Management by targets
This webinar explores the issues associated with management by targets and how this has the potential to impact safety outcomes. As Goodhart said “when a measure becomes a target, it ceases to be a good measure”. We explore in some detail the Chernobyl incident and how this was a victim of management by targets. The webinar is presented by Trish Kerin and aligns with the upcoming free Loss Prevention Bulletin Anniversary Edition.
Achieving world-class process safety performance
John Bresland, former chair of the US Chemical Safety and Hazard Investigation Board (CSB) joins Trish Kerin to discuss his key learnings from investigating incidents from his time at the CSB as well as his long career in process safety.
Pike river leadership, culture and design
The IChemE Safety Centre commenced a project in June 2014 to develop a list of agreed lead process safety metrics. In July 2015, this material was published as a guidance document Guidance Lead Process Safety Metrics - selecting, tracking and learning. This webinar hosted by Trish Kerin, explores the lead metrics outlined in the document.
Process safety culture
On the 23 March 2005, an explosion and fire occurred at the BP Texas City refinery. It resulted in 15 fatalities and 180 people being injured.
The US Chemical Safety and Hazard Investigation Board (CSB) commenced an investigation of the incident which would last for approximately two years, however approximately five months into the investigation, the CSB issued an urgent recommendation to the "BP Group Executive Board of Directors to convene and independent panel of experts to examine BP’s corporate safety management systems, safety culture, and oversight of the North American refineries." This panel became known as the Baker Panel, as it was led by former Secretary of State James A Baker.
This webinar discusses the incident and safety culture with panelist Dr Paul V Tebo, a member of the Baker Panel.
Normalisation of deviance
This webinar focuses on the topic of normalisation of deviance. First identified by Diane Vaughan in her review of the Challenger disaster, The Challenger Launch Decision: Risky Technology, Culture, and Deviance at NASA, normalisation of deviance has been identified in many subsequent process safety related disasters.
The webinar explores the cultural aspects of normalising deviance through the Columbia case study, and draws links to main stream process safety incidents.
Remembering Bhopal — what have we learnt?
The 3 December 2014 marks the 30th anniversary of the Bhopal tragedy. The worst industrial incident in history, with thousands of fatalities and hundreds of thousands of people affected. The IChemE Safety Centre produced a special member webinar to mark the event, and remind us all why we need to be ever vigilant in the world of process safety.
Incident investigation and how to avoid common pitfalls
This webinar focuses on incident investigation and how to avoid common pitfalls. Presented by David Ramsey, Managing Director of Kelvin TOPSET, where he shares his vast experience in investigations.
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How to learn more from accidents
This webinar focuses on How to learn more from accidents. Presented by Nancy Leveson, Professor of Aeronautics and Astronautics at MIT where she describes a systems approach to accident prevention. The topics covered include why are we not learning enough from accidents today, do operators really cause most accidents, and how we can increase learning. Examples from the process industry are used to describe a new, more effective approach to analysing the cause of accidents. The new approach is starting to be adopted widely for aviation accidents and incidents.
What Longford taught me about process safety
Mike Connell, Principal Safety Analyst with the Major Hazards Program of WorkSafe Victoria talks about how the incident at Longford and its aftermath shaped his growing understanding of the importance of process safety.
Control room competency
Presented by John Bresland, former chair of the US Chemical Safety and Hazard Investigation Board (CSB). John will explore the importance of having qualified and trained process technicians working in oil refineries and chemical plants and will look at how process technicians are trained around the world.
Learning from creeping changes
Presented by Dr Zsuzsanna Gyenes, deputy to the Director ISC, this webinar focuses on learning from incidents relating to creeping changes via two case studies from two different sectors. It also suggests process safety lead metrics associated with these events to help monitor the changes applying the ISC process safety lead metrics guidance document.
Leadership and safety in uncertain situations
Presented by Trish Kerin. This webinar discusses the importance of leadership and what actions you can take to help your teams perform at their best during these unprecedented times. Please note while the trigger for this discussion is COVID-19, this topic was not discussed as Trish is not an expert in this area. For reliable information on this topic please see your government advisory websites.
