This document discusses making process safety risks more visible through key performance indicators (KPIs). It suggests reviewing existing KPIs against industry guidance, measuring KPIs more frequently including automation, and ensuring the right people have access to KPI results. Real-time visibility of operational indicators and safety systems was highlighted as important for avoiding incidents. Alignment of data sources and a phased approach to implementation was advised. Benefits realized by other organizations include improved plant availability and reduced costs.
11. BP Texas City
Key Indications Were Missed
Maintenance & Testing of Critical
Instrumentation and Alarms- high
level alarms did not operate and were
not routinely tested
Operational Compliance-staff
routinely deviated from plant checks
to save time
Shift Handover- no formal shift
handover process resulted in the
level in vessel not being
communicated resulting in overfilling
Control Loops-key control systems
were left on manual resulting in high
levels in vessel
December 2011
12. Process Safety
What if Process Safety risks were as visible as Health & Safety risks?
Which warning signs are most likely to help you
avoid an incident ?
Swiss Cheese Model
Hazards
Risk Control Barriers
December 2011 Visibile Process Safety Risks
14. Indicators
Line of sight, example...
Reality
Outage completed to plan
Reality
Staff Training Complete
MOC of Electronic Governor not
MOC and Overspeed Test
completed
Procedures Up to date
Manual Trip System Not Tested
Overspeed Test Procedure not
followed e.g. (Failure to inform
Control Room) Two Realities...
But we need to join them together
December 2011 Visibile Process Safety Risks
16. KPI Ranking
Operational Indictors are the key to avoiding incidents...
0 1 2 3 4 5 6
Operational Control Indicators
Generic Indicators
Programme Indicators
December 2011 Visibile Process Safety Risks
17. Indicators
Lagging Indicators also act as warnings when captured at a low level
Major Process Safety Incident:
Major • Equipment damage > £100k
Process • Loss of Production > 24 hours
Safety
• Injuries / fatalities (RIDDOR)
Incident
• Major environmental impact
Significant Process Safety Incident:
Significant
• Equipment damage > £20k but <£100k
Process
Safety • Significant release of energy or hazardous
matter
Incident
• Fire and explosions
Minor Process Safety Incident:
• Demand on safety system
Minor
Process • Process upset – control loops out of
control, equipment in manual
Safety
• Breaches of plant limiting conditions
Incident
Visible Process Safety Risks
December 2011
18. The role KPIs play in
highlighting the warning signs