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What is Process Safety?

Process Safety is concerned with preventing major hazards arising from the loss of containment of dangerous materials or the uncontrolled release of energy (such as fire, explosion or structural failure).

It typically involves:
  • A loss of operational control due to human error or equipment malfunction.

  • Equipment or structural failure arising from fatigue, corrosion or exceeding the design limit.

Process Safety Management (PSM) is the application of management controls to ensure that process hazards are identified, understood and controlled to prevent process related accidents from occurring.
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What is Process Safety?
The Challenge
Application
Our Approach
Our Solutions
The Benefits
Our Experience
The Challenge

Major accidents happen infrequently and the passing of time, without a process-related accident, is not necessarily an indication that all is well and may contribute to a dangerous and growing sense of complacency. When people lose an appreciation of how their safety systems were intended to work, safety systems and controls can deteriorate, lessons can be forgotten, and hazards and deviations from safe operating procedures can be accepted.

Continual vigilance is required to prevent major accidents arising from process-related hazards.

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Application
Whilst originally developed for the chemical industry, process safety management is equally relevant to other industries with complex systems and major accident potential (such as mining or aviation).
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Our Approach

Ibis helps clients develop and deliver focused and cost-effective approaches to organisations wishing to assess and assure the safety of their complex system, processes or operation.

We seek to assist clients develop a robust and resilient PSM system that is integrated into their current operation.

One approach is to implement a three phase process:
  • Conduct a process safety management audit / assessment to identify areas for improvement.

  • Develop and/or improve on selected process safety elements.

  • Execute the specific process safety improvement initiatives.

Ibis can provide assistance in each of these areas.
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Our Solutions
A range of PSM services may be provided including:
  • Risk assessment and hazard analysis.

  • Layer of Protection Analysis.

  • Human factors assessments.

  • Safety in design.

  • Performance monitoring.

  • Safety systems.

  • Procedure development.

  • Training.

  • Auditing.

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The Benefits

The major objective is reduced risk of a major accident which may cause loss of life, environmental damage or significant asset loss.

PSM may also provide benefits in the area of operability, productivity and stability and quality of process.

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Our Experience

Ibis conducted a Process Safety Systems gap analysis for Norilsk Cawse Nickel. In addressing these gaps opportunities were identified for significant improvements in the safety management systems to improve risk control and sustainability into the long term.

Ibis conducted a Pressure Equipment Integrity review for Penrice Soda Products against the requirements of AS3788 In-Service Inspection of Pressure Equipment, South Australian statutory requirements, and guidance material obtained from the UK Health and Safety Executive.

Ibis consultants have substantial Safety Case experience for companies including Melbourne Water, Basell-Lyondell, Marstel Terminals, Huntsman Chemicals and PaperlinX. This includes hazard studies, process safety procedure writing and assistance with control measure performance monitoring.

Ibis consultants have conducted Safety Integrity classification and validation studies according to AS61508 and AS61511, using Layer of Protection Analysis (LOPA) and risk graph methods, for companies including Santos, ESSO, Aker Kvaerner and Caltex.

Ibis has worked with BHP Billiton Nickel West to develop and implement a tailored process safety approach to catastrophic mining risks. The approach has helped focus management attention on the low frequency and high consequence risks and to ensure that the critical controls are maintained and sustainable.

Ibis has worked with Nickel West to apply this method to surface and underground mines. It has been successfully applied to the risks of underground fire, surface slope stability, underground fall of ground, explosives handling, surface mine vehicles interactions and underground winder operations.

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For more information call us on: 03 9005 4615  |  To download a PDF version of this page, please CLICK HERE
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