Business continuity and safe shutdown
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses what actions you can take to safely operate your plant during these unprecedented times. She will highlight practical details about safe shut down and requirements of minimum staffing level. Please note while the trigger for this discussion is COVID-19, this topic was not discussed as Zsuzsanna is not an expert in this area. For reliable information on this topic please see your government advisory websites.
Process safety application and culture for other industries
Presented by Trish Kerin. Trish discusses the elements of process safety that failed on the Dreamworld Thunder River Rapids Ride incident from 2016 and how the learnings can be applied to your industry.
Safety Lore No 1: start up accidents
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on start up accidents. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 2: storage tank maintenance
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on storage tank maintenance. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 3: flare systems
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on flare systems. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 4: ageing assets
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on ageing assets. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 5: creeping changes
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna describes one case study where creeping changes appeared to be the contributing factor and highlights the key points. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 6: flanges
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on flanges. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 7: road transportation accidents
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on road accidents associated with transportation of hazardous materials. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 8: shift handover
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on road accidents associated with shift handover. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 9: permit to work
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on road accidents associated with permit to work systems. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Human Factors and culture in process safety - through cave diving
Trish Kerin talks about cave diving and how it is planned and organised. She uses it as an example of the application of human factors and organisation culture, drawing parallels back to process industries and application in facilities.
Safety Lore 10: alarm management
Presented by Dr Zsuzsanna Gyenes. Zsuzsanna discusses two case studies that occurred in the past, stressing the key learnings on alarm management. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Applying process safety during concept select
The IChemE Safety Centre commence a project in 2019 to develop guidance on the application of process safety and inherently safer design principles to the concept selection stage of an engineering project. This material was published as a guidance document in May 2020. Trish Kerin explores the concept select phase outlined in the document.
Why training is not enough when it comes to competency
Trish Kerin discusses how competency is obtained, from initial training to practice and experience. She will take you through the structure of the ISC Competency Guidance Supplementary guide on how to build and develop process safety competence.
Lead Process Safety Metrics - pressure relief devices
Steve Fogarty and Zsuzsanna Gyenes talk about lead process safety metrics. The topic addresses the ISC Guidance document on lead process safety metrics and its supplementary document on PRD’s. The webinar provided practical examples as how to apply these metrics in industrial operation.
Remote and virtual risk assessment - impacts of COVID-19
Trish Kerin discusses the current best practices for managing risk assessments during the COVID-19 pandemic.
The human side of process safety
Trish Kerin explores human factors through the lens of a series of high profile process safety incidents. She explores how human factors influenced the outcomes. It is not possible to engineer the human out, therefore we must strive to achieve better ways to influence human performance positively.
Understanding the difference between occupational health and safety and process safety
Occupational Health and Safety and Process Safety are similar in many aspects but there are certain features that are applied only one or the other and are not interchangeable. Therefore, it is of utmost importance to understand what is the difference between the two areas. Dr Zsuzsanna Gyenes gives some useful information as to what do we mean by area and guide the students through case studies which will help them to implement the learnings.
Natural hazards triggering technological disasters - Natech
Trish Kerin explores the issues with preparing for Natech events. The webinar corresponds with the week that Houston was struck by Hurricane Harvey in 2017. She explores what occurred at that time, as well as learnings since then.
Process Safety concepts
Trish Kerin discusses the ISC framework for process safety and how it applies for various process safety concepts. For this discussion she is looking at how process safety concepts apply in different industries, and how you can apply them in your organisation.
Process safety leadership and how to have some fun
Trish Kerin shares her insights on process safety leadership, using fun storytelling to achieve great process safety outcomes.
Lessons from regulators
Trish Kerin discusses key lessons with two former regulators. Dame Judith Hackitt was the Chair of the UK Health and Safety Executive and is also involved in advising Governments in UK and in Australia on reform of Building Safety Regulation. Jane Cutler was the CEO of the National Offshore Petroleum Safety and Environmental Management Authority in Australia. Prior to their regulatory roles, both worked in industry, so they will share their experiences and invaluable advice for industry.
Dame Judith Hackitt is currently the Chair of Make UK and of Enginuity and an IChemE Past President. Jane Cutler is currently on the board of the Australian Maritime Safety Authority and the current Deputy President of IChemE.
