ANSI/API Recommended Practice 754
Process Safety Performance Indicators for the Refining and
Petrochemical Industries
ANSI/API RP 754 | FIRST EDITION | APRIL 2010 | 39 PAGES | HARD COPY PRICE $105.00 | PRODUCT NO. K75401
As a result of the U.S. Chemical Safety and Hazard
Investigation Board (CSB) investigation of the 2005 BP
Texas City incident, the CSB issued several
recommendations including the development of an
American National Standards Institute (ANSI) standard
that creates “performance indicators for process safety in
the refinery and petrochemical industries. Ensure that the
standard identifies leading and lagging indicators for
nationwide public reporting as well as indicators for use at
individual facilities. Include methods for the development
and use of the performance indicators.”
ANSI/API RP 754 identifies leading and lagging process
safety indicators that are useful for driving performance
improvement. The indicators are divided into four tiers
that represent a leading and lagging continuum. Tier 1 is
the most lagging and Tier 4 is the most leading. Tiers 1
and 2 are suitable for nationwide public reporting and
Tiers 3 and 4 are intended for internal use at individual
sites.
The document was developed for the refining and
petrochemical industries, but may also be applicable to
other industries with operating systems and processes
where loss of containment has the potential to cause
harm. Applicability is not limited to those facilities
covered by the OSHA Process Safety Management
Standard, 29 CFR 1910.119 or similar national and
international regulations.
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You may access RP 754 in a read-only platform at:
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Phone: 1-800-854-7179
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(Local and International)
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API members receive a 30% discount where applicable.
Contents
Page
1
1.1
1.2
1.3
1.4
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guiding Principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
2
Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3
3.1
3.2
Terms, Definitions, Acronyms, and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4
Leading and Lagging Performance Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5
5.1
5.2
5.3
5.4
Tier 1 Performance Indicator—Process Safety Event (T-1 PSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tier 1 Indicator Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tier 1 Indicator Definition and Consequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculation of Tier 1 PSE Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Tier 1 PSE Severity Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6.1
6.2
6.3
Tier 2 Performance Indicator—Process Safety Events (T-2 PSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tier 2 Indicator Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tier 2 Indicator Definition and Consequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculation of Tier 2 PSE Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7.1
7.2
Tier 3 Performance Indicators—Challenges to Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Purpose of Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Examples of Tier 3 PSEs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8
8.1
8.2
Tier 4 Performance Indicators—Operating Discipline & Management System Performance . . . . . . . . . 16
Purpose of Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Examples of Tier 4 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9
9.1
9.2
9.3
9.4
9.5
Guidelines for Selection of Process Safety Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose of Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lagging versus Leading Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Characteristics of Effective Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection of Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
17
18
18
18
19
10
10.1
10.2
10.3
10.4
Reporting Performance Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Format and Forum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transparency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stakeholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PSE Data Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
19
20
21
8
8
8
9
9
11
11
11
11
Annex A (informative) Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Annex B (informative) Listing of Chemicals Sorted by Threshold Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Annex C (informative) Decision Logic Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
v
Page
Figures
1
“Swiss Cheese (Static) Model” and “Spinning Disk (Dynamic) Model” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2
Process Safety Indicator Pyramid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3
Example of Safe Operating Limit for Tank Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B.1 Inhalation Toxicity: Packing Group and Hazard Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Tables
1
Tier 1 Material Release Threshold Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2
Tier 2 Material Release Threshold Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3
Stakeholder Report Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
vi
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RP 754, Fatigue Risk Management Systems for Personnel in the Refining and Petrochemical Industries
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RP 755, Process Safety Performance Indicators for the Refining and Petrochemical Industries
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Effective January 1, 2010. API Members receive a 30% discount where applicable. The member discount does not apply to purchases made
for the purpose of resale or for incorporation into commercial products, training courses, workshops, or other commercial enterprises.
Ordering Information
Online: www.api.org/pubs
Phone: 1-800-854-7179 (Toll-free in the U.S. and Canada) | (+1) 303-397-7956 (Local and International)
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