PROCESS INDUSTRIES

Embedding Process Safety Leadership

Neil Smith

Network Services Director

Diversity of Process Industries’ Major Accidents

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• Oil Exploration

– Piper Alpha

– Deepwater Horizon

• Oil Refining

– Texas City

• Petrochemicals

– Flixborough

– Feyzin

– Pembrokeshire

• Fertilisers

– Toulouse AZF

• Fuel Storage

- Buncefield

• Specialty & Fine Chems

- Bhopal

- Seveso

- H&W

• Pharmaceuticals/Inters

- Akzo Buckhaven

- Merck

• Nuclear

– Chernobyl

Maximising Business Performance Through Skills Development

Background – why this project?

Common Threads

Widely different Process Industry Sectors with many different RISKS from plant & operations

However - Process Safety Leadership does not discriminate between industry sectors

• Catastrophes appear to originate at the sharp end

• Usually resulting from a series of coincident failures of hardware, management systems, procedures

• Exacerbated by ownership changes/restructuring

• Lack of understanding, ownership and clarity at Board or Senior Executive level

• Made worse by insufficient training & competence

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Process Safety Project Board

Early 2010 – Skills Academy Board members highlighted the need to address perceived gaps in Process Safety Management training

Analysis of existing training indicated a high volume of training programmes aimed at PSM ‘specialists’ and a dearth of programmes for senior executives and supervisors & operators

Agreement reached with CIA in summer 2010 to establish a Process Safety Management Project Board.

Project Board and Expert Panel established in September 2010

Priority established to develop training standards ensuring transparency and consistency of Process Safety Leadership training for Senior Executives and Board Members of Top-Tier COMAH sites

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Process Safety Project Board membership

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Process Safety Project Board

Purpose

•to build on recent work by CIA, IChemE, HSE

•to identify and coordinate all PSM training and development activity

•to develop a national framework for PSM Training & Standards

•to Champion the uptake of training by Top Tier companies

•to promote the understanding & accountability of PSM at Board & Senior Executive Level

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What does the UK Process Industry want?

• Clarity on relevant Guidance and Training

• Tailored to each level in the organisation

• Supported by the key trade and representative bodies

• Underpinned by the Competent Authorities

• Quality Assured training to a National Standard

• …………..A joined-up integrated approach for all

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PSM Expert Panel

Purpose

•to specify the technical content & subject matter for PSM Guidance & Training

•to identify the priorities for PSM Training

•to develop the criteria for PSM provider accreditation

•to ratify the standards of PSM Training for company and individual accreditation

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Focus on key roles and responsibilities

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Above-site Senior Executives

Site Leadership

Technical Specialists

Front-Line Supervisors

Front-Line staff

Training Standard for Process Safety Leadership

Training Standard for Process Safety Management

Gold Standard for Process Safety Specialist

Training Standards to be developed

Training Standards to be developed

Process Safety Management Project

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Project Board

Expert Panel

Wider industry consultation

Industry Endorsed Training Standards

Draft Training Standards

Quality Assurance of PSM Provision

Quality Assurance of PSM Training

A quality assured provider network for Process Safety

•Accreditation of the training organisation

•Endorsement of the course content against the training standards

•Approval of the trainers’ and facilitators’ skills knowledge and competence

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Our Goal for 2011

To engage at least 50 companies that operate Top Tier or

High Hazard sites to commit to PSM Training and

Accreditation for all relevant employees

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A high impact strategic project that is gaining in momentum

Excellent employer and stakeholder commitment to support development activities

First training standard (Process Safety Leadership) - Completed

Invitation to top-tier COMAH site senior executives to participate.

74 companies have expressed an interest, 164 individuals identified for training, and25 companies already signed up to programmes

Delivery model for Process Safety Leadership training established.

Assessment of training providers underway with a number of providers endorsed with more by the end of October.

A number of ‘early adopters’ already committed to undertake the Process Safety Leadership training

Maximising Business Performance Through Skills Development

The Results so far...

• Understand the business case for effective Process Safety Management

• Understand the nature of major accidents and how hazards and risks are defined and quantified.

• Understand the key elements of Process Safety Management Systems

• Understand assurance processes for effective risk management

• Understand how to promote a positive Process Safety culture through effective engagement of the workforce

• Understand the importance of good Process Safety leadership principles and how to implement them.

• Understand how to achieve continuous improvement in process safety performance

Maximising Business Performance Through Skills Development

Training Standard – Process Safety Leadership for Senior Executives

1 day course to include a ‘follow up’ review within 3-6 months

Closed course (single company, external venue )

Up to 10 delegates *£6,000 per course (incl. follow up)

Closed course (single company, in-house )

Up to 10 delegates *£5,600 per course (incl. follow up)

Open course (multi company) – external venue

6 to 10 delegates £750 per delegate +

£1,000 per company (follow-up)

* Guide price

Maximising Business Performance Through Skills Development

Programme format & costs

What next?

• Identify who, at the ‘Senior Executive’ & ‘Site Director’ level should participate in the Process Safety Leadership training.

• Contact the Academy to book an in-house or open programme for Process Safety Leadership training.

• Identify PSM ‘specialist’ colleagues who can contribute to the PSM Project Board or Expert Panel

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Contact details

http://process.nsacademy.co.uk/process-safety.aspx

Karen Brown / Emma Seaton

Process Safety Training Co-ordinators

01325 740911

K.Brown@process.nsacademy.co.uk

E.Seaton@process.nsacademy.co.uk

Ian Mains

Commercial Director

07894 483691

I.Mains@process.nsacademy.co.uk

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