Guidelines for Defining Process Safety Competency Requirements

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• Publisher: Wiley-AIChE
• Year: 2015
• ISBN:
  9781118795255
• Edition: 1
• Topic: Physical Sciences
• Subtopic: Industrial & Technical Chemistry

This Guideline presents the framework of process safety knowledge and expertise versus the desired competency level in a "super-matrix" format, vertically and diagonally. The matrix references for potential remedies/required training may be tailored to a company's internally developed training, reference externally available training, or some combination of the two.

Chapters include: Identify Process Safety Roles & Competency Needs; Process Safety Competency Matrix; Individual and Corporate Process Safety Competencies; Conduct Assessments vs. Needs; Develop Gap Closure Plans; and Sustaining Competencies.

1
INTRODUCTION

1.1 WHY PROCESS SAFETY COMPETENCY?

The Process Industries successfully use hazardous materials and operate potentially hazardous processes safely every day. It is the very ability to do so that demonstrates the value of the process industries to society. The safe and successful operation of these processes is only accomplished by companies and individuals who have demonstrated the ability to carry out their tasks correctly and safely. This proper application of knowledge and skills demonstrates what we refer to as competency.

In times past, the apprentice often spent years training under the watchful eye of the master craftsman until the apprentice could show competency in the trade. Then, and only then would the apprentice be recognized with the title of craftsman. And so it is today, the process industries need to not only gain skills and knowledge to properly operate process equipment, but they must also be able to demonstrate the application of these skills and knowledge to fulfill the mission of the organization. This challenge continues throughout the lifecycle of the organization as individuals and roles change through time, so a structured approach to managing competency is needed.

This Guidance book was written to help organizations use a structured approach to define the necessary competencies needed to successfully fulfill the mission of the organization and meet the regulatory requirements in the jurisdiction in which it operates.

1.2 PURPOSE

The intent of this guideline book is to provide a framework defining the minimum recommended process safety knowledge and expertise (competence) necessary for a company or organization that handles hazardous materials to ensure that process safety is managed effectively. This book guideline does discuss how supporting personnel involved with engineering design and projects can modify the tools to best suit their use (see Section 2.1.11 Additional Roles). The main tool for conveying this information is through a Process Safety Competency Matrix (PSCM) or the Matrix. This Matrix is based on the principles outlined in the CCPS Guidelines for Risk Based Process Safety (RBPS) (CCPS 2007) Guidelines.

The Matrix forms the basis for ensuring that these competencies are maintained as changes are made in the organization (see CCPS Guidelines for Managing Process Safety Risks During Organizational Change) (CCPS 2013).

1.2.1 Address Applicable Regulations and Requirements

This book provides guidance on how to enhance existing Process Safety Management (PSM) programs that are designed to comply with regulations such as the OSHA PSM Standard (29 CFR 1910.119) in the United States, the Seveso Directive in Europe, the PSM regulation AQ/T 3034-2010 in China or the Singapore Standard SS 506 for Process Safety. It will also help companies that are implementing the Process Safety Competency and Management of Change (specifically Management of Organizational Change) elements of the RBPS Guidelines or the Process Safety Code under Responsible Care^® (RCMS and RC14001 2013).

1.2.2 Identify Process Safety Competency Requirements

For facilities handling hazardous materials, the process-specific hazards can also present a need for process safety competency. This book provides guidance on how an organization can identify the necessary process safety competencies to manage the risks of handling hazardous materials. Levels of competency will likely align with the knowledge, skills and experience needed to manage hazards, based on the severity of the hazard and complexity of the process. Most process safety competencies will be associated with individuals located at an operating facility that handles hazardous chemicals. However, some process safety competencies may be associated with individuals at corporate or business unit offices, engineering or research centers, or outside consulting or engineering personnel.

1.2.3 Assess Individuals Against Recommended Competencies

After the recommended process safety competencies are determined, gaps between required training or experience levels can be identified. These gaps can then be filled by providing the necessary training, or by hiring new employees or contractors with the requisite competencies.

1.3 AUDIENCE

The target audience for this book is individuals who develop and manage process safety programs for either entire companies or an individual site. It includes corporate executives, business unit managers, corporate and site process safety managers, corporate and site process safety experts, operations managers, operators, mechanical integrity personnel, and other process safety personnel. It also includes process safety consultants and engineering companies. As evidenced by the extensive list, there is a need for awareness of process safety competencies throughout the organization, especially at the corporate level.