Safety Lore 11: Ammonia Nitrate Fertilisers
Dr Zsuzsanna Gyenes talks about incidents related to ammonium nitrate fertilisers and offers key recommendations as to how to avoid such incidents to occur in the future, via two case studies.
Over the Top: Process Safety Lessons related to liquid level in Process Vessels and Tanks
Garry Law discusses some of the reasons why level instruments misread or their output is misunderstood and how this can lead to overfilling a vessel or tank. He also discusses some common design and installation errors as well as dispelling several myths relating to level measurement.
Safety Lore 12: Methane explosions in mines
Dr Zsuzsanna Gyenes discusses two case studies that occurred in the past. Underground coal mining is and has always been a dangerous job. In addition to the risk of asphyxiation and the danger of falling coal, there is the hazard of an explosion of methane gas, which is continuously expelled by coal seams and becomes potentially explosive when mixed with air. Mines must have good ventilation to prevent methane building up. In addition to that, initial methane explosion can trigger coal dust explosion with causing further devastating effects.
Lead Metric: Permit to Work Checks performed to Plan and Permit to Work non-conformance
Dr Zsuzsanna Gyenes, IChemE Safety Centre and Carolyn Nicholls, RAS Limited discuss the IChemE Safety Centre’s supplementary publication on Lead Metrics: Permit to Work.
A supplementary publication to the IChemE Safety Centre Guidance Document “Lead Process Safety Metrics – selecting tracking and learning 2015” was published by the ISC. This guidance note is intended to provide context for the Lead Metric “Permit to work checks performed to plan” and “Permit to work non-conformance” and expand on those metrics. This guidance should be used to help identify suitable performance metrics for your system. It aims to define the key elements of a PTW and suggest metrics that can be used to help monitor the performance of your PTW system.
The document sets out general phases in the lifecycle of a PTW, and identifies potential metrics for each phase and typical elements of a PTW but is not intended to provide a model for development of a PTW system.
Equality, Diversity and Inclusion in Safety
Trish Kerin is joined by Macsene Isles-Ahite, one of IChemE's Trustees and David Lloyd-Roach, IChemE Director, Qualifications to discuss the importance of Equality, Diversity and Inclusion in achieving safety outcomes. Both Macsene and David are involved in linking IChemE's ED&I strategy, policy and direction to Strategy 2024.
Hydrogen Incidents Taxonomy
Laurentiu Zamfirescu discusses the ever-growing concern for global warming and expanding endeavours to reduce our carbon footprint have led to the acceleration of certain energy sectors and technologies. Hydrogen is one of these sectors, with a great promise for a greener energy future. However, as with any other new industry or endeavour, the risks are not well known and costly mistakes, perhaps due to uncontrolled events, can take place. The aim of the webinar is to present the findings of a review conducted by AMOG Consulting of hydrogen incident databases and information sources, as well as to present the project lifecycle phases the various incidents have their root and contributory causes to, and apply any learnings to future design safety planning.
Safety Lore 13: Audits
Dr Zsuzsanna Gyenes discusses two cases studies that occurred in the past, stressing the key lessons on audits. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore 14: Hazard Identification
Dr Zsuzsanna Gyenes discusses two cases studies that occurred in the past, stressing the key lessons on hazard identification. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
PFAS risk, where is it and how do we manage it?
Dr Matthew Askeland discusses key areas of PFAS risk as informed by global academic and in-practice data sets, as well as lessons from the past PFAS management approaches, and proceed into the future by discussing how global specialists are tackling the PFAS problem from a host of different engineering disciplines. The discussion will centre on emergent technologies which have been engineered to be considered game changers with respects to the way in which we manage the chemical group known as PFAS, within the specific learning of what has been effective/ineffective in the past (cost effective and practical).
Getting the best from a remote HAZOP
HAZOP is an established process hazard identification and assessment technique, which has traditionally been conducted by a team in a meeting room. Due the COVID-19 pandemic, as well as action to address climate change, there is pressure to move to more online or remote attendance at HAZOP studies. But what are the challenges this presents to HAZOP leaders and how can those be overcome to still conduct an effective HAZOP study remotely? This webinar was jointly hosted by Nigel Allen, Technical Manager - Major Hazards, Dekra and Trish Kerin, ISC Director.
