Copyright © 2002 E. I. du Pont de Nemours and company. All rights reserved. Process Safety in the Workplace Human Involvement Hansjürgen Labudde, SHE

Copyright © 2002 E. I. du Pont de Nemours and company. All rights reserved.

Process Safety in the Process Safety in the WorkplaceWorkplace

Human InvolvementHuman Involvement

Hansjürgen Labudde, SHE Training Manager - Europe


Agenda

IntroductionIntroduction

Shift in Beliefs

The DuPont approach of Process Safety & Risk Management

Establishing a Safety Culture

Providing Management Leadership and Committment

Implementing a comprehensive PS&RM program

Achieving Operating Excellence through Operational Discipline

Conclusion


What you might know about DuPont

Worldwide benchmark for industrial SHE

$24 Billion in revenue

79,000 employees operating in 70 countries on 6 continents

5 core business segments including DuPont Safety & Protection

g


Sales:Sales: $ 6.31 billion$ 6.31 billion

ATOI: ATOI: $ 727 million$ 727 million

Employees: Employees: 18,20018,200

Approx 66% of European sales are produced, refined Approx 66% of European sales are produced, refined or manufactured in the regionor manufactured in the region

DuPont in Europe, Middle East & Africa 2002


DuPont locations in the region

Joint ventures

Offices

Plants

R&D/Technical Service Centres


All injuries are preventable

Industrial average

over 40

DuPont

only 0,4

Injuries with more than 3 lost work days

per 1000 employees per year


DuPont Core Values

Respect

to employees

and customers

Safety,

Health &

Environment

(SHE)

Ethics


Agenda


Shift in Beliefs






Conclusion


Business Excellencethrough

SHE Excellence?

A Shift in Beliefs


Shifting a Belief:

Drive towards excellence!

Zero injuriesZero spills.Zero wrong financial transactions.Zero …..

Things go wrong, accidents happen.

Safety performance can be managed.


Shifting a Belief:

Understand root causes!

Of accidents.Of productivity problems.Of complaintsOf …..

Fatalities and serious injuries are investigated because it is required by law.

All accidents and incidents are investigated because we want to learn.


Shifting a Belief:

From reaction to prevention!

InitiativeOperational disciplinePersonal responsibility…..

Safety performance is a question of luck.

Safety performance can be managed.


Shifting a Belief:

Focus on people!

Lean organization.Tap the capabilities of all employees.Empower people…..

Employees must be supervised so that they comply.

Employees must be educated and empowered so that they perform.


Teams

• Management Commitment• Condition of Employment• Fear/Discipline• Rules/Procedures• Supervisor Control, Emphasis, and Goals• Value All People• Training

• Personal Knowledge, Commitment, and Standards• Internalization• Personal Value• Care for Self• Practice, Habits• Individual Recognition

• Help Others Conform• Others’ Keeper• Networking Contributor• Care for Others• Organizational Pride

InjuryRates

Errors

Failures to

perform

Natural Instincts

Supervision

Self

Where do you want to be?Where do you want to be? How fast do you want to get there?How fast do you want to get there?

Dependent

Independent Interdependent

Developing an Organization

Rea

ctiv

e


The employee is in the focus

Active

Informed

Aware about company goals

Responsible

Decisive

Self-confident

Independent

Team oriented


Agenda


Shift in Beliefs






Conclusion



• Flixborough (6/74) 28 fatalities - $167MM

• Seveso (7/76) Contaminated countryside

• Mex. City (11/84) 550+ fatalities - $26MM

• Bhopal (12/84) 3M+ fatalities - 200M affected

• Chernob. Nuc. Plt. (4/86) 31 fatalities - 300 mi2 evacuated

• Piper Alpha Plat. (7/88) 165 fatalities

• Pasadena, Tx. (11/89) 23 fatalities - $797MM

• Channelview, Tx. (7/90) 17 fatalities - $14MM

• Pemex, Mexico (7/96) Multiple fatalities - $253MM $8MMM loss to economy

• Petrobras, Brasil (6/2001) 10 fatalities - $300MM

• Toulouse, France (9/01) 29 fatalities20,000 homes damaged

* Large property damage losses (17th edition); M&M Protection Consultants; 1166 Avenue of the Americas, NY, NY 10036

Some industrial key accidentsSome industrial key accidents


Industrial IncidentsIndustrial Incidents

Unfortunately, that listing was only a Unfortunately, that listing was only a partial (small) list of many incidents partial (small) list of many incidents that have occurred in the energy and that have occurred in the energy and chemical industries worldwide.chemical industries worldwide.

So, what’s the best answer?So, what’s the best answer?


