Key Concepts of Process Safety to Process Safety Purpose and Scope Application What Is Process Safety? Process Safety Is Not "Personal Safety" Why Is Process Safety Important? Business Impact Code of Ethics Conservation of Life Case Studies Large Companies Small Companies Universities Key Questions Process Safety Culture, Leadership, and Performance Key Concepts What Is Safety Culture? Characteristics of Safety Cultures Employee Participation Evaluating and Improving Safety Cultures Process Safety Leadership Process Safety Performance Process Safety Systems Key Concepts 57 3.2.1 Process Risk Managing Process Risk Protection Layer Model Process Safety Systems 66 3.4 Barrier Protection Layer Models Swiss Cheese Model Bow Tie Diagrams Case Study Operational Discipline Key Concepts Benefits of Strong OD Program Characteristics Organizational Personal Evaluating General Approaches Evaluating Personal Leadership Processes Section II Practical Approaches for Designing Safe Processes Design Safe Processes Using Codes and Standards Documenting the Technology Sustaining the Information The Process and Equipment Design Basis Applying Inherently Safer Process Design Understanding the Hazards Understanding the Process Risks Selecting the Equipment Selecting Safe Operating Limits for Process Equipment Establishing Safe Equipment Layout Establishing Equipment Integrity Documenting the Process and Equipment Design Specifications Measures of Success Identify and Assess Process Hazards Physical Property Data Completing the Intrinsic Hazards Assessment Toxicity Hazards Assessing Toxicity Hazards Flammability Hazards Assessing Flammability Hazards Assessing Explosion Hazards Combustible Dust Hazards Assessing Combustible Dust Hazards Chemical Reactivity Hazards Assessing Chemical Reactivity Hazards Developing a Chemical Compatibility Matrix Other Process Hazards Measures of Success Evaluate and Manage Process Risks What Is Process Hazards and Risk Analysis (PHRA)? When Is a PHRA Done? Who Does a PHRA? How Is a PHRA Done? Process Hazards Consequence Analysis 182 7.5 Hazardous Event Evaluation HAZOP What-If/Checklist Other Methodologies Human Factors Facility Siting Inherently Safer Processes Protection Layers Risk Analysis 205 Qualitative Risk Analysis Layer of Protection Analysis Quantitative Risk Analysis PHRA Revalidation Measures of Success Practical Approaches for Implementing Process Safety 8. Operate Safe Processes Providing Competency Training Sustaining Safe Developing Procedures: Process Safety Systems Developing Procedures: Safe Operations Developing Capability: Process Safety Systems Developing Capability: Safe Operations Measures of Success 9. Maintain Process Integrity and Reliability Inspection, Testing, and Preventative Maintenance Programs The Difference between Integrity and Reliability Ensuring Equipment Fitness for Service Maintenance Capability and Competency Identifying Critical Equipment Identifying Causes of Equipment Failure Developing an Effective Maintenance System Posed When Developing the Maintenance System Equipment Risk Based Inspection Equipment Reliability Equipment Quality Assurance Equipment Integrity Programs Combining Programs Ensuring Equipment Fitness for Service Addressing Equipment Deficiencies Monitoring the Equipment Maintenance System Measures of Success Change Processes Safely Defining Changes Managing Changes Communicating Changes Case Study Understanding Organizational Changes Understanding Technology Changes How Change is Managed Measures of Success Manage Incident Response and Investigation The Six Phases for Managing Incidents Effective Investigations Classifying the Types of Responses and Incidents Defining Emergencies Defining Incidents Planning and Responding to Emergencies Planning for Incidents Responding during the Incident Recovering From and Investigating Incidents Recovering from the Incident Investigating after the Incident Combining Resources When Recovering and Investigating Changing and Sustaining after the Incident Implementing the Changes Sustaining the Changes Incident Investigation Methods Why-Trees 312 X Contents Fishbone Diagrams Root Cause Analyses Fault Tree Analyses Applying Bow Tie Diagrams to Investigations Searching for the Event-Related Causes Visualizing Barrier Weaknesses on the Bow Tie Diagram Searching for the Systemic Causes Visualizing Systemic Weaknesses on the Bow Tie Diagram Searching for the Foundational Causes Case Measures of Success Monitor Process Safety Program Effectiveness Key Concepts Sensitivity to Operations Learning Organizations Process Safety Metrics (Key Performance Indicators) Development of Metrics Use of Metrics Process Safety Audits Preparing for an Audit Conducting an Audit Documenting an Audit Measures of Success Section IV Practical Approaches for Achieving Process Safety Excellence Develop Personal Capability in Process Safety Process Safety Roles and Responsibilities How to Be Effective in Process Safety Roles Developing Technical Process Safety Knowledge Influencing the Organization Thinking and Communicating Independently Developing a Learning Plan Commit to a Safe Future Maintaining an Effective Process Safety Program Looking to the Future of Process Safety