Shakeel H. Kadri

My process safety culture journey

Outline of my talk..

My brief background… My “Safety Culture” journey… My Global Process Safety team –

Culture Development

My brief background…

Shakeel Kadri My Education:

o BS and MS ChE and MBA Finance My experience – first 20 years at Air Products [1978-98]

Process Engineering role designing Air Separation facilities Process Engineering Team Leadership Role in designing, building and

operating Specialty and Electronics Gas Facilities My first involvement on process safety related activities [1984] Process Engineering, Technology and Design Engineering Team Leadership

Role for Industrial Gas Division Engineering Department Manager within Global Engineering My next four years at Air Products [1998-2002] Divisional EH&S Manager Global Engineering Quality Manager

My last 12+ years at Air Products [2002-2015] Global Process Safety Manager Director of Global Process Safety and Risk Management

Shakeel Kadri My Last Role at Air Products [2002 to 2015]

Accountable for directing Process Safety function on a global basis to ensure that Process Safety skills and competencies are appropriately deployed across all engineering, operations, and commercial activities worldwide in all Air Products Businesses in the 40 plus countries.

Process owner of the Global EH&S Risk Management process and is responsible for the overall global execution of this process, including deployment, training and maintenance.

My Industry Involvement

• On CCPS Planning Committee [2004] and CCPS Technical Steering [2002] Committees

• On the process safety committees of the American Chemistry Council, the American Petroleum Institute, the Mary Kay O'Connor Process Safety Center, the Compressed Gas Association, the European Industrial Gases and Association, and the American Fuel and Petrochemical Manufacturers Association.

• Major interest in process safety culture, metrics, risk and performance improvement, industry sharing, global harmonization of standards

• Fellow of both CCPS and AIChE

The Global Community Committed to Process Safety 6

My Contribution at CCPS [2002-2014]

Leaders and Events that molded my

Safety Culture Learning

A Total Safety Challenge The Beginning of AP’s Safety Journey

In 1974 Ed Donley challenges the organization to raise safety performance to that of the best companies in the chemical industry

Ed Donley Chairman (1978-1986)

To start this challenging journey, consultants were retained to assess AP’s safety program. − The consultants focused their assessment on Safety Leadership rather

than auditing plants

Consultants concluded that we lacked a total management approach to safety. − Ownership and accountabilities of safety needed to be defined /

clarified

− Focus and effort by senior leaders on safety needed improvement.

Air Products Total Safety Philosophy “What We Believe”

1. all accidents and injuries are preventable… not inevitable;

2. safety is a management responsibility... and safety can be managed;

3. safety is an individual responsibility …and a condition of employment;

4. safety is a way of life ... around the clock

Nothing is more important than safety…not production, not sales, not profits…

Ed Donley, Chairman (1978-1986)

Air Products Total Safety Philosophy Safety Accountabilities

• Chairman of the Board [and CEO] is the Chief Safety Officer • gives safety the highest priority • demands superior safety performance .

• Line Managers are directly accountable for the safety performance of their organizations

• Safety is everyone’s job and responsibility

0

2

4

6

8

10

12

14

16

18

1975 1980 1985 1990 1995 2000 2005 2010

Inju

ry R

ate

(per

200

K h

rs)

Calendar Year

RecordableLost Time

Creating a Safety Culture at Air Products 35+ Year Journey - Evolution

Total Safety Culture

Total Safety Commitment

Basic Safety Process

Behavior Based Safety

Active caring

Goal is Continuous Improvement

13 Air Products - Company Confidential 13

DELAWARE CITY N20 PLANT Incident aftermath

1 August 1976

• AP’s first major process safety incident with multiple fatalities

• Delaware City Nitrous Oxide plant. Explosion – 4 on-site fatalities.

• Identified the need for a hazard review process.

14 Air Products - Company Confidential

Del Delaware City N20 Reactor

15 Air Products - Company Confidential 16

Incident aftermath

Run-away reaction potential not understood Emergency water quench system did not operate adequately Venting area not adequate

16

• A flat-bottomed LIN storage tank overpressured • Inner vessel separated from its foundation and lifted out from the

outer tank and fell to grade • Breaking liquid outlet line on adjacent LOX flat-bottomed tank • Resulted in a LOX spill of 800 Ton • 5 off-site fatalities

NEW MARTINSVILLE ASU Incident aftermath

31 January 1978

17 Air Products - Company Confidential 17

NEW MARTINSVILLE ASU Incident aftermath

31 January 1978

The system met all industry practices Hazard review was performed Fault tree analysis showed tank failure in about 250 tank years

Total Safety Risk

Recognized early in Air Products Process Safety journey, through these tragic incidents, to include in the hazard analysis a quantitative assessment of the probability of failure of major safety protection systems

The failure probabilities can be reduced by incorporating redundancy of critical components and by frequent testing of the components

To improve risk to the plant people and risk to the general public….

A Total Safety Program requires us to prevent falls from ladders, cuts, and burns, as well as preventing runaway reactions,

explosions, and toxic releases

Dr. PLT Brian Executive VP of Engineering

22

THINKING about PROCESS SAFETY

Elements of Process Safety Organizational Culture*

* AIChE Center for Chemical Process Safety; Lessons Learned from the Space Shuttle Columbia, Elements of Process Safety Organizational Culture

1. Maintain Sense Of Vulnerability 2. Combat Normalization Of Deviance 3. Establish an Imperative for Safety 4. Perform Valid/Timely Hazard/Risk

Assessments 5. Ensure Open and Frank Communications 6. Learn and Advance the Culture

Global Process Safety Team Culture Development

Asia Process Safety

Europe Process Safety

Americas Process Safety

Global Process Safety Team

How did I win the hearts and

minds?

Internal

External

Team Relationship

One-on-one Relationship