What are the most effective process safety metrics for evaluating inherent safety principles?

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Process safety is a vital aspect of chemical engineering, as it aims to prevent and mitigate hazards that could harm people, property, or the environment. One of the ways to improve process safety is to apply inherent safety principles, which are design strategies that minimize or eliminate hazards at the source, rather than relying on add-on controls or protective measures. However, how can you measure the effectiveness of inherent safety principles in your processes? In this article, we will explore some of the most useful process safety metrics that can help you evaluate and improve your inherent safety performance.

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Ir. Adam Maulana Musthafa, CFSP, CCPSC

Process Safety | HSE | Operations Integrity Management | Fire Protection
Omari Hussein Sabuni

Mechanical Engineer| Maintenance & Reliability| Condition Monitoring| Heat Exchanger Consultant| Ultrasonic Agitation…

1 Inherent safety index

One of the most common process safety metrics for inherent safety is the inherent safety index (ISI), which is a numerical value that reflects the degree of inherent safety of a process or a unit operation. The ISI is calculated by comparing the actual values of certain parameters, such as temperature, pressure, inventory, toxicity, or flammability, with their respective threshold values, which represent the maximum acceptable levels for safe operation. The lower the ISI, the higher the inherent safety of the process. The ISI can help you identify the areas of your process that need improvement, and compare different design alternatives based on their inherent safety.

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Ir. Adam Maulana Musthafa, CFSP, CCPSC

Process Safety | HSE | Operations Integrity Management | Fire Protection
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Measuring how effectively we implement Inherently safer principles may not be straightforward, but in the life cycle of hazardous plants, the following can be used: 1. Design Stage - No. of higher risk scenarios identified during HAZID, HAZOP, or other PHAs - No. of Recommendations from inherently safer design workshops - Risk quantifications from quantitative studies - No. of critical operating parameters that require operator actions instead of automatic safety functions - No. of SIFs' 2. Constructions & Installations - No. of higher-risk activities - No. of simultaneous activities with interfacing hazards 3. Start-Up and Operations - Demand on/ Activation of Safety System (Instrumented, mechanical, etc.) - SOL Exceedance

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Omari Hussein Sabuni

Mechanical Engineer| Maintenance & Reliability| Condition Monitoring| Heat Exchanger Consultant| Ultrasonic Agitation Consultant| Power Plant Operations & Services| Asset Management| Writer | FRACAS| Oil & Gas
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Safety is not an option; it's a fundamental requirement in industries where complex processes pose inherent risks. Achieving safety excellence means integrating inherent safety principles into process design and operations. But how do we measure the effectiveness of these principles? Risk Reduction Metrics Risk Reduction Factor (RRF): When evaluating inherent safety, the RRF is a pivotal metric. It quantifies the reduction in risk achieved by implementing inherent safety measures compared to a baseline scenario without them. A higher RRF signifies a more effective incorporation of inherent safety principles. This metric is often expressed as a ratio: the risk with inherent safety measures divided by the risk without.

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2 Hazard and operability study

Another process safety metric for inherent safety is the hazard and operability study (HAZOP), which is a systematic and qualitative method to identify and analyze potential deviations from normal operation, and their causes and consequences. The HAZOP uses a set of guide words, such as no, more, less, or reverse, to examine each element of the process, and determine whether it could lead to a hazardous or undesirable situation. The HAZOP can help you assess the risks associated with your process, and recommend corrective actions or design changes to enhance its inherent safety.

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Omari Hussein Sabuni

Mechanical Engineer| Maintenance & Reliability| Condition Monitoring| Heat Exchanger Consultant| Ultrasonic Agitation Consultant| Power Plant Operations & Services| Asset Management| Writer | FRACAS| Oil & Gas
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Hazard Identification Metrics Identifying potential hazards is the first step in ensuring inherent safety. Effective hazard identification metrics provide insights into the thoroughness of this process. Number of Process Hazards Identified: This metric quantifies the quantity of hazards identified during the design and planning phases. Fewer hazards found indicate better inherent safety. It is important to not only count the hazards but also categorize them by severity and probability. Severity of Identified Hazards: Beyond counting, assessing the potential severity of each identified hazard is crucial. This helps in prioritizing mitigation efforts.

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Mojtaba Hosseini

Site HSE manager at Petropars (PPars)/??????? ???? ????????
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Some of the most effective process safety metrics for evaluating inherent safety principles include as below: 1. Inherent Safety Index (ISI) 2. Risk Priority Number (RPN) 3. Chemical Reaction Risk Assessment (CRRA) 4. Safety Integrity Level (SIL) 5. Process Safety Leading and Lagging Indicators, and near-miss reporting. 6. Layers of Protection Analysis (LOPA)

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3 Dow's fire and explosion index

A third process safety metric for inherent safety is Dow's fire and explosion index (F&EI), which is a quantitative measure of the fire and explosion hazard potential of a process or a plant. The F&EI is based on the type, quantity, and physical state of the materials involved in the process, as well as the process conditions and equipment characteristics. The F&EI can help you estimate the potential damage and loss of life from a fire or explosion incident, and evaluate the effectiveness of your inherent safety measures to reduce the hazard potential.

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4 Inherent safety culture

A fourth process safety metric for inherent safety is inherent safety culture, which is the collective attitude, behavior, and commitment of the organization and its employees towards implementing and promoting inherent safety principles. Inherent safety culture can be assessed by using surveys, interviews, audits, or observations, to measure the level of awareness, knowledge, skills, motivation, and participation of the stakeholders in inherent safety activities. Inherent safety culture can help you foster a positive and proactive environment that supports and rewards inherent safety initiatives and improvements.

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5 Inherent safety performance indicators

A fifth process safety metric for inherent safety is inherent safety performance indicators (ISPIs), which are specific and measurable variables that reflect the progress and achievement of inherent safety goals and objectives. ISPIs can be classified into leading or lagging indicators, depending on whether they measure the inputs or the outputs of the inherent safety process. Leading indicators, such as the number of inherent safety training sessions, audits, or reviews, can help you monitor and improve your inherent safety performance and culture. Lagging indicators, such as the frequency, severity, or cost of incidents, accidents, or near misses, can help you evaluate and learn from your inherent safety outcomes and impacts.

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6 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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What are the most effective process safety metrics for evaluating inherent safety principles?

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1 Inherent safety index

2 Hazard and operability study

3 Dow's fire and explosion index

4 Inherent safety culture

5 Inherent safety performance indicators

6 Here’s what else to consider

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