PROCESS INDUSTRIES
Embedding
Process Safety
Leadership
Neil Smith
Network Services
Director
Diversity of Process Industries’ Major Accidents
• Oil Exploration
– Piper Alpha
– Deepwater Horizon
• Oil Refining
– Texas City
• Petrochemicals
– Flixborough
• Fuel Storage
- Buncefield
• Specialty & Fine Chems
- Bhopal
- Seveso
- H&W
• Pharmaceuticals/Inters
– Feyzin
- Akzo Buckhaven
– Pembrokeshire
- Merck
• Fertilisers
– Toulouse AZF
• Nuclear
– Chernobyl
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Background – why this project?
Good progress on Process Safety Management post Buncefield,
evidenced by:
• Proactive industry response to Baker Report post Texas City
disaster during 2006 & 2007
• Publication of CIA Guidance on PSL Best Practice in 2008
• Programme of regional PSM workshops since 2009 and
continuing
• However, leadership weaknesses continue to be exposed
Maximising Business Performance Through Skills Development
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
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
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Process Safety Management Project
Project Board
Quality Assurance of
PSM Provision
Expert Panel
Draft Training
Standards
Industry Endorsed
Training Standards
Wider industry
consultation
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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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The Results so far...
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, and
25 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
Training Standard –
Process Safety Leadership for Senior Executives
• 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
Programme format & costs
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
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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