Sigma-HSE Newsletter - March 2024
On-Demand Webinar: Identifying Appropriate Fire and Explosion Hazard Data for your Unit Operations
Manufacturers need to understand if their materials are flammable, and what risks are inherent in the material being handled. The storage, processing, handling, and packaging of materials create potentially hazardous conditions in the workplace with a risk of fire and explosion.
To mitigate the risk of fire and explosion, industry is required under different Health & Safety legislation, for example, DSEAR/ATEX/NFPA in the UK/EU/USA and in some cases with the added compliance requirement of COMAH/Seveso to undertake adequate risk assessment and identify hazardous areas.
To perform risk assessments a Materials Safety Data Sheet (MSDS) is used to understand the physical properties of the material being processed. Although, MSDS data provided can help, it is not always comprehensive enough for the specificities of your process conditions/unit operations and may result in expensive over-engineering.
From this webinar you will gain an understanding of:
Speaker: Dr Andy Fowler – UK Technical Director
Where: Online, just register for free HERE.
On-Demand Webinar: Understanding The Hazards Associated with Electrostatic Discharge
Join our upcoming Electrostatic Discharge (ESD) webinar to enhance your understanding of the critical principles and preventive measures against static electricity in various industries.
This informative webinar will cover the fundamentals of ESD, exploring the risks it poses in industries handling flammable materials. Our expert will guide you through effective strategies, including the proper use of ESD protective equipment, grounding techniques, and safe handling procedures.
Don’t miss this opportunity to stay informed and implement essential safety practices to minimise the risk of ESD incidents.
Register now for a comprehensive ESD webinar that prioritizes workplace safety and protection of sensitive electronic components.
Speaker: Dr Emmanuel Addai, Sr. Process Safety Consultant
Where: Online, just register for free HERE.
Understanding the Pillars of a High Reliability Organisation
High Reliability Organisations (HROs) are businesses or organisations, where the potential for substantial harm is significant. The approach that HROs take hinges on mindful organisational leadership that transcends the conventional role of business/revenue-based leadership into a philosophy that prioritises proactive risk management.
The foundations of High Reliability Organisations are rooted in six core principles that must form the basis of your understanding and application of safety in that business. These principals include:
Mindful Leadership
At the core of a HRO is the concept of mindful leadership. This leadership style must go beyond the notion of merely delegating safety concerns to technical experts. Instead, it should involve leaders who acknowledge the potential for significant harm and keep this awareness at the forefront of their decision-making. The belief that major events are unlikely should prompt a continuous commitment to prevent harm.
Definition & Problem Anticipation
HROs are proactive in their approach to risk management. Understanding the hazards at play is foundational and involves creating a learning organisation that constantly evolves and improves. By anticipating potential problems and putting preventive measures in place, HROs aim to control and mitigate risks before they escalate.
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Containment of Unexpected Events
The shift from a reactive stance of fixing things after they've gone wrong to a proactive one is pivotal. HROs actively address issues before they manifest into problems. The goal is to reduce unexpected events through a culture of continuous improvement. While unknown unknowns may persist, cultivating a just culture ensures accountability for doing the right thing at all levels of the organisation.
Learning Orientation
The hallmark of an HRO is its commitment to constant improvement. By managing hazards appropriately and consistently seeking ways to enhance safety measures, these organisations become adept at navigating potential risks.
The journey towards becoming a High Reliability Organisation involves an unwavering dedication to proactive risk management and continuous improvement and is underscored by the significance of mindful leadership and proactive risk management.
To learn more about High Reliability Organisations and Process Safety Management you can watch our previous webinar on-demand HERE.
Management of Change (MoC) and DSEAR
Management of Change (MoC) stands as a cornerstone in process safety management, particularly within major hazard industries. However, despite its significance, MoC remains one of the most challenging aspects to implement and control.
Inadequate MoC practices have played a pivotal role in numerous catastrophic incidents. For instance:
?An Example of Management of Change (MoC)
Imagine a process plant that decides to change its cleaning material. This decision could stem from supply-chain challenges or a cost-saving initiative. On the surface, it appears straightforward—a mere alteration in cleaning agents. However, if the right questions are not asked to the right people, crucial aspects may be overlooked during this change. Failure to address these details could result in unpleasant surprises, jeopardising project delivery or even leading to a disaster.
Once the change has been requested, as part of the MoC process, the change is screened. An appropriate screening question would be to check whether the new cleaning material is flammable. If the cleaning material is found to be flammable, hence determined a dangerous substance, then Dangerous Substances Explosive Atmosphere UK Regulations (DSEAR) apply. DSEAR Regulation 5 states “No new work activity involving a dangerous substance shall commence unless an assessment has been made and the measures required by these Regulations have been implemented”.
The next step involves engaging a DSEAR assessor who determines the hazardous area classification based on the original design and provides recommendations, including but not limited to:
The project is then implemented along with recommendations. Subsequently, a DSEAR verification confirms that the changes align with the assessment and that fire and explosion risks are appropriately managed.
The Stealth of Small Changes:
Often, seemingly minor alterations slip under the radar of formal MoC processes. These adjustments accumulate over time, subtly transforming the plant. The original DSEAR report, once reflective of the site’s safety status, may no longer accurately represent the current situation. The site may be blind to new DSEAR concerns. To address these small changes, scheduling periodic DSEAR assessments to maintain safety vigilance is essential. Low-risk processes should seek re-evaluation every 5 years, while high-risk processes are recommended assessments every 2 years. These assessments ensure that site changes haven’t inadvertently escalated the risk of fire or explosions.
Another overlooked small change can be key personnel turnover within the organisation. To proactively prevent loss of knowledge, a DSEAR consultation knowledge transfer to key personnel can prove invaluable, especially with consultants who are well-versed in the site’s process safety journey.
Resources Library
Learning from our Process Safety Experts
To access our repository of technical articles and on-demand webinars, providing a wealth of insight into mitigating fire and explosion risk, check out our website resources page.