Approaches to the Collection of Process Safety DataApproaches to the Collection of Process Safety Data

By Dr. Stephen Rowe, Dekra Insight

Excellence in process safety performance requires an integrated approach to addressing programs, culture, and competency. One important aspect of competency is having a wealth of the right information available, and accessible, to support and underpin the overarching safety management system. This includes both asset information (P&IDs, vessel register, instrumentation, piping and physical equipment inventory, safety systems - including safety instrumented functions, etc. - and process information - batch manufacturing records, quality/IPC procedures, raw material information, material safety data, process safety data, etc. While the requirements for asset information and most process information is reasonably prescriptive – and hence can be reliably audited and assured - the specification of required process safety data is far from prescriptive. This often leads to ineffective or inefficient systems and can completely undermine otherwise excellent process safety management systems.

Process safety data includes information on the relevant properties of materials in the context of the basis of safety. For any given unit operation – and indeed, any given piece of equipment – the basis of safety can be different for different materials and processes. This potential “ambiguity” poses the biggest challenge to corporations in ensuring robustness in the basis of safety – and the process safety data requirements that underpin it.
 
In our experience, organizations go about the collation of process safety data in one of several ways, as described below.

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Approach 1: Complete Dataset
Some organizations place a blanket requirement to procure a complete set of data on all materials and processes, irrespective of the basis of safety.

Approach 2: Prescribed Dataset
It is not uncommon to find organizations that have a prescribed “list” of data requirements for new or existing materials or processes. The list is often generated from knowledge of typical plant configurations where they are (assumed to be) consistent across a multinational organization. The specific tests are dictated by the requirements of the basis of safety.

Approach 3: Flowchart Approach
In acknowledging that the basis of safety may vary between different handling or processing plants, some organizations use a flow chart to guide material testing towards an ultimate basis of safety. Examples of such flow charts can be found in Figures 1 (for dust/gas/vapor explosion risks) and 2 (for runaway reaction and thermal instability risks). Abbreviations are explained in the glossary at the rear of the paper.

Approach 4: Tailored (Case-Specific) Approach
Having no prescribed dataset is not uncommon with data requirements for new materials/processes/plant equipment being identified on a case-by-case basis. Where appropriate procedures are followed by competent personnel (i.e. those with relevant subject matter expertise), this can be highly effective and targeted. However, across an organization its robustness becomes a function of local competency and hence it can be prone to inconsistency and resulting variable outcomes.

Approach 5: Prescribed Data + Situational Data Approach
Several key parameters plus selected additional parameters according to processing methods and risks are usually required to define a basis of safety. The key parameters provide initial characterization of the hazards of the materials/processes involved. This data is utilized in a preliminary risk assessment – the outcome of which may be a requirement for further test data for specification of the basis of safety.
A 6th approach is to assume worst case material process properties and design and implement safety measures accordingly. While simple, this leads to extreme inefficiencies.

Some assessment of the advantages and disadvantages of each approach to process safety data collection is provided in Table 1.

Of the approaches referenced, the tailored approach, where testing is based on the specific situation and what issues need to be addressed, provides the most relevant data in the most efficient test program. This approach requires design of the testing program by competent professionals who are able to assess the specific facility and equipment in advance of any testing or risk assessment, and then refine data needs based on initial data acquired. If data requirements are not specified by competent professionals, this approach can result in incomplete or inappropriate data.

The prescribed plus situational approach is the next best choice for striking the balance between robustness, effectiveness and efficiency. The initial prescribed data meets the needs of highlighting the process safety characteristics of the material/process and feeds and informs the risk assessment phase of scale-up. This data must be collected in all cases. The subsequent situational data requirements derive from the outcome of the risk assessment which focuses on the additional data requirements necessary to specify the basis of safety. The approach is best described schematically in Figure 3.

Conclusion
There are a variety of strategies that may be used for the collation of process safety data, but getting the right data in the most efficient way requires knowledgeable professionals who understand what data is needed to assess risks and design appropriate mitigation measures.

Dr. Stephen Rowe manages the activities in the UK of Dekra Insight Process Safety (Chilworth Technology Ltd). He has a career background in the assessment of chemical reaction hazards and the laboratory assessment of a full range of process safety hazards including dust, gas, and vapor flammability and explosives characterization. He is an experienced trainer and regular contributor to national and international process safety conferences and symposia.

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