The UK Strategy for skills in Process Safety Management 2012 – 2014

The UK Strategy for skills in Process
Safety Management 2012 – 2014
A skills blueprint for industry
Progress Report April 2013

Contents
Background ................................................................................................................................................2
The Process Safety Management Project ..................................................................................................3
The PSM Project contribution to competence management ....................................................................4
Programme Achievements .........................................................................................................................5
The PSM Project Board priorities ...............................................................................................................7
Increasing awareness of Process Safety Management. .............................................................................8
PSM Project Board .....................................................................................................................................9
PSM Expert Panel .......................................................................................................................................9
THE UK STRATEGY FOR SKILLS IN PROCESS SAFETY MANAGEMENT 2012 – 2014: A SKILLS BLUEPRINT FOR INDUSTRY PROGRESS REPORT APRIL 2013
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Background
Following the incidents at Buncefield and Texas City late in 2005, the Health and Safety
Executive (HSE) continues to press the UK Process Industry to fully address Process Safety
Management (PSM) and its implementation in their organisations. Much has been done by
many interested stakeholders during the last several years to try to engage the sector in this
important matter. In January 2007, the publication of the Baker Report on the Texas City
explosion brought PSM into sharp focus and revealed major failures in the understanding of
PSM and the responsibility for it by the senior executives in the owner company.
The formation of the Process Safety Leadership Group (PSLG) in September 2007 was
designed to meet the need for an effective framework for interaction between industry, trade
unions and the COMAH Competent Authority (CA); a framework in which they could carry out
a dialogue to jointly develop, progress and implement meaningful, effective
recommendations and practices that improve safety in our industries. The PSLG membership,
with senior representatives of the relevant trade associations, the CA and trade unions, also
sees a need to raise the profile of process safety leadership throughout the petrochemical
and chemical industries in response to criticisms by both the Baker Panel (Texas City) and the
Major Incident Investigation Board (Buncefield) that leadership in this area was lacking and a
contributory factor to these events.
The HSE held a “Leading from the Top” seminar in April 2008 and has produced a number of
PSM publications. The Process Safety Forum was formed to facilitate the sharing of lessons
learned and best practice across the Chemical, Nuclear, Tank Storage and Upstream /
Downstream oil sectors. The Chemical Industries Association (CIA) followed with an in-depth
review of best practice across the country and produced its own PSM Guidelines later that
year, and UKPIA launched its Process Safety Leadership Commitment, signed by all major oil
companies. In the last two years, the Institution of Chemical Engineers (IChemE) and the
Institution of Mechanical Engineers (IMechE) and other respected bodies and consultants
have developed courses and have established regular Process Safety seminars to encourage
businesses to engage in PSM. However, the uptake by industry has been fragmented and
points to the weaknesses which may exist in PSM at senior executive level in many of our
companies, with the issue compounded by the uncoordinated delivery of numerous PSM
topics by many providers to a variety of audiences.
THE UK STRATEGY FOR SKILLS IN PROCESS SAFETY MANAGEMENT 2012 – 2014: A SKILLS BLUEPRINT FOR INDUSTRY PROGRESS REPORT APRIL 2013
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The Process Safety Management Project
In order to address the key issues leading to this market failure, in early 2010 the CIA and the
National Skills Academy for the Process Industries (the Skills Academy) identified the need
from their members and customers for a joined-up and integrated programme of PSM
training and education for employees at all levels. The need for understanding at board and
site director level was a recurring theme during these discussions, as was the requirement to
tailor PSM training to each level in the organisation, and a strong desire for training to be
sponsored by the key trade bodies, supported by the HSE and validated by the appropriate
body. After further research and consultation, the PROCESS SAFETY MANAGEMENT PROJECT
was launched in November 2010, led by a Project Board now composed of senior
representatives from the Skills Academy, CIA, HSE, IChemE, IMechE, UK Petroleum
Industries Association (UKPIA), Tank Storage Association (TSA), Unite the Union and Cogent
SSC, and senior industrialists with experience, expertise and interests in PSM from across the
sector.
A gap analysis undertaken by the European Process Safety Centre confirmed the existence of
a significant number of courses focussing on support for PSM specialists and, critically,
highlighted that there were very few courses targeted at Senior Executives, Management and
Operations staff, with fewer still designed to deliver a general PSM awareness for nonspecialists
in process safety.
