Guidelines for implementing process safety management systems

Contents Preface ................................................................................ ix Acknowledgments ............................................................... xi List of Tables, Figures, and Appendices .............................. xiii 1. Introduction ................................................................... 1 1.1 Overview and Objective of This Book ............................... 1 1.2 Scope ............................................................................... 1 1.2.1 What Kinds of Companies and Operations Are Covered? ..................................................... 1 1.2.2 What Information Is in This Book? What Is Not? ................................................................... 4 1.3 How to Use This Book ...................................................... 4 2. Get Management Commitment ..................................... 7 2.1 Why Get Management Commitment? .............................. 7 2.2 Getting Top-Level Commitment ........................................ 8 2.2.1 Selecting the Right Sponsor(s) ........................... 8 2.2.2 Selling the Need for PSM ................................... 10 2.2.3 Selling the Need for Top-Level Commitment ....... 19 2.3 Using Top-Level Commitment .......................................... 23 2.3.1 Setting Goals for PSM ........................................ 23 2.3.2 Communicating the Importance of PSM .............. 28 vi Contents This page has been reformatted by Knovel to provide easier navigation. 2.3.3 Providing Resources .......................................... 33 Appendix 2-1 Sample Document Presenting PSM to Senior Management ......................................................... 39 3. Define Goals .................................................................. 45 3.1 Introduction ....................................................................... 45 3.2 Select PSM Framework .................................................... 45 3.2.1 CCPS Model ...................................................... 47 3.2.2 Other Models ...................................................... 47 3.3 Establish a PSM Team ..................................................... 50 3.3.1 Who Should Be on the Team? ............................ 51 3.3.2 How Should This Team Work? ........................... 51 3.3.3 Soliciting Team Members' Participation ............... 56 3.3.4 Scheduling and Organizing the First Meeting .............................................................. 59 3.3.5 Conducting Team Meetings ................................ 61 3.4 Define Company-Specific Attributes ................................. 62 3.4.1 Characterize Company Management System Approach ............................................................ 63 3.4.2 Define Supervision/Delegation Approach ............ 67 3.4.3 Define Documentation Approach ........................ 69 3.4.4 Define Communication Approach ........................ 70 4. Evaluate the Present Status ......................................... 73 4.1 Recognize the Objective ................................................... 73 4.2 Select an Evaluation Tool ................................................. 75 4.2.1 Audits ................................................................. 79 4.2.2 Surveys .............................................................. 83 4.3 Perform the Evaluation ..................................................... 86 4.4 Identify Gaps and Overlaps .............................................. 89 Contents vii This page has been reformatted by Knovel to provide easier navigation. 5. Develop a Plan ............................................................... 95 5.1 Review the Preliminary Plan ............................................. 95 5.2 Select an Implementation Strategy ................................... 95 5.2.1 Companywide Approach ..................................... 96 5.2.2 Facility-Specific Approach .................................. 97 5.2.3 "Hybrid" Approach .............................................. 99 5.3 Define Priorities ................................................................ 100 5.3.1 Priority Facilities ................................................. 101 5.3.2 Priority Elements ................................................ 104 5.3.3 Limitations on the Scope of the Plan ................... 105 5.4 Estimate Resource Needs and Schedule ......................... 106 5.4.1 Develop a Program Plan ..................................... 107 5.4.2 Develop a Schedule ........................................... 112 5.4.3 Develop a Resource Plan ................................... 112 5.5 Communicate and Get Approval of the Plan .................... 121 Appendix 5-1: Example Facility Ranking Process ................... 124 Appendix 5-2: Example of Management Presentation on PSM Plan .......................................................................... 126 6. Develop Specific Process Safety Management Systems ......................................................................... 129 6.1 Select an Approach .......................................................... 129 6.1.1 Total Quality Management (TQM) Techniques ........................................................ 130 6.1.2 Using Model Programs ....................................... 134 6.1.3 Business Process Redesign ............................... 137 6.2 Select a Team .................................................................. 142 6.3 Develop the System ......................................................... 145 6.4 Recheck against Criteria .................................................. 146 viii Contents This page has been reformatted by Knovel to provide easier navigation. 7. Put the System into Practice ........................................ 147 7.1 Pilot Testing ...................................................................... 147 7.1.1 Factors to Consider in Pilot-Site Selection .......... 148 7.1.2 Gaining Local Support for the Pilot Test .............. 149 7.1.3 Implementing a Successful PSM Pilot ................. 150 7.1.4 Assessing Pilot Test Results ............................... 158 7.2 Plan and Manage Installation ........................................... 159 7.2.1 Where to Begin Installation ................................. 159 7.2.2 Who Should Manage Installation ......................... 161 7.3 Sell the System ................................................................. 161 7.3.1 Describe System Benefits ................................... 162 7.3.2 Reinforce Buy-In from Management .................... 163 7.3.3 Reinforce Buy-In from Participants ...................... 165 7.4 Design and Provide Training ............................................ 168 7.4.1 Training Managers ............................................. 169 7.4.2 Training Trainers ................................................ 169 7.4.3 Training Users .................................................... 170 7.4.4 Training others (e.g., Contractors) ...................... 171 7.4.5 Training Methods and Tools ............................... 172 Conclusion ............................................................................... 173 8. Measure and Monitor Installation ................................ 175 8.1 Introduction ....................................................................... 175 8.2 Monitor Installation ............................................................ 175 8.2.1 Plant-Level Monitoring ........................................ 176 8.2.2 Companywide Monitoring ................................... 177 8.3 "Customer Feedback" and Follow-Up .............................. 182 Conclusion ............................................................................... 185 Contents ix This page has been reformatted by Knovel to provide easier navigation. 9. Expanding Beyond Initial Scope .................................. 187 9.1 Introduction ....................................................................... 187 9.2 Expanding Beyond Minimum Requirements .................... 187 9.3 Involve Other Activities ..................................................... 188 9.4 Involve Other Functions .................................................... 188 9.5 Expand to Other Processes .............................................. 190 9.6 Expand Internationally ...................................................... 190 9.6.1 Evaluate Local Needs ......................................... 192 9.6.2 Establish Priorities .............................................. 193 9.6.3 Match Systems to Local Needs ........................... 193 Conclusion ............................................................................... 194 Epilogue ............................................................................. 195 Case Study in Implementing Process Safety Management .................................................................. 197 Background .............................................................................. 197 Introduction .............................................................................. 199 Getting Management Commitment .......................................... 200 Defining Goals ......................................................................... 201 Evaluating the Present Status ................................................. 203 Developing a Plan .................................................................... 204 Developing Specific PSM Systems .......................................... 206 Putting the System into Practice .............................................. 207 Measuring and Monitoring ....................................................... 209 Expanding Beyond Initial Scope .............................................. 210 Bibliography ....................................................................... 213 Index ................................................................................... 215