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Enhancing Process Safety: A Guide to Reporting KPIs and Events (with Expert Classification Insights)

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Enhancing Process Safety: A Guide to Reporting KPIs and Events (with Expert Classification Insights)


Introduction:


In the pursuit of operational excellence and the mitigation of major hazards, the systematic tracking and analysis of both leading and lagging indicators in Process Safety is paramount. By identifying trends and root causes, organizations can proactively implement measures to prevent recurrence and continuously improve their safety performance. This post will guide you through the classification and reporting of Process Safety indicators, drawing from the principles outlined in API 754, with illustrative examples and expert insights into event classification based on practical experience.








The Power of Leading and Lagging Indicators:


Both leading and lagging indicators provide crucial insights for enhancing Process Safety:


  • Lagging Indicators: These are reactive metrics that reflect past incidents or failures. Analyzing them helps in understanding the consequences of safety system breakdowns and preventing similar events.
  • Leading Indicators: These are proactive metrics that monitor the health and effectiveness of safety barriers and management systems. Tracking them allows for early intervention before incidents occur.









1. Classification of Process Safety Indicators:

As per API 754, Process Safety indicators are categorized into four tiers, forming a pyramid where the higher tiers represent events of greater consequence:


  • Tier 1: Loss of Primary Containment (LOPC) events of greater consequence. These are significant events that typically require external reporting.


    • Examples:
      • A large crude oil spill that reaches a nearby river, causing significant environmental damage.
      • A major fire at a refinery resulting in fatalities or serious injuries to workers.
      • A significant explosion at a chemical plant leading to offsite impacts.
      • A rupture of a high-pressure gas pipeline causing a widespread evacuation.
      • (Note: In Tier 1 and 2, the LOPC involves the release of the primary hazardous material.)

  • Tier 2: LOPC events of lesser consequence. These also often warrant external reporting for industry benchmarking.


    • Examples:
      • A smaller oil spill contained within the facility's boundaries and cleaned up without significant environmental impact.
      • A flash fire that causes minor injuries to workers but is quickly extinguished.
      • A release of toxic gas that requires onsite personnel to wear respirators but does not affect the surrounding community.
      • A leak from a storage tank that is contained by secondary containment.
      • (Note: In Tier 1 and 2, the LOPC involves the release of the primary hazardous material.)

  • Tier 3: LOPC events with a consequence less than Tier 2 PSEs, and challenges to safety systems. This tier, along with Tier 4, is primarily for internal use. Examples include LOPC below a Tier 2 threshold (acute release) and minor leakages over prolonged periods. Non-LOPC examples include Safe Operating Limit Excursions (SOLE) and Demand on Safety Systems (DSS).


    • Examples:
      • A small leak from a pump seal that is quickly repaired. (LOPC, but note distinction below)
      • An overflow of a chemical tank that is contained within a bund. (LOPC, but note distinction below)
      • A high-temperature alarm on a reactor that triggers an automatic shutdown. (SOLE)
      • A test of a safety shutdown system that reveals a faulty sensor. (Challenged to Safety System - CTSS)
      • A pressure relief valve lifting during an upset condition. (DSS)
      • (Note: Tier 3 can include LOPC of auxiliary fluids within safety systems, in addition to challenges to safety systems and other events.)

  • Tier 4: Operating discipline and management system performance. This lowest tier focuses on Key Performance Indicators (KPIs) reported at a local level, specific to an activity, asset, facility, or plant.


    • Examples:
      • Percentage of safety critical equipment with up-to-date inspections. (KPI)
      • Number of overdue preventive maintenance tasks. (KPI)
      • Percentage of operators trained on new procedures. (KPI)
      • Number of safety walkarounds completed per month. (KPI)
      • Number of near-miss incidents reported. (KPI - leading)
      • Number of overdue corrective actions from safety audits. (KPI)

(Refer to the attached pyramid image for visual examples of process safety events and KPIs across these tiers.)





2. Reporting Guidance:


Effective reporting is crucial for leveraging the insights from Process Safety indicators:

  • Tier 1 and 2 Events: Process Safety events falling under Tiers 1 and 2 should be reported externally for industry benchmarking. This practice, aligned with the American Petroleum Institute's (API) Recommended Practice (RP) 754, contributes to broader industry learning through organizations like IOGP, CONCAWE, EPSC, and CEFIC.
  • Tier 3 and 4 KPIs: Key Performance Indicators (KPIs) gathered at Tiers 3 and 4 are intended for internal use. They serve to monitor the effectiveness of key safety barriers and the strength of operating discipline. Furthermore, these KPIs are used to evaluate the performance of the barriers put in place to manage the risk of Process Safety events.


Refined Event Classification (Focus on ESDV Example) (Based on Process Safety Experience):


Drawing from extensive experience in process safety hazardous events classification, a nuanced approach is essential for accurate reporting. To simplify the process, it's vital to:


  • Determine the Primary Containment: In the case of an ESDV installed on a crude oil flowline, the primary containment is the crude oil flowline itself.
  • Distinguish LOPC: The hydraulic fluid within the ESDV's operating mechanism is not the primary containment. Therefore, a hydraulic leak is a specific type of LOPC (of an auxiliary fluid) and must be categorized with care.

Considering these factors and practical insights from the field, the classification of an ESDV hydraulic leak event is as follows:


  • Hydraulic Leak (General): Primarily classified as a Challenged to Safety System (CTSS) - Tier 3. This reflects the impairment of the ESDV's reliability.
  • ESDV Failure on Demand: If the hydraulic leak leads to the ESDV failing to operate when required, the classification changes to Demand on Safety System (DSS) - Tier 3.
  • Leak Discovery Context:
    • Routine Inspection (Minor Leak): May be classified as a Critical Equipment Failure - Tier 4.
    • Routine Inspection (Significant Leak): May be classified as Tier 3 due to the severity of the challenge to the safety system.


Conclusion:

By diligently classifying and reporting both Process Safety events and performance-based KPIs, organizations can gain valuable insights into their risk landscape. This data-driven approach, focusing on both past occurrences and the health of preventative measures, is fundamental to fostering a strong process safety culture and ultimately reducing the risk of major incidents. The refined classification approach, particularly for complex scenarios like ESDV failures, ensures accurate reporting and effective learning from events, informed by practical process safety expertise.


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