Operational Excellence in EHS Requires Focus on Risk Culture, Competencies and Conduct of Operations
1:30 to 3:30 PM, Wednesday October 11, 2017 in Houston, TX
Jerry L. Jones, PE, CSP, CHMM, CFEI
Chemical Engineering Consultant
Purpose and Target Audience
This workshop concerning Operational Excellence focuses on EHS performance improvement and is intended to help with “accelerating the potential for member growth and strengthening the members' business and operations” as described in SOCMA’s mission statement.
This workshop should be of value to individuals in small to medium sized chemical enterprises:
- at all levels of production operations management from plant managers to shift supervisors,
- in process and project engineering, maintenance, utilities supply, logistics, EHS, quality assurance and human resources (e.g. training and performance improvement).
Mr. Jones will discuss a variety of good practices for EHS management that are consistent with key aspects of “operational excellence” as adopted by leading organizations in government and the chemical process industry. These are all based on risk management strategies, intentional competency development, and rigorous Conduct of Operations practices to drive continual improvement.
The practices described and discussed can help any small to medium sized chemical manufacturer ensure the safe and successful scale up and transfer of new technology or new products into production as well as driving improvements in reliability, safety, efficiency and quality assurance of day-to-day production operations for existing products.
The workshop will address how an organization must focus on the following to continually improve on the Operational Excellence Journey in relation to EHS and other aspects of its business:
- The Organization’s Risk Culture
- Integrated Management System Framework Driven by Risk Considerations
- Continual Learning with Focused Competency Development Based on Risk
- Conduct of Operations with All Engaged to Minimize “Organizational Drift”
In order to ensure that all participants have a common frame of reference for the workshop, the first portion will include:
- a brief discussion of various descriptions or definitions of Operational Excellence and the stages or phases organizations go through on the journey, and
- a review of some key lessons learned across the CPI during the last 50+ years from major accidents and the enterprise risk management approaches now widely used to try to prevent having to relearn these lessons.
This initial discussion will also include a case study example with a breakout session for small groups to discuss specific management system failures (the root causes) for the events to illustrate the reasons to go beyond just regulatory requirements.
During the remainder of the workshop there will be several additional breakout sessions for smaller groups to discuss proactive approaches to drive continual improvement and ensure adherence to standards, competency development, and excellence in Conduct of Operations including methods to detect (e.g. looking for incident warning signs) and correct “organizational drift”.
Free tools that are useful on the Operational Excellence journey for EHS are available online (e.g. organizational self-assessments with scoring protocol) from the American Institute of Chemical Engineers (AIChE) Center for Chemical Process Safety (CCPS) under the CCPS Vision20/20 strategy. These will be discussed as part of the breakout session exercises and can be used to help drive continual improvement efforts.
Mr. Jones has been a speaker at numerous previous SOCMA regional and national meetings and this workshop builds on his previous discussions of enterprise risk management.
He retired from full time employment in 2010 with >40 years of experience across CPI sectors including chemicals, polymers, pharmaceuticals, and electronics industry materials. He is currently a chemical engineering consultant for industry and government clients and also serves as an AIChE CCPS process safety instructor and staff consultant involved with development of CCPS guidelines and training materials.
During his career he has worked in process development and engineering, plant design, EHS, and process safety functions and supported manufacturing operations in over a dozen countries while an employee of Monsanto, SRI International, Raychem, and Genentech/Roche. He has also served as the VP of Chemical Process Technology and VP of Operations for several small venture capital funded specialty chemicals and materials companies in the optical materials field.
He has extensive experience with the implementation of risk-based management systems including those for process safety and quality. He earned BS and ME degrees in chemical engineering from Cornell and an MS in environmental engineering from Stanford. He is a licensed professional engineer in Illinois and California and holds a number of safety related certifications.
Layer of Protection Analysis (LOPA)—A Competency That Can Help Your Organization Better Manage Chemical Process Risks
3:45 – 5:00 PM, Wednesday October 11, 2017 in Houston, TX
Arthur M. Dowell III, PE
Chemical Process Safety Consultant
Process Improvement Institute
How safe is safe enough? Additional safeguards or independent protection layers can always be added but how can your team decide and defend how many and what type of safeguards or barriers are enough to prevent or mitigate a chemical process event?
LOPA is a tool that focuses risk reduction efforts toward the impact events with the highest risks. It provides a rational basis to allocate risk reduction resources efficiently for a specific scenario.
Scenarios are identified typically using a scenario-based process hazard analysis (PHA) evaluation procedure. For selected higher risk scenarios, LOPA is an analysis tool/approach that can be used to analyze one incident scenario (cause-consequence pair) at a time, using values for the initiating event frequency, independent protection layer failure probabilities, and consequence severity, in order to compare a scenario risk estimate to risk criteria for determining where additional risk reduction or more detailed analysis is needed.
A case study of a scenario will be presented to guide attendees through an example to illustrate how a LOPA is done to help a team with risk based decisions for a process.
Mr. Dowell is a chemical process safety consultant. He has 42 years industrial experience at Rohm and Haas (now owned by the Dow Chemical Company) in technical support to operations, engineering design, plant startup, research, technology management, hazard and risk analysis, and incident investigation. He has eight years of risk assessment consulting service to upstream oil and gas, mid-stream gas, and chemical processing. He is recognized in the industry for his work in process safety management systems, incident investigation, and risk assessment and has many years conducting incident investigations. Mr. Dowell has extensive experience leading PHAs (Process Hazard Analyses), and performing consequence analysis and fault tree analysis. He is a proficient user of FMEA, what-if/checklist, event trees, and, an emerging technique, HAZROP (Hazard Reliability, and Operability Analysis). He taught multiple internal courses for Rohm and Haas PHA facilitators. He was a co-developer of the Multiple Cause, Systems Oriented Incident Investigation System at Rohm and Haas in the 1980s, and has conducted numerous training courses on incident investigation within Rohm and Haas and for the industry overall. He has been using LOPA (Layer of Protection Analysis) for chemical processes for more than 20 years, spearheading its use in Rohm and Haas Company, publishing it in industry symposia, and mentoring and training engineers in its use. Mr. Dowell served several years on the ISA S84 Standard Committee and the US Technical Advisory Group for the IEC 61511 Standard Committee. He was one of the primary authors of technical report TR84.0.02 for analysis of the performance of Safety Instrumented Functions (SIFs). Mr. Dowell is a Fellow of AIChE and a senior member of ISA (the Instrumentation Systems and Automation Society). He served the South Texas Section of AIChE on the Executive Committee and as secretary and treasurer. He is a licensed Professional Engineer (Chemical Engineering) in both Pennsylvania and Texas.