Process Safety& Risk ManagementProcess Safety& Risk Management

The application of Management Systems to The application of Management Systems to the the IDENTIFICATIONIDENTIFICATION, , UNDERSTANDINGUNDERSTANDING, , and and CONTROLCONTROL of Process Hazards to of Process Hazards to prevent a major fire, explosion, or toxic prevent a major fire, explosion, or toxic release which could lead to a fatality or release which could lead to a fatality or multiple lost workday cases.multiple lost workday cases.


The DuPont Approach to Managing Process Safety

Four Key Steps:

1. Establishing a Safety Culture

2. Providing Management Leadership and Commitment

3. Implementing a comprehensive PS&RM Program

4. Achieving Operating Excellence through Operational Discipline


Agenda


Shift in Beliefs


Establishing a Safety CultureEstablishing a Safety Culture



Achieving Operating Excellence through Operating Discipline

Conclusion


The Step

Establishing the safety culture!


The Safety CultureThe Safety Culture The Safety CultureThe Safety Culture

Founded 1802

Explosion 1815

Explosion 1818

Safety is a Management Responsibility

Damage $ 80 000

40 people killed Damage $ 120 000


DuPont gun powder barrelsDuPont gun powder barrelsE. I. du Pont de NemoursE. I. du Pont de Nemours

Core Value Roots

1811 rules Safety is a line management Responsibility No employee may enter a new rebuilt mill until a member of top management has

personally operated it


One Company’s Mission One Company’s Mission m

“…….adhere to the highest standards for the safe operations of facilities and the protection of the environment, our people, our customers, and the citizens of the communities in which we do business.”

“Value the safety of our coworkers, our community and the need to return home safely to our families each day.”


One Company’s Mission One Company’s Mission m


Successful Fundamentals

1.All injuries, occupational illnesses, safety and environmental incidents are preventable.

2.Management is responsible for safety.

3.Safety is an individual’s responsibility and a condition of employment.

4.Training is an essential element for safe

workplaces.

5.Audits must be conducted.


Successful Fundamentals

6.All deficiencies must be corrected promptly.

7. It is essential to investigate all injuries and incidents

with injury potential.

8.Off the job safety is an important part of the safety effort.

9. It is good business to prevent injuries and illnesses.

10. People are the most important element of the

Safety and Occupational Health Program.


Agenda


Shift in Beliefs






Conclusion


The Step

Management Leadershipand Commitment


Management Leadership in Process Safety

Principle

Management leadership and commitment form the foundation of efforts to improve process safety. Although leadership and initiative are needed throughout all levels of an organization, it is crucial that senior management provide visible support and encouragement.


Key Responsibilities Establishing the Safety Culture Establishing PSM policies/guidelines Committing resources Involving employees Establishing clear accountability Auditing for degree of compliance Personally participating in PSM activities

Management Leadership and Commitment


Agenda


Shift in Beliefs






Conclusion


The Step

Implementation of aComprehensive Process Safety& Risk Management Program


AuditingProcess

Technology OperatingProcedures and Safe

Practices

Management ofChange

Process HazardsAnalysis

Quality Assurance

Prestart-Up SafetyReviews

Mechanical Integrity

Management of“Subtle” Change

Emergency Planningand Response

Management of Change

Incident Investigationand Reporting

Contractor Safetyand Performance

Training andPerformance

Process Safety and Risk Management Model

MANAGEMENTMANAGEMENTLEADERSHIP &LEADERSHIP &COMMITMENTCOMMITMENT



TECHNOLOGY

FACILITIES

PERSONNEL

Process Safety ManagementProcess Safety Management


TechnologyTechnology


Process TechnologyProcess Technology

Process Technology describes the process

and operation

Understanding the hazards is the first step

Consists of three parts


The 3 Parts of Process TechnologyThe 3 Parts of Process Technology

Hazards of Materials

Process Design Basis

Equipment Design Basis


Process Hazards AnalysisProcess Hazards Analysis

Process Hazards Analyses identify,

evaluate, and control hazards

- orderly and methodical approaches

- many people involved

Standard


Procedures & Safe PracticesProcedures & Safe Practices

Provide clear understanding of operating parameters and limits for safe operation

They explain the consequences of problems and the steps necessary to correct and or avoid them

Developed and documented for each process g


Management of Change - Management of Change - TechnologyTechnology

Changes may invalidate prior

assessments

All changes must be rigorously reviewed

Sites must have procedures to manage

changes.


