Safety and Risk Management in Process Industry

Safety Management Systems

Lecture-5

Dr. Ing. Naveed Ramzan

Dr. Shahid Naveed 23. April 2008 / Dr. Ing Naveed Ramzan

Lecture Scope

-- Why safety management systems? -- Basic safety process -- What is a safety management system? -- Features of safety management system -- What does it take to build a safety management system? -- How to develop & motivate a safety culture?

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

Why Safety Management System

vanticipate and address safety issues before they lead to an incident or accident vdeal effectively with accidents and near misses vvaluable lessons learned are applied to improve safety and efficiency vreduces losses and improves productivity.

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

Why Safety Managements Systems

Moral obligation to PROTECT THE EMPLOYEES. Reduce injuries and associated cost. Comply with safety & health regulations (OSHA)

Avoid increasing premiums. Provide good public image.

Dr. Ing Naveed Ramzan

--- A better approach of doing business anyway

Dr. Shahid Naveed 23. April 2008 /

Basic Safety Process

Change Thinking

Avoiding costs To Good Business

Source: Minister of Public Works and Government Services, Ottawa, Ontario, Canada K1A 0S5.
Dr. Shahid Naveed 23. April 2008 / Dr. Ing Naveed Ramzan

What is Safety Managements Systems?

The 4

Ps of safety management

vPhilosophy vPolicy vProcedures vPractices

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

What is Safety Managements Systems?

The 4 Ps of safety management

vPhilosophy-Safety management starts with Management Philosophy: there will always be threats to safety; organization's standards safety is everyone's responsibility v v v

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

What is Safety Managements Systems?

The 4 Ps of safety management

vPolicy-Specifying how safety will be achieved v Clear statements of responsibility, authority, and accountability; v Incorporate safety goals into every aspect v Skills and knowledge

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

What is Safety Managements Systems?

The 4 Ps of safety management

vProcedures-What management wants people to do to execute the policy v Clear direction to all staff; v Planning, organizing, and controlling v Monitoring and assessing safety status

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

What is Safety Managements Systems?

The 4 Ps of safety management

vPractices-What really happens on the job v Well designed, effective procedures; v Avoiding the shortcuts v Taking appropriate action

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Features of safety management system

1. Senior Management Commitment 2. Safety Policy 3. Safety Information 4. Setting Safety Goals 5. Hazard Identification and Risk Management 6. Management of change 7. Process and Equipment Integrity 8. Safety Audit/Assessment 9. Accident and Incident Reporting and Investigation 10.Safety Orientation and Recurrent Training 11.Emergency Response Plan 12.Documentation
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Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

1. Senior Management Commitment

Commit funding to the Safety Program. Assign a person the authority/accountability for the Safety Program. Allow time expenditures for Safety to function. Commit to a Safety Policy. Actively support the Safety Program.
Dr. Shahid Naveed 23. April 2008 / Dr. Ing Naveed Ramzan

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Commitment Cognizance Competence

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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2. Safety Policy
Safety Policy should include, at a minimum: v a clear declaration of commitment and objectives; v a means for setting safety goals and regular review of safety performance; v clear statements of responsibility applying to every department or functional area in the organization; Management is confident that staff understand and accept v clearly stated accountabilities converging the that they have importantat role intop of the organization; ensuring safety
.

Benefits

v a means for ensuring compliance with regulations; v a means for ensuring adequate safety management knowledge and skills at all levels; and v compatibility or integration with other management systems.
Dr. Shahid Naveed 23. April 2008 / Dr. Ing Naveed Ramzan

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3. Safety Information
This would include: v safety goals and evaluation of progress towards those goals; v records of accidents and incidents including internal/external investigation findings and corrective actions; v safety concerns raised by employees including analysis and resultant action;
.

v results of safety reviews , audits and appropriate, corrective action; v records of all safety initiatives or interventions.

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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3. Process Safety Information

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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4. Setting Safety Goals

Most common weakness in setting safety goals
is focusing on outcomes i.e. Counting Accidents

Sound safety goal setting concentrates

Benefits

Clearly stated goals lead to a commitment to action which v and either eliminating or mitigating will enhance the safety them of an organization

v on identifying systemic weaknesses and accident precursors,

compares managing safety to "fighting a guerrilla war in which there are no final victories (Professor James Reason )

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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5. Hazard identification and Risk assessment

Description and definition of system

Safety analysis

Hazard identification

Frequency estimation

Risk quantifiction

Risk documentation & follow up plan

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Dr. Ing Naveed Ramzan

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Risk management

System modification to incorporate suggested risk control measures

Accident modeling

Quantitative risk assessment

Probabilistic safety analysis

5. Hazard identification and Risk assessment

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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6. Management of Change

Hazard identification and risk management should be undertaken, at a minimum:

v during implementation of the safety management system; v when major operational changes are planned; v introducing new equipment or procedures; v and when key personnel change.

