Management of Change
Emergency Preparedness
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Principles of PSM
Process Safety Information
Process Hazard Analysis
Operating Procedures
Employee Training
Contractors
Pre-Startup Safety Review
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Defense in depth
Principles of PSM (continued)
Mechanical Integrity of Equipment
Non-routine Work Authorizations
Managing Change
Incident Investigation
Emergency Preparedness
Compliance Audits
Lessons learned from a failure
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T2 CHEMICAL PLANT FAILURE
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T2 Failures
Mechanical Integrity
Management of Change
Process Hazard Analysis
Emergency Preparedness
Failure to maintain LOP leads to disaster
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Process Safety Management
Applicable to any industrial activity
Scalable
Flexible
Well-documented
Defense in Depth, INSAG-10 can be extended to include
the PSM principles
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COMPARISON OF DiD AND PSM
IAEA DEFENSE IN DEPTH
Deterministic design
US OSHA PROCESS SAFETY
MANAGEMENT
Process Safety Information
Process Hazard Analysis
Operating Procedures
Pre-Startup Safety Review
Mechanical Integrity of Equipment
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Defense in depth
Probabilistic studies and defense in Process Safety Information
depth
Process Hazard Analysis
Operating Procedures
Employee Training
Means of achieving operational
safety
Operating Procedures
Employee Training
Contractors
Pre-Startup Safety Review
Mechanical Integrity of Equipment
Non-routine Work Authorizations
Managing Change
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Defense in depth
Enhancement of safety
Process Safety Information
Process Hazard Analysis
Operating Procedures
Employee Training
Contractors
Pre-Startup Safety Review
Mechanical Integrity of Equipment
Non-routine Work Authorizations
Managing Change
Incident Investigation
Emergency Preparedness
Compliance Audits
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Accident control
Emergency Preparedness
Management of severe accidents
Emergency Preparedness
Emergency response
Incident Investigation
Emergency Preparedness
Safety assessment and verification
of defense in depth
Compliance Audits
The regulatory body
Compliance Audits
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International peer review processes Process Safety Information
Process Hazard Analysis
Operating Procedures
Employee Training
Contractors
Pre-Startup Safety Review
Mechanical Integrity of Equipment
Non-routine Work Authorizations
Managing Change
Incident Investigation
Emergency Preparedness
Compliance Audits
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Management of change (word modified for reactor
operators) 1910.119(l)
The reactor operator shall establish and implement
written procedures to manage changes (except for
"replacements in kind") to process chemicals,
technology, equipment, and procedures; and, changes
to facilities that affect a process.
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The procedures shall assure that the following
considerations are addressed prior to any change:
The technical basis for the proposed change;
Impact of change on safety and health;
Modifications to operating procedures;
Necessary time period for the change; and,
Authorization requirements for the proposed change.
Particularly applicable to research reactors, where change is
frequent
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PSM is enhancing operational safety at US chemical
plants
U.S. Chemical Safety and Hazard Investigation Board
(csb.gov) investigates incidents and relates underlying
causes to PSM correctable failures
PSM principles are applicable to reactors and reactor
operators
PSM principles will enhance operational safety
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Recommendations for reactor operators
Review operating procedures in terms of PSM
Use PSM lessons learned to make operating
procedures more robust
Adopt PSM principles as guides for all aspects of
reactor operations
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Resources
29 CFR 1910.119
AIChE Center for Chemical Process Safety library
http://www.aiche.org/ccps/resources/publications
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Keep your cores
controlled and your
plants safe
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THANK YOU
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QUESTIONS?
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