The ISC released a guidance document on a risk assessment technique called Delta HAZOP. The traditional HAZOP process is a structured process that, when done well, produces a robust and thorough analysis of failure scenarios and identifies safeguards to manage the risk. Where a HAZOP is repeated, or another form of PHA continues to be repeated through the life of a facility, the finding of significant issues is likely to decrease after two or three cycles. Therefore, to achieve a high-quality output, where items of significant value are uncovered it was necessary to look at the process differently. This realisation led to the development of a process known as Delta HAZOP. The focus is on understanding the creeping changes to the process that have occurred and ensuring that the risks associated with them have been understood and addressed. This does not negate the need for a robust Management of Change process.
Alarm Rationalisation and Lead Process Safety Metrics
In this webinar Garry Law from Safety Solutions presents about alarm rationalisation including referencing the upcoming IChemE Safety Centre Guidance document on metrics for alarm rationalisations.
Safety Lore No 15: Dust Explosions
Dr Zsuzsanna Gyenes discusses two cases studies that occurred in the past, stressing the key lessons on dust explosion. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Effectively removing mercury contamination in Oil and Gas Exploration and Production systems
Mercury is a highly toxic, naturally occurring element encountered in various chemical and elemental forms throughout nearly all Oil and Gas production and processing systems. The Presence of mercury creates substantial health, safety and environmental issues that reduce efficiencies in maintenance activities and considerably add to costs in demolition. Understanding accumulation, distribution, and the sorption dynamics of mercury throughout process is instrumental in the application of improved chemical decontamination and waste management techniques used during plant turnarounds and the clean out of gas processing equipment. This webinar will address these issues in the oil and gas industry by utilising cutting edge chemistry to remove the mercury up to 99%. The outcomes benefit the environment and people who are maintaining plant and equipment that previously was mercury contaminated. This technology is transferable to other industries that contain mercury contaminated equipment.
Speaker: Melanie Windust, National Technical Lead: Occupational Hygiene, ADE Consulting Group Melanie is a certified occupational hygienist with post graduate qualifications in occupational hygiene and occupational health & safety and a recent addition to ADE. She is an innovative Occupational Hygienist with experience in a diverse and complex range of industries including major hazard facilities, aviation, mining, dangerous goods, logistics, oil, and gas, regulatory and manufacturing, at union and non-union sites. She has been a COH for nearly 20 years and has vast experience in chemical and hygiene risk management, baseline risk assessments, monitoring program development and working with businesses to develop effective solutions. Melanie Received the Draeger Young Hygienist Award in 2010.
Manage change, or it will manage you
In this webinar Brenda Seggerman will speak about various incidents that were caused by inadequate management of change. She will share her experiences in this, however this presentation does not reflect her experience at Tate and Lyle.
Presenter: Brenda Seggerman works as a Global Process Safety Engineer for Tate and Lyle. She currently works in managing hazards due to combustible dust and chemical process safety in food ingredient production. Brenda has worked in the food, power, and chemical industries for over 15 years. She has a BS in Chemical Engineering, an M.S. in Environmental Engineering, and is a Professional Engineer. Process safety has been a passion for Brenda ever since she was involved in a chemical release incident. This has led her to speak on process safety to the US EPA and at the AIChE Global Congress on Process Safety. She also served a term as a director in the AIChE Safety & Health Division.
Safety Lore: No 16 - Procurement
The procurement process is a part of the company’s corporate strategy and a vital component that helps in ensuring effective supply chain management. The procurement process involves elements such as purchase planning, development of specifications along with supplier research and selection in case of new suppliers and contract administration. When hiring contractors, the tender should specify the required qualifications, adequate knowledge, and evidence from the contractor company. Companies need to be intelligent customers when procuring services or equipment that may impact on the control of major accident hazards. Dr Zsuzsanna Gyenes discusses two cases studies that occurred in the past, stressing the key lessons on procurement. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Could PSM have prevented the Chernobyl catastrophe?