1.4 HOW TO USE THIS PROCESS

The PSCM provided in these guidelines provides a template for organizations to map their process safety job roles against those listed in the Matrix. It is not intended to prescribe how a process safety organization defines and develops individual competencies, but is intended to provide a template for organizing and managing process safety competencies and determining if there are any gaps.

The PSCM was developed using the four pillars and 20 elements of process safety as defined in the CCPS Guidelines for Risk Based Process Safety (CCPS 2007). For engineering design process safety competencies, additional guidance is included based on the CCPS Guidelines for Engineering Design for Process Safety (CCPS 2012). The five levels of proficiency are listed below:

• Awareness
• Basic Knowledge
• Practitioner
• Expert
• Leader

The Matrix is provided in a Mcrosoft ® Excel spreadsheet to be used for easy customization. There are multiple worksheet tabs of information that will be described throughout the chapters of the guidelines, therefore, it is strongly recommended to have the Matrix downloaded or printed while reading through this book. The Proficiency Levels tab further describes the five proficiency levels. The Skill and Knowledge tab provides guidance on the process safety competencies for each proficiency level for each RBPS element. The RBPS Table tab of the Matrix lists specific competency requirements for each RBPS element and the proficiency levels required for typical job roles in an organization. Once a company’s job roles are mapped to the Matrix, gaps can be identified and an action plan developed to address these gaps.

1.5 RISK BASED PROCESS SAFETY ELEMENTS

Process safety practices and formal safety management systems have been in place in some companies for many years. Over the past 20 years, government mandates for formal process safety management systems in Europe, the U.S., and elsewhere have prompted widespread implementation of a management systems approach to process safety management. However, after an initial surge of activity, process safety management activities appear to have stagnated within many organizations. Incident investigations continue to identify inadequate management system performance as a key contributor to the incident. And audits reveal a history of repeat findings indicating chronic problems whose symptoms are fixed again and again without effectively addressing the technical and cultural root causes. This is one of the reasons the Center for Chemical Process Safety (CCPS) created the next generation process safety management framework – Risk Based Process Safe ty (RBPS).

An RBPS management system consists of four main accident prevention pillars or foundational blocks, with twenty process safety elements under the blocks. The RBPS pillars and process safety elements are shown in Table 1.1

A thorough description of the RBPS pillars and elements can be found in the CCPS Guidelines for Risk Based Process Safety (CCPS 2007). Elements directly impacted by this book and the PSCM are covered in the following sections.

Table 1.1 RBPS Pillars and Process Safety Elements

Pillar	Process Safety Element
Commit to Process Safety	Process Safety Culture Compliance with Standards Process Safety Competency Workforce Involvement Stakeholder Outreach
Manage Risk	Operating Procedures Safe Work Practices Asset Integrity and Reliability Contractor Management Training and Performance Assurance Management of Change Operational Readiness Conduct of Operations Emergency Management
Learn From Experience	Incident Investigation Measurement and Metrics Auditing Management Review and Continuous Improvement

In the next sections the process safety competency element, and a few selected elements that have ...

Table of contents

• COVER
• SERIES
• TITLEPAGE
• COPYRIGHT
• DEDICATION
• FILES ON THE WEB ACCOMPANYING THIS BOOK
• ACRONYMS AND ABBREVIATIONS
• GLOSSARY
• ACKNOWLEDGEMENT
• PREFACE
• EXECUTIVE SUMMARY
• CHAPTER 1: INTRODUCTION
• CHAPTER 2: IDENTIFY PROCESS SAFETY ROLES & COMPETENCY NEEDS
• CHAPTER 3: PROCESS SAFETY COMPETENCY MATRIX
• CHAPTER 4: INDIVIDUAL AND ORGANIZATIONAL PROCESS SAFETY COMPETENCIES
• CHAPTER 5: ASSESS COMPETENCIES VS. NEEDS
• CHAPTER 6: DEVELOP GAP CLOSURE PLAN
• CHAPTER 7: SUSTAINING COMPETENCIES
• APPENDIX 1: EXAMPLE COMPETENCIES FOR AUDITING
• APPENDIX 2: PHM COORDINATOR & HA FACILITATOR QUALIFICATIONS
• APPENDIX 3: HAZOP FACILITATOR
• APPENDIX 4: SHOWING GAP CLOSURE PROGRESS
• Index
• EULA