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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6. Process Equipment Integrity

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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7. Accident and Incident Repor ting and Investigating

Every incident and accident is an opportunity to learn valuable safety lessons

v The lessons will be understood, only if the occurrence is analyzed

v Every incident and accident should be reported and investigated

Reporting
Report formats , responsibilities , investigation, analysis and corrective actions to avoid recurrence
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Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

8. Accident and Incident In vestigating

Causes
v Accidents occurs due to unsafe acts or unsafe conditions

Purpose
v Prevent reoccurrence v Comply with rules/regulations v Reinforce employees awareness

Benefits
v Overall learning for organization v Using the information for corrective actions vInternal positive feedback system

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Who Should Investigate?

v Simple / Non Disruptive Accident --- Usually by first line supervisor - Advantages due to own area - Familiar with people - Better understanding of equipment & operations - Personal interest v Accidents with Noticeable Losses --- Middle management involvement --- Inter departmental coordination v Serious Accidents --- Top management/safety professional & external agencies etc. --- Group experts

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Who Should Investigate?

v Simple / Non Disruptive Accident --- Usually by first line supervisor - Advantages due to own area - Familiar with people - Better understanding of equipment & operations - Personal interest v Accidents with Noticeable Losses --- Middle management involvement --- Inter departmental coordination v Serious Accidents --- Top management/safety professional & external agencies etc. --- Group experts

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Accident Repor t Form

v General Information v A summary ( Sequence of events) v Cause Analysis v Recommendations

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Follow - Up

v Keeping follow up of recommendation is Basis of Success v People often get busy in routine work and forget v v Achieve actions/results being polite and tactful Adopt practical approaches

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Safety Audit/Assessment

v Should be conducted regularly; v Should include the activities of contractors v Correctness of policies, procedures and practices is checked

Benefits
Management is assured on a regular basis that policies, procedures and practices are correct and alerted when an area need attention

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Safety Audit/Assessment

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Safety orientation and training

TRAINING - Who Should Receive Safety Training New employees Transfer employees Hazardous Operations Problematic employees

Conducting Safety Training Explain the Task and Hazards Show HOW TO DO the job correctly Have the employee demonstrate the task Provide FEEDBACK and CORRECTIVE MEASURES

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Recommended Safety training

1910.38 Employee Emergency Plans and Fire Prevention 1910.120 Hazardous Waste Operations/Emergency Response 1910.134 (1926.103) Respiratory Protection 1910.151 Medical Service and First Aid 1910.1000 Toxic Materials 1910.1200 Hazard Communications 1926.21 Safety Training and Education 1926.58 Asbestos

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Recommended Safety training

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Emergency Response Plan

An emergency response plan outlines in writing what should be done after an accident happens who is responsible for each action. The Plan should: be relevant and useful to people on duty at the time of an accident; include checklists and emergency contact details; be updated when contact details change; and be exercised to ensure the adequacyStaff of the plan and the will know what

Benefit

to do the event of readiness of the people who must make it in work. an emergenc y or accident

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Documentation

Documentation should include va policy statement from the Accountable Executive; vthe reporting chain and responsibilities of key personnel; vthe hazard identification and risk management process; vthe safety reporting process; vaudit/review processes; and vall other activities of the program

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Documentation
Records should be kept of: vall activities related to identification of hazards, risk assessment, and action taken; vresults of all investigations of accidents and incidents, including analysis and action taken; vall safety reports issued or received including analysis and action taken Benefits . any safety recommendations; Safety policies , responsibilities and procedures safety program vfindings of internal audits, assessments andof program reviews; and are documented and available vmanagement action

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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How to develop a Safety Culture?

Safety culture is --- An informed culture v v people understand the hazards and risks involved in their own operation staff work continuously to identify and overcome threats to safety

--- A just culture v v errors must be understood but willful violations cannot be tolerated the workforce knows and agrees on what is acceptable and unacceptable

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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How to develop a Safety Culture?

--- A reporting culture

Benefits

--- to Staff have a way to bring the v people are encouraged voice safety concerns

safety concerns to the people who can do something about them -- Staff become stakeholders in --- A learning culture safety management , ensuring its effectiveness

v when safety concerns are reported they are analyzed and action is taken

v people are encouraged to develop and apply their own skills and knowledge v safety staff are updated on safety issues by management v safety reports are fed back to staff so that everyone learns the lessons

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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Requirements of Safety Management Systems (Summarized)

Clear Policy on Employee Safety Establishment of a Safety and Risk Management Program Appointment of a Safety Program Coordinator with the authority and responsibility Ensure adequate funding and resources are available Understand duties, liabilities, and exposures under safety laws and regulations Perform safety and health audits for hazard identification and control Establish a worker safety program which fosters an active participation from employees

Safety Management Success

SUCCESS coming from Desired Events as a result of

Safe Acts and Conditions

depending on

Right Personal & Job Factors

which evolve from

Good organization and safety management systems

Dr. Shahid Naveed

23. April 2008 /

Dr. Ing Naveed Ramzan

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