Over thirty years ago, Unit 4 in the Chernobyl Nuclear Power Station suffered what is considered the worst incident in the story of nuclear energy. In this webinar we analyse the process safety practices at the station using current tools and methodology. Specifically, we want to determine if a proper PSM program could have provided some guidance on improving process safety at the station and, hence, helped prevent the incident.
Safety Lore No 17: Intermediate Bulk Containers
Dr Zsuzsanna Gyenes discusses two case studies that occurred in the past, stressing the key lessons on intermediate bulk containers (IBCs). It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Technical Safety Planning: Case Studies of the Good and the Bad
Laurentiu Zamfirescu and Steve Fogarty, AMOG Consulting highlight the importance and benefits of technical safety planning and provide case studies of projects that have suffered from no or inadequate technical safety planning as well as projects that have benefitted from good technical safety plans and assurance.
Safety Lore No 18: Flammable Atmospheres
Presented by Trish Kerin. Trish discusses two case studies that occurred in the past, stressing the key lessons on flammable atmospheres. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Safety Lore No 19: Confined Space Entry
Presented by Trish Kerin and Craig Wright who discuss two cases studies that occurred in the past, stressing the key lessons on confined space entry. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.
Evidence based insights about procedural systems and process safety
Workers’ use of and adherence to procedures can be an important risk mitigation method in the process industries. In this presentation, Dr. Peres will present findings from the Next Generation Advanced Procedures’ (NGAP) consortium on the attributes associated with more (less) effective procedural systems. NGAP is an industry/academia consortium focused on conducting industry driven empirical research to improve the risk profile of procedural systems and develop technology to support this.
Remembering the Philadelphia Gulf Refinery Fire - 50 years on
7 August 1975 is remembered for the highest firefighter fatality count in Pennsylvania State’s modern history. What started as a crude oil tank fire at the Girard Point refinery (then operated by Gulf Oil Corporation) was initially brought under control. However, containment issues and problems managing the spent firewater left a precarious situation; a layer of naphtha hidden beneath the firefighting foam suddenly ignited, with the resulting inferno rapidly advancing through the flooded refinery. A massive emergency response was eventually able to reclaim the facility, but at a cost; eight firefighters dead. Memorial plaques outside of the Fireman’s Hall Museum in downtown Philadelphia honour each of the fallen.
This tragic incident has been largely forgotten about in the process industries; however, the memory is kept alive within the firefighting community. The official investigation report does not exist on the internet; the presenting author was able to track this down after months of trawling historical newspapers and reaching out via union leaders, fire commissioners, and national archives. This presentation will reveal why a floating roof storage tank should never be brought “off-float” in error, the importance of effective communication in emergency response, and why there should always be a plan for managing firefighting run-off water.
Process safety has doubtless come a long way in the last 50 years, however, there is an unfortunate ending to this story that suggests that maybe we have yet to learn the lessons of the past.
The Pre-Start up Safety Review (PSSR) process
The Pre-Start-up Safety Review (PSSR) process, also known as Operational Readiness, is intended to ensure that modifications installed match the approved design, the installation is mechanically complete, components have been functionally tested, and the system is ready to hand over to the operations team for operational prestart-up checks and start-up procedures. This webinar addresses PSSR activities leading to turnover to operations.
Effective PSSR involves establishing a well-defined workflow, providing effective tools, ensuring follow-through, and continually improving the process through user and client feedback. Many of these concepts are described in general terms in various guidelines and reference materials. However, effective implementation cannot be achieved through generalities. The devil is in the detail and the quality of the implementation.
This webinar describes several specific practices and tools that have been proven effective to drive better PSSR and project turnover. These practices may be scaled to apply to projects and modifications of any size as well as to procedure changes and maintenance restart applications. Experiences are shared that demonstrate the importance of selecting the correct tools and resources to support the work. Those experiences demonstrated that successful practices tend to become self-reinforcing. Practices were continued, expanded, and improved based on the compounding effect of successful results. The ideas and anecdotes that will be shared in the webinar offer insights into better practices that could improve existing PSSR implementation.
Safety Lore 20: Corrosion
Presented by Craig Wright who discuss two cases studies that occurred in the past, stressing the key lessons on corrosion. It also provides useful tips and recommendations as how to avoid future recurrence of such accidents.