Process Safety Management and Human Factors

1. Introduction to process safety management in a practical context

1.1 Prelude

1.2 Introduction

1.3 The rise of process safety management

1.4 Process safety management and human factors
References

2. Introduction to human factors and the human element

2.1 Introduction

2.2 Terminology and scope

2.3 Why and how human factors are important

2.4 Managing human failures

2.5 Safety critical tasks

2.6 Human factors in design

2.7 Conclusions
References

3. Leadership and process safety management

3.1 Introduction

3.2 Process safety elements: leadership

3.3 Understanding the leadership challenges

3.4 Process safety leadership: a model

3.5 Monitoring and managing process safety management performance

3.6 Way forward and chapter concluding remarks
Further reading

4. The awareness of risk, complacency, and the normalization of deviance

4.1 Introduction

4.2 Toward understanding deviation

4.3 What does complacency mean for process safety?

4.4 Complacency and the normalization of deviance

4.5 The elements of Situational Complacency

4.6 David’s story

4.7 Conclusions

4.8 Final thoughts
References

5. Competence assurance and organizational learning

5.1 Introduction

5.2 Assuring human performance

5.3 Competence and human performance

5.4 Wider organizational learning

5.5 Concluding remarks
References

6. Integration of human factors in hazard identification and risk assessment

6.1 Introduction

6.2 Human factors engineering in design and operational phases

6.3 Task design

6.4 Procedures

6.5 Human resources

6.6 Physical exposures

6.7 Fitness for duty

6.8 Incident investigation

6.9 Safety culture

6.10 Conclusions
Further Reading

7. Inherent safety impact in complying process safety regulations and reducing human error

7.1 Introduction

7.2 The causes of accidents in chemical process industries

7.3 Inherently safer design in process safety management

7.4 Reduction of human error through inherent safety

7.5 Case study

7.6 Conclusion
References

8. Asset and mechanical integrity management

8.1 Preamble

8.2 Process safety model

8.3 People_process_technology alignment to achieve process safety excellence

8.4 Asset integrity management

8.5 Industry case studies

8.6 Human factors

8.7 Way forward and chapter concluding remarks
References

9. Management of change

9.1 Introduction

9.2 The cases for change

9.3 Scope of a management of change

9.4 Change versus "replacement-in-kind"

9.5 Management of change review process

9.6 Management of change closure

9.7 Management of organizational change

9.8 "Minor" change

9.9 Concluding thoughts: modern trends in risk tolerance
References

10. Management of risk through safe work practices

10.1 Introduction

10.2 Human factors in risk management

10.3 Behavioral safety

10.4 Human performance gaps

10.5 Risk management through safe work practices: safe system of work, operating procedures, and safe work practices

10.6 Overview: establishing an effective safe system of work

10.7 Developing an internal document management system and document
framework

10.8 Safety programs

10.9 Summary
References

11. Process safety information, hazard control, and communication

11.1 Introduction

11.2 Process safety information element

11.3 Implementation framework for process safety information

11.4 Human errors applicable to process safety information

11.5 Concluding remarks
Acknowledgment
References

12. Prestart-up and shutdown safety reviews

12.1 Introduction

12.2 Why is a prestart-up safety review required?

12.3 Prestart-up safety review considerations

12.4 Key roles and responsibilities in prestart-up safety reviews

12.5 Prestart-up safety review team

12.6 Prestart-up safety review team composition

12.7 Prestart-up safety review team leader

12.8 Process safety management assessments

12.9 Implementing a prestart-up safety review

12.10 Generating and approval of the prestart-up safety review plan

12.11 Executing the prestart-up safety review

12.12 Field and physical inspections

12.13 Approval of the prestart-up safety review report and corrective actions

12.14 Corrective action management

12.15 Prestart-up safety review completion and closure

12.16 Conclusion
Appendix 1
Reference

13. Contractor management

13.1 Introduction

13.2 Overview of contract life cycle

13.3 Reasons for contracting work

13.4 Developing the scope of work

13.5 Internal/external prequalification

13.6 Site visit verification

13.7 References checks

13.8 Selection of contractors: criteria and weighting and contractor selection criteria

13.9 Stakeholder weighting assignments

13.10 Health, safety, and environment evaluation

13.11 Veto rights

13.12 Commercial assessment

13.13 Risk ranking of contractors

13.14 Contract execution

13.15 Contract/project kick-off

13.16 Contractor premobilization

13.17 HSE Alignment Workshops

13.18 Site-specific training implemented

13.19 Contractor mobilized

13.20 Contractor performance management

13.21 HSE audit: 30 days’ postmobilization

13.22 Leadership visibility

13.23 Listening moments

13.24 Contractor audits

13.25 Corrective action management

13.26 Contractor relationship management

13.27 Contract closeout
References

14. Emergency response management and control

14.1 Introduction

14.2 Why have emergency response plan

14.3 Scope of the Incident Management System or emergency response plan

14.4 Integrated "all-hazards" approach

14.5 Organizational principles of all-hazards approach

14.6 Emergency response priorities

14.7 Emergency management principles

14.8 Objectives-driven response

14.9 Incident action plans

14.10 Common and consistent terminology

14.11 Manageable span of control

14.12 Organizational response structure

14.13 Scalable response

14.14 Response triggers

14.15 Managing incident response through the utilization of the planning cycle

14.16 Business continuity

14.17 Plan linkage

14.18 Application of the Incident Management System in varying response frameworks

14.19 Single command

14.20 Coordinated command

14.21 Coordinated command structure

14.22 Expectations and assumptions for the effective operation of the ERP or IMS

14.23 Human factors in emergency response planning

14.24 Concluding remarks
Further reading

15. Human performance within process safety management compliance assurance

15.1 Introduction

15.2 Sociotechnical systems and human failure

15.3 Gaps within process safety management assurance

15.4 How to assure human performance

15.5 Concluding remarks
References

16. Regulating PSM and the impact of effectiveness

16.1 Introduction

16.2 Purpose of regulations

16.3 Prescriptive and performance-based regulations

16.4 Impact of effectiveness of PSM regulations

16.5 Challenges of having too many regulators

16.6 Chapter concluding remarks
References

17. Readying the organization for change: communication and alignment

17.1 Introduction

17.2 Key elements of organizational readiness and alignment

17.3 Creating a shared PSM vision

17.4 Sharing the vision

17.5 Aligning the organization—organizational change management

17.6 Conducting the stakeholder impact assessment

17.7 Managing organizational change

17.8 Communication methodologies

17.9 Seven best practices in organizational change management

17.10 Summary
References

18. Do we really learn from loss incidents?

18.1 Introduction

18.2 Barriers to learning

18.3 How to learn more effectively from external incidents

18.4 How to make effective recommendations

18.5 Concluding remarks: lessons from history
Acknowledgement
References
Further readings

19. Gauging the effectiveness of implementation and measuring the performance of PSM activities

19.1 Introduction

19.2 PSM assurance

19.3 Design of PSM

19.4 Supervision of PSM

19.5 Verification of PSM

19.6 Metrics for PSM

19.7 Audits of PSM

19.8 Verification workshops

19.9 Validation

19.10 Management review meetings

19.11 Operational intelligence

19.12 Closing thoughts
References

20. Human errors, organization culture, and leadership

20.1 Introduction

20.2 Human error and organizational culture

20.3 The human paradoxes leading to incidents

20.4 Closing thoughts
Epilogue

Appendix 1: Sample PSSR checklist and report
Appendix 2: Reference list and international standards and codes