19841984 A large amount of water was put into a methyl A large amount of water was put into a methyl

isocyanate tank. The resulting overpressure and related isocyanate tank. The resulting overpressure and related system failures caused the tank to vent and a large cloud of system failures caused the tank to vent and a large cloud of gases was released and drifted onto the nearby densely gases was released and drifted onto the nearby densely populated area. The severity of this accident makes it the populated area. The severity of this accident makes it the worst recorded within the chemical industry, with fatalities worst recorded within the chemical industry, with fatalities estimated in the thousands, ~2,800 from the immediate estimated in the thousands, ~2,800 from the immediate release and possibly up to 15,000 related deaths since.release and possibly up to 15,000 related deaths since.

Bhopal, IndiaBhopal, IndiaTechnologyTechnology Industrial Incident #1Industrial Incident #1


Contributing Factors:

plant modification/change - HAZOP

not recognizing safety critical systems and

their operability

design codes

training and competence

Technology Technology Industrial Incident #1Industrial Incident #1


19211921 Two explosions at the BASF plant killed 430 and

destroyed 700 homes. Blasting powder was being used to breakup storage piles of ammonium sulphate and ammonium nitrate. This procedure had been used 16,000 times without mishap. The 4,500 tons of the mixture exploded and left a crater 250 feet in diameter and 50 feet deep.

Tough stuff to set off. But when it goes, it goes !

Oppau, GermanyOppau, GermanyTechnologyTechnology Industrial Incident # 2Industrial Incident # 2


Toulouse Grande Paroisse

On Friday September 21,2001 at 10:15 am…..


Contributing Factor:

not recognizing hazards of materials

Technology Technology Industrial Incident # 2Industrial Incident # 2


FacilitiesFacilities


Quality AssuranceQuality Assurance

Quality Assurance “bridges the gap” between Quality Assurance “bridges the gap” between

design and installation: design and installation:

fabrication and parts meet specificationsfabrication and parts meet specifications

delivery to the right locationdelivery to the right location

properly assembled and installed properly assembled and installed


Pre-Startup Safety ReviewPre-Startup Safety Review

Provides a final check for new or modified Provides a final check for new or modified equipment to ensure the facilities areequipment to ensure the facilities are

“ “ safe to operate “safe to operate “

Std


Mechanical IntegrityMechanical Integrity

Process related equipment that contains Process related equipment that contains highly hazardous chemicals must be highly hazardous chemicals must be maintained from the time of design maintained from the time of design throughout the life of the facility.throughout the life of the facility.

Mechanical integrity focuses on system Mechanical integrity focuses on system integrity to contain hazardous materials.integrity to contain hazardous materials.


Mechanical IntegrityMechanical Integrity

Deals with:Deals with: Maintenance proceduresMaintenance procedures Training and performance of employeesTraining and performance of employees Quality controlQuality control Equipment tests and inspections, including Equipment tests and inspections, including

predictive and preventative maintenancepredictive and preventative maintenance


Management of “Subtle” ChangesManagement of “Subtle” Changes

Subtle Changes have led to catastrophic events!Subtle Changes have led to catastrophic events!

All process changes, including those within the All process changes, including those within the

“documented” process technology, but are not a “documented” process technology, but are not a

replacement-in-kind, must receive appropriate replacement-in-kind, must receive appropriate

review and authorization.review and authorization.


19741974 At the Nypro(UK) chemical facility, a At the Nypro(UK) chemical facility, a

large quantity of cyclohexane vapor was large quantity of cyclohexane vapor was released when a 20 inch “makeshift” released when a 20 inch “makeshift” bypass pipe ruptured. The resulting bypass pipe ruptured. The resulting massive vapor cloud explosion killed 28 massive vapor cloud explosion killed 28 workers. workers.

Flixborough, EnglandFlixborough, EnglandFacilitiesFacilities Industrial Incident # 5Industrial Incident # 5



management of change procedures

design codes

maintenance procedures - recommissioning

plant layout - position of occupied buildings

emergency plan

FacilitiesFacilities Industrial Incident # 5Industrial Incident # 5


19841984 Technicians at the power plant allowed the fourth

reactor to fall to low power levels as part of a “controlled experiment”. The reactor overheated causing a meltdown of the core. Explosions blew the top off the reactor building releasing radioactive material into the atmosphere for over 10 days. 31 workers were killed and the extent of lingering health effects has been significant and subject of debate. It is now entombedIt is now entombed..

Chernobyl, UkraineChernobyl, UkraineFacilitiesFacilities Industrial Incident # 6 Industrial Incident # 6



management of change procedures

equipment/facility design

procedures and safe practices

emergency shutdown plan

FacilitiesFacilities Industrial Incident # 6 Industrial Incident # 6


PersonnelPersonnel


Training and PerformanceTraining and Performance

Trained employees are an absolute

requirement, and be physically able,

mentally alert and capable of using good

judgment.

