How can you design a resilient process safety plan?

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Process safety is a critical aspect of plant operations, as it aims to prevent or mitigate the consequences of major accidents involving hazardous substances, such as fires, explosions, or toxic releases. A resilient process safety plan is one that can adapt to changing conditions, recover from disruptions, and learn from incidents. How can you design a resilient process safety plan for your plant? Here are some key steps to consider.

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Gholamreza Golshani

Electrical Engineer ?? | Content Manager?? | Creative Content Creator ? | Content Marketing ?? | I help people promote…
Mahmood Khan [Sitara I Imtiaz (Star for Distinction)]

Director Business Technologies @ Confidential | Project Management Professional
Saptarshi Datta

Technical Program Manager | Engineering Leader

1 Identify and assess hazards

The first step is to identify and assess the potential hazards that could cause or contribute to a major accident in your plant. This involves conducting a systematic and comprehensive analysis of the sources, scenarios, and effects of hazardous events, as well as the existing safeguards and control measures. You can use various methods and tools, such as hazard and operability studies (HAZOP), failure modes and effects analysis (FMEA), or bow-tie diagrams, to identify and assess hazards.

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Gholamreza Golshani

Electrical Engineer ?? | Content Manager?? | Creative Content Creator ? | Content Marketing ?? | I help people promote their efficiency at work.??
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Designing a resilient process safety plan involves a comprehensive risk assessment, compliance with regulations, and fostering a strong safety culture. Provide regular training, develop an emergency response plan, and conduct process hazard analyses (PHA) to identify and mitigate risks. Implement multiple layers of protection, continuously monitor processes, and establish a robust change management process. Learn from incidents through thorough investigations, maintain detailed documentation, and conduct regular audits for continuous improvement. This holistic approach ensures a safer working environment by actively addressing potential hazards and adapting to changing conditions.

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Saptarshi Datta

Technical Program Manager | Engineering Leader
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In my experience designing and commissioning large infrastructure projects, what often gets overlooked are business/operations continuity risks. For example, projects in South Asia face significant constraints during the monsoon months where execution becomes challenging and sometimes not feasible. Incorporating these business/operations continuity risks into the HAZOP is a must.

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Miles Montegut

Operations and HSE Specialist, OSHT
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One way would be to simple apply the PSM requirements. The tricky part is providing assurance the plan is being followed. Do you use a simple checklist, that the program is in place? Or do you actually go see and assess the program, and conduct competence assessments on the people involved.

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2 Implement risk reduction measures

The second step is to implement risk reduction measures that can prevent or mitigate the hazards identified in the previous step. These measures can be classified into three layers of protection: prevention, control, and mitigation. Prevention measures aim to eliminate or reduce the likelihood of hazardous events, such as by using inherently safer design, applying good engineering practices, or maintaining equipment integrity. Control measures aim to detect and respond to hazardous events, such as by using alarms, interlocks, or emergency shutdown systems. Mitigation measures aim to limit the consequences of hazardous events, such as by using fire protection, explosion relief, or emergency response plans.

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3 Monitor and review performance

The third step is to monitor and review the performance of your process safety plan on a regular basis. This involves collecting and analyzing data on process safety indicators, such as near misses, incidents, audits, inspections, or compliance. You can use various methods and tools, such as key performance indicators (KPIs), dashboards, or root cause analysis, to monitor and review performance. The purpose of this step is to identify and correct any gaps, weaknesses, or deviations in your process safety plan, as well as to capture and share any lessons learned.

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Gholamreza Golshani

Electrical Engineer ?? | Content Manager?? | Creative Content Creator ? | Content Marketing ?? | I help people promote their efficiency at work.??
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A resilient process safety plan involves thorough risk assessments, layered protection measures, and a robust emergency response. Establishing a safety culture, conducting regular drills, and updating the plan in line with changes ensure continuous improvement. Collaboration with stakeholders, adherence to industry standards, and learning from incidents contribute to a plan that minimizes accidents and enhances operational resilience.

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4 Enhance organizational culture

The fourth step is to enhance the organizational culture that supports and promotes process safety. This involves creating and maintaining a positive and proactive attitude towards process safety among all levels of staff, from senior management to frontline operators. You can use various methods and tools, such as leadership commitment, communication, training, or reward systems, to enhance organizational culture. The purpose of this step is to foster a culture that values and prioritizes process safety, as well as to encourage continuous improvement and learning.

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Jason Cox

Field Superintendent Zyme Flow
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At my former employer we had a big disconnect between management and the field personnel. They talked a good game about safety, but most times production goals came first. Everyone has to be on board and working together.

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5 Adapt to changing conditions

The fifth step is to adapt your process safety plan to changing conditions, both internal and external. This involves anticipating and responding to changes that could affect your process safety, such as new technologies, regulations, markets, or threats. You can use various methods and tools, such as scenario planning, risk assessment, or change management, to adapt to changing conditions. The purpose of this step is to ensure that your process safety plan remains relevant, effective, and resilient in the face of change.

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6 Engage with stakeholders

The sixth and final step is to engage with stakeholders that have an interest or influence on your process safety, such as regulators, customers, suppliers, contractors, or communities. This involves establishing and maintaining a constructive and transparent dialogue with stakeholders, as well as soliciting and addressing their feedback, concerns, or expectations. You can use various methods and tools, such as stakeholder mapping, consultation, or reporting, to engage with stakeholders. The purpose of this step is to build trust and credibility, as well as to enhance collaboration and cooperation, with stakeholders.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Mahmood Khan [Sitara I Imtiaz (Star for Distinction)]

Director Business Technologies @ Confidential | Project Management Professional
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1. Split the Process into Proceedures . 2. Establish Controls. 3. Remove Redundancies. 4. Cognizant Reviews. 5. Apply Corrections. 6. Repeat Above

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How can you design a resilient process safety plan?

1

2

3

4

5

6

7

1 Identify and assess hazards

2 Implement risk reduction measures

3 Monitor and review performance

4 Enhance organizational culture

5 Adapt to changing conditions

6 Engage with stakeholders

7 Here’s what else to consider

Plant Operations

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How can you design a resilient process safety plan?

1

2

3

4

5

6

7

1 Identify and assess hazards

2 Implement risk reduction measures

3 Monitor and review performance

4 Enhance organizational culture

5 Adapt to changing conditions

6 Engage with stakeholders

7 Here’s what else to consider

Plant Operations

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