Process Safety – A Comprehensive Approach Leading to Connected Compliance
Process Safety Management (PSM) is a program comprised of multiple management systems designed to prevent toxic releases, fires, and explosions in the process industries. These management systems can appear highly divergent, but there are many interrelationships. OS provides industry experts who each average more than 30 years of expertise who are not only technically competent, but also approach projects with these key interrelationships in mind. In other words, we understand that each management system output becomes the input for another system and must be properly prepared to prevent rework later. Our PSM program also incorporates the US EPA Risk Management Plan (RMP) elements.
Regardless of your company’s size or industry, OS offers comprehensive consulting services to provide the right expertise to assess your needs, diagnose problems, and deliver enterprise level risk-based solutions that enhance compliance.
And, we offer our world-class OESuite® software, which is the most comprehensive offering in the marketplace to address your PSM needs. A comprehensive PSM solution should, when aligned with the right safety culture and execution strategies, help deliver sustainable Operational Excellence.
OESuite® PSM Alignment
Where is Industry Today?
A recent report by Pilco & Associates in April 2020 shows that process safety incidents have increased roughly 50% since 2016. With the onset of COVID-19, we fully expect there to be additional challenges to process safety performance since companies have been deferring compliance activities including PHAs, Audits, and Inspections. As a result, Process Safety Health will be crucial to ensure companies are watching for impending threats including organizational drift which is being exacerbated by remote PSM professionals who often have limited influence to drive PSM programs in the current environment of reduced access to facilities and in-person facetime meetings with key decision makers. Without careful planning, COVID-19 measures can unintentionally chip away at the foundational cultural tenants of an organization whereby formerly critical priorities, teamwork and collaborative efforts are destabilized and lose effectiveness.
Without executing both Cultural Safety and Conduct of Operations (CoO), companies will struggle to implement an effective Process Safety Management (PSM) system. Process Safety requirements are only effective when the organization’s safety culture is at a level where employees are fully engaged, aligned with the leadership, and are performance driven, coupled with effective CoO that further reduce human error.
So Why Cultural Safety and Conduct of Operations?
Between 70% and 90% of unwanted events are attributable to human or organizational failure. To reduce failures, organizations must focus on mitigating human performance and not just asset performance. This requires a relook at how your program is designed and performing.
You can have best-in-class PSM standards and procedures but without proper execution you still have major exposure to potential process safety incidents. A high functioning safety / process safety culture gives rise to a Connected Culture which is the foundation for the operational discipline necessary to effectively carry out standards and procedures. In turn, Operational Discipline requires a Conduct of Operations (CoO) framework to facilitate consistent and accurate execution of those same standards and procedures. CoO has to underpin the Connected Culture to enable operational discipline.
If you are governed by PSM, the operational discipline inherent in Cultural Safety Excellence strengthens execution of Process Safety systems, resulting in Operational Safety Excellence.
From building a PSM program from the ground up to conducting PHAs and Audits to providing field technicians to conduct MOCs and Incident Investigations… we support your team. We offer technical content for PSM, Mechanical Integrity (MI), and Management of Change (MOC) to accelerate development of your program.
Other related activities that we perform include:
Process Safety Culture Assessment
Individual Element Auditing
General PSM / RMP Consulting
Resolution of PSM Gap / Audit Findings
And if you want to go beyond basic compliance, we can help you develop a Risk-Based Process Safety (RBPS) program that aligns with the Chemical Center for Process Safety (CCPS) Vision 20/20 Program.
Today, the Connected Culture enables companies to move beyond lagging to leading indicators. Predictive analytics enable anomaly detection to identify threats, so that incidents are prevented as opposed to typical scenarios where incidents are managed and mitigated after they’ve already occurred.
OS offers a comprehensive solution for Process Safety Health. Our Process Safety Health monitoring is part of an overall Operational Risk Management (ORM) framework that creates a holistic risk registry to proactively monitor the organization to ensure the right priorities are managed below the risk tolerance set by the board. The interoperability enabled by OESuite® creates a Connected Workforce leading to data-driven decisions and insights, meaning field personnel can see threats as they emerge. The intersection between the Connected Workforce and PSM is what we call Connected Compliance.
With OESuite® a Connected Workforce enables workers in the field to conduct compliance activities using our comprehensive set of mobile-enabled PSM modules. Connected Compliance bridges Cultural Safety, ORM, and CoO with the human aspect of safety and aligns it with the organizational objectives. These need to be measured, and auditing is a key monitoring tool available to check adherence to standards. The final aspect of sustaining organizational performance objectives is achieved through Process Safety Health Monitoring as part of an overall Operational Performance Management (OPM) framework.
OESuite® Business Benefits for Process Safety / RMP
OESuite® Mobile Applications
Our mobile applications enable field personnel to log incidents and near misses, conduct audits, commission changes and initiate changes in the field. Operators can access complete information on work order status, permit isolation conditions, and other important process safety information on the fly. Whether on a tablet or phone, technicians can access mission critical information is at your disposal on your device at any time. The result is safer startups, enhanced sharing of risk information, and improved efficiency.
MOC, Mechanical Integrity, and Process Safety Information are the core of Intelligent Operations and Operational Risk Management.
Process Safety Excellence means going above and beyond doing PHAs, Audits, and Incident investigations. By breaking down the data management silos and rethinking how to digitize PSM, companies can get away from after-the-fact disparate information sources to true risk management.
At Operational Sustainability®, we help you devise a strategy to achieve world-class process safety performance. Once you have the basic elements in place, we can help you progress to Risk-Based Process Safety, incorporating relevant attributes of Conduct of Operations to achieve sustained top quartile performance.
Operational Sustainability® assists clients with Process Safety by developing business processes, standards, policies, procedures, and field guides. The Operational Sustainability® OESuite® software effectively addresses all aspects of PSM from an integrated perspective, including risk-based process safety. Our PSM software comes with pre-configured process templates, reports, and dashboards. The Operational Sustainability® Process Safety Technical Content set incorporates the 14 Process Safety elements, helping organizations address key Process Safety challenges in a systemic, repeatable way.
Management of Change Facility and Technology Procedure
Not only does OS offer customizable technical content, we also offer our industry leading OESuite® software platform with nearly 40 modules. To accelerate the implementation of our software, we offer:
Pre-configured Work Processes
Best Practices and “To Be” Workflows
Computer-Based Training (CBT) Modules
Our Technical Content will save you thousands of hours, while allowing you to focus on your organization’s core capability.
OESuite® Integrations / Connectors
OS can help you comprehensively address PSM/RMP compliance. PSM forms the core for our Operational Risk Management (ORM) solution and offers foundational elements including Management of Change (MOC), Technical Engineering Content and Data (also referred to as Process Safety Information), and Enterprise Loss Prevention (ELP) leading to a single source of truth. These three foundational elements are highly integrated through the OESuite® platform.
Some key integrations include:
Management of Change with Work Orders
Incidents with MOCs
PHAs, Audits and Incidents with Corrective and Preventative Action (CAPA)
Training with Competency
MOC with CAPA
Procedures with Document Management
Work Permits with Work Orders
PSM is key to running an organization within defined risk tolerances for chemical hazards. OS leverages an API 754 reporting framework as a hub to roll-up information from OESuite® to detect potential threats. In addition, OS Visual Operations enables users to see threats as they materialize in near-real time at a P&ID or Process Flow Diagram Level.