The definitive leadership guide on safe practices
The release of chemicals and other hazardous materials pose significant, potentially catastrophic threats worldwide. An alarming number of such events, all of which are preventable, occur too often. Reducing the frequency of serious incidents is a fundamental responsibility of leadership at all levels, from frontline managers and supervisors to C-suite executives and the board of directors as well. Process Safety Leadership from the Boardroom to the Frontline is a practical, authoritative guide that clearly demonstrates how to create a viable culture of safety within an organization, implement and maintain disciplined management systems, and address the risks of process safety deficiencies.
The most important factor in any management system is leadership. For chemical process safety management, effective and informed leadership provides direction, reinforces commitment, and drives responsibility. Written by experts from the Center for Chemical Process Safety, the world's largest provider of engineering curriculum materials for process safety, this pragmatic book contains the critical information and guidelines required to lead and manage process safety. Detailed yet accessible chapters examine topics such as strengthening management system accountability, driving operation within constraints, ensuring corporate memory, verifying execution, and more. Designed to be frequently used, shared, and discussed by leadership teams throughout an organization, this indispensable resource:
- Demonstrates the many ways process safety benefits an organization, based on benchmarking and broad industrial experience
- Develops skills and expands knowledge needed to drive consistent, reliable process safety performance
- Describes essential behaviors and actions for leaders to drive excellence in process safety cultures and disciplined management systems
- Helps establish risk criteria and safeguards for companies
- Presents new and previously unpublished experiences, approaches, and thinking
Written for executives, plant leaders, functional managers, frontline supervisors and also individual contributors, Process Safety Leadership from the Boardroom to the Frontline provides a much-needed guide for instituting safe practices within a company.
The Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology since 1985. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 10 training modules through its Safety in Chemical Engineering Education (SAChE) series.
Table of Contents
Acronyms and Abbreviations xi
Acknowledgements xiii
Nomenclature and Style xv
Preface xvii
Executive Summary xix
How to Use this Book xxv
1 The Business Case for Process Safety 1
1.1 Corporate Social Responsibility 2
1.2 Business Flexibility 4
1.3 Loss Prevention 5
1.4 Sustainable Growth 7
1.5 Leadership Excellence 9
1.6 Summary 9
1.7 References 10
1.8 Incidents Represented in Figure 1.2 12
2 Leading and Managing Process Safety 13
2.1 Process Safety Definition 13
2.2 How Process Safety Works: Risk Reduction and Risk Management to Eliminate Accidents 22
2.3 Learning from Incidents 25
2.4 Personal Leadership Accountability 30
2.5 Downturns and Boom Times: Special Process Safety Leadership Challenges 34
2.6 Compliance: Required but not Enough 39
2.7 Management Systems: Helpful but not Sufficient 43
2.8 References 44
3 Leadership Attributes 47
3.1 Creating a Shared Vision 48
3.1.1 Establish the Imperative for Process Safety 48
3.1.2 Reflect the Imperative in Your Words and Actions 51
3.1.3 Drive the Imperative Throughout the Organization 54
3.1.4 Earn the Social License to Operate 57
3.2 Develop and Maintain Knowledge and Competence 60
3.2.1 Personal Knowledge and Competence 60
3.2.2 Develop and Empower Others 64
3.3 Show Integrity and Commitment 71
3.3.1 Courage and Conviction 71
3.3.2 Accountability 73
3.3.3 Responsiveness 76
3.3.4 Consistency 78
3.4 Communicate with Inspiration 80
3.4.1 Stay Connected and Visible 80
3.4.2 Influence and Drive Process Safety Culture 83
3.5 References 91
4 Leadership of the Process Safety Management System 93
4.1 Identify Required Barriers 94
4.1.1 Start with Risk Criteria and a Risk Matrix 95
4.1.2 Analyze Hazards and Risks 98
4.1.3 Identify Required Barriers 101
4.2 Manage Barriers 102
4.2.1 Conduct of Operations and Operational Discipline 102
4.2.2 Standards 110
4.2.3 Asset Integrity and Mechanical Integrity 113
4.2.4 Operating Procedures and Safe Work Practices 116
4.2.5 Management of Change 118
4.2.6 Emergency Management - Preparation and Response 123
4.3 Manage Competency (Organizational Capability) 127
4.3.1 Competency 128
4.3.2 Effective Training 130
4.3.3 Process Knowledge Management 133
4.3.4 Contractor Management 135
4.4 Verify Performance and Improve 139
4.4.1 Audits 139
4.4.2 Metrics 141
4.4.3 Incident Investigation and Resulting Actions 143
4.4.4 Management Review and Continual Improvement 146
4.5 Build and Strengthen Culture 151
4.5.1 Introduction to Culture 151
4.5.2 Workforce Involvement 152
4.5.3 Stakeholder Outreach 155
4.6 Summary 158
4.7 References 159
5 Leadership Roles and Accountabilities 161
Table 5.1 Executive Leadership Role 164
Table 5.2 Operations Leadership Role 166
Table 5.3 Engineering Leadership Role 168
Table 5.4 EH & S Leadership Role 170
Table 5.5 Research and Development (R & D) Leadership Role 172
Table 5.6 Purchasing Leadership Role 174
Table 5.7 Human Resources Leadership Role 176
Table 5.8 Plant Superintendent Role 178
Table 5.9 Maintenance Leadership Role 180
Table 5.10 Plant Engineer Role 182
Table 5.11 Plant Operator Role 184
Table 5.12 Maintenance Technician Role 187
Table 5.13 Process Safety Specialist Role 189
6 Deploying Process Safety Leadership Accountability and Responsibility 191
Table 6.1 Corporate Process Safety Leadership Team RACI Matrix 193
Table 6.2 Operations Leadership Team RACI Matrix 197
7 Make it Happen 201
7.1 References 207
Index 209
