Process safety as part of chemical safety

This article is the fifth installment in Protect’s series on chemical safety, which offers practical insights into meeting regulatory requirements. This time, the topic is process safety. The article reviews the key components of a process safety management system and how risks associated with chemical processes can be managed systematically.

A process safety management system refers to a production facility’s systematic approach to managing risks associated with chemicals and their processes. Process safety focuses particularly on risks that are unlikely to occur but could have serious consequences—such as explosions, fires, or leaks of hazardous chemicals.

Process safety management requires specialized expertise and systematic leadership. When assessing the situation at your own facility, you can use, for example, the model developed by Tukes, which outlines the requirements and the means to meet them.

The process safety system consists of several components that are used to identify, assess, and manage risks associated with chemical processes.

Figure 1. Process safety system. (Source: Tukes)

Process safety requires clear responsibilities and sufficient expertise throughout the organization. The operator must ensure the competence of its personnel and the management of contractors. Every employee must understand their role in maintaining process safety and the related guidelines.

Risk identification and assessment are at the heart of process safety. Hazardous factors at the facility are identified, the magnitude of the risks is assessed, and the necessary measures for managing them are defined. Risk assessments must be updated regularly as part of continuous improvement.

Process safety must be taken into account in all aspects of the facility’s operation and maintenance. The operator must maintain records of preventive and scheduled maintenance, as well as related measures. In addition, equipment critical to process safety must be identified, and its operational reliability must be ensured.

Change management is a key component of process safety. The operator must have a documented procedure in place to assess the risks associated with changes before they are implemented.

Examples of such changes include:

• technical changes

• organizational changes

• documentation changes

• changes related to hazardous chemicals

With a clear procedure in place, the operator can assess the risks associated with the change and any measures that need to be taken in connection with it before the change is implemented. Changes may also require authorization from the authorities.

Process safety includes preparing for potential accidents. Personnel must be trained to act safely in emergency situations or in the event of an accident, and these procedures must be practiced regularly. Preparedness must also take into account post-accident measures, such as environmental cleanup.

Performance monitoring includes continuous monitoring of process safety and the investigation of deviations. The operator must define what constitutes a process safety deviation and distinguish it from normal operations. The investigation of deviations aims to identify the root causes that led to them so that similar situations can be prevented in the future.

Internal and external audits help to review and assess the facility’s overall situation. Audits are used to evaluate the effectiveness of the process safety system and identify any areas for improvement. Process safety should also be addressed regularly during management reviews.

Understanding process safety helps companies manage the risks associated with hazardous chemicals and the related production processes. The principles of a process safety management system must be taken into account even before new production facilities are commissioned, but existing licensed facilities must also comply with and meet the same requirements.

Without systematic management of process safety, risks can grow unnoticed—until the consequences become serious.

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