Training qualification must be documented.


ContractorsContractors

For contractors working in and around highly For contractors working in and around highly hazardous material processes, or performing hazardous material processes, or performing maintenance/repair on or near a covered maintenance/repair on or near a covered process ……….process ……….

they are required to comply with same they are required to comply with same regulations and guidelines as industry /site!regulations and guidelines as industry /site!


Investigations are essential to improve Investigations are essential to improve performanceperformance

The objective is to find the contributing factors The objective is to find the contributing factors and implement corrective actions(s)and implement corrective actions(s)

The degree of the investigation will depend on The degree of the investigation will depend on severity or potentialseverity or potential

Incident Investigation & ReportingIncident Investigation & Reporting


Management of Change - PersonnelManagement of Change - Personnel

People are the essential ingredient:People are the essential ingredient: process experience process experience knowledge and skill in managing Process knowledge and skill in managing Process

SafetySafety maintain minimum experience level and maintain minimum experience level and

knowledge through personnel and knowledge through personnel and organizational changesorganizational changes


Emergency Planning & ResponseEmergency Planning & Response

Planning and training for potential Planning and training for potential emergencies are essential for effective emergencies are essential for effective responseresponse


AuditingAuditing

Auditing must be used to assure that all Auditing must be used to assure that all elements of Process Safety Management are elements of Process Safety Management are being implemented properly.being implemented properly.

Proper auditing must include positive and Proper auditing must include positive and corrective feedback corrective feedback


19891989 During maintenance work on a During maintenance work on a

reactor settling leg, a large release of reactor settling leg, a large release of flammable vapor occurred at the Phillips flammable vapor occurred at the Phillips 66 chemical complex. The result was a 66 chemical complex. The result was a massive vapor cloud explosion, followed massive vapor cloud explosion, followed by a series of further explosions and fires.by a series of further explosions and fires.

Pasadena, TexasPasadena, Texas

PersonnelPersonnel Industrial Incident # 3Industrial Incident # 3



site and industry standards for maintenance

not followed

training and competence

work permit system - contractors

positioning of occupied buildings



19841984 A major fire and a series of catastrophic explosions A major fire and a series of catastrophic explosions

occurred at the government owned and operated PEMEX occurred at the government owned and operated PEMEX LPG Terminal. Approximetly 500 people were killed and LPG Terminal. Approximetly 500 people were killed and the facility was destroyed. After the intial release, the first the facility was destroyed. After the intial release, the first BLEVE occurred. For the next 90 minutes, a series of BLEVE occurred. For the next 90 minutes, a series of BLEVEs followed as other LPG vessels violently BLEVEs followed as other LPG vessels violently exploded. It started with a ruptured line and was made exploded. It started with a ruptured line and was made worse by failed safey systems and worse by failed safey systems and layout.layout.

Mexico City, MexicoMexico City, Mexico




plant layout - the positioning of vessels

emergency isolation

survivability of critical systems

emergency plan and site access




unknown at this time

under investigation

UnknownUnknown Industrial Incident # 7Industrial Incident # 7


AuditingProcess


Practices

Management ofChange


Quality Assurance













Agenda


Shift in Beliefs






Conclusion


The Step

Achieving “Operating Excellence”


Importance of Operating DisciplineImportance of Operating Discipline

The safe manufacture, use and handling of The safe manufacture, use and handling of hazardous materials requires hazardous materials requires

DedicationDedication & & CommitmentCommitment

TECHNOLOGY FACILITIES

PERSONNEL

in the way you managein the way you manage



OD--What Is It?

Dedication and commitment by every member of the organization to carry out each task the right way every time.

Operating Excellence--What Is It?Operating excellence results when an organization establishes OD and completes all tasks properly, thus contributing to the organization’s goal of achieving business excellence.


Why is OD Important?

IT HELPS1. Change a “paper” PSRM program into a

reality--an action program.

2. Organizations achieve their goals, because improvement programs are implemented to their fullest.

3. Protect personnel from injury.

4. Protect jobs by helping to prevent the loss of facilities.

5. Ensure a quality product.

6. Keep a business healthy


AuditingProcess


Practices

Management ofChange


Quality Assurance













Agenda


Shift in Beliefs






Conclusion


Good Safety = Good Business

CONCLUSION I


CONCLUSION II



Ďakujem za pozornosť

Danke schön

Thank you



Thank you very muchPlease contact for any questions

Gerhard Reibersdorfer

Tel: +352 3666 5313E-mail: [email protected]

Documents

Copyright © 2002 E. I. du Pont de Nemours and company. All rights reserved. Process Safety in the Workplace Human Involvement Hansjürgen Labudde, SHE