To develop Training Standards for Process Safety Management aimed at delivering a higher
level of awareness of PSM across the various levels of responsibility within COMAH and other
Major Accident Hazard organisations, an Expert Panel was established by the PSM Board.
Training Standards outline the detail to be covered in training programmes to ensure the
required level of knowledge or competence can be achieved, and against which training
content, whether delivered by in-house training staff or by external training providers, can be
benchmarked.
Training Standards will in most cases also give an indication of the level of knowledge and
experience required of the individuals delivering the training, whether an assessment or end
of course test is required or recommended, and will identify any specific resources that will
support the effective delivery of the training.
Cogent SSC is the standards setting body for training and qualifications in the UK Process
Industries and manages the development of the PSM Training Standards, supported by
process safety specialists from industry, trade associations, unions, training organisations and
the COMAH Competent Authority within the PSM Expert Panel.
The development of Training Standards has been informed by the analysis of available
training, indicating a market failure in the availability and take-up of awareness level courses
targeted at different levels within industry. The priorities for Training Standard development
have been agreed by members of the Project Board and the Expert Panel.
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The PSM Project contribution to competence management
The Health & Safety Executive has been fully supportive of the PSM Project from the outset.
In January 2012, the CA published its Delivery Guide for the Inspection of Competence
Management Systems at COMAH Establishments. The Delivery Guide will help the CA to
identify those sites where competence compliance is a priority, and to assess the extent to
which a competence management system is being effectively managed and implemented
Ian Travers, Head of Chemical Industries Strategy Unit, HSE and PSM Project Board member
states:
“The control of major hazard risks requires a structured and systematic approach
based on sound process safety management principles. Provision of an effective
process safety management system is a key requirement of the COMAH Regulations
and its development, implementation and maintenance requires competent staff at
all levels within major hazard organisations but especially at senior management
level.
These training standards and the underpinning training will help equip senior
executives, managers and operators with the understanding and skills needed to
ensure major hazard risks are being effectively managed within their organisation.”
One of the first companies to test the Process Safety Leadership for Senior Executives training
standards was Croda International Plc. Terry Thistlethwaite, Vice President of Group SHE at
Croda, a speaker at ‘Raising the Bar’ conference, explained that their business already
operated a tight ship with professional guidance from a Group Safety, Health & Environment
(SHE) department, including a process safety model already established and regular reviews
of process risks. Terry described why they chose to invest in further Process Safety
Leadership training, stating:
“We realised that although we invest heavily in process safety within the business,
this was mainly at operational level and the Executive Committee but not at
Managing Director level, this was a gap we wanted to close.
The key outcomes from attending the PSL course show Managing Directors taking
ownership of process safety, making more interventions during site visits and a
general desire to keep learning. We know that this course delivers as it has been
developed with industry, is fully aligned to industry regulations and is delivered by
accredited, experienced professional trainers to address a key business need.”
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Programme Achievements
In 2011 the Project Board commissioned the development of Training Standards to raise
awareness of Process Safety Management across all tiers of leadership, management and
operations in industry.
On 15 th March 2012, the PSM Project Board presented “The UK Strategy for skills in Process
Safety Management 2012 – 2014, A skills blueprint for industry” consulting on their key
priorities and a range of proposed developments at the ‘Raising the bar on Process Safety
Management’ conference. The conference was well attended with over 150 representatives
from industry, stakeholders and regulatory bodies hearing from keynote speakers about the
PSM Project objectives, the challenges facing High Hazard industry in the UK, and
participating in workshops to discuss and consult on future development priorities.
The results of the consultation indicated overwhelmingly support for the PSM programme
development objectives, with a key focus on the development of PSM training standards at
three distinct levels:
Process Safety Leadership for Senior Executives
• aimed at Senior Executives and Board Members of hazardous facilities, who
are ultimately responsible for process safety performance within their
organisation.
Process Safety Management Foundations
• aimed at managers, supervisors, designers, safety personnel, and senior
contract employees, and suitable for young engineers and anyone who would
like to develop a more detailed understanding of process safety management.
Process Safety Management for Operations
• aimed at all staff who operate or maintain plant and may have an impact on
process safety and non-operational staff who would like to develop an
understanding of process safety management.
To support the delivery of training to meet the requirements of these Process Safety
Management training standards, the Skills Academy has engaged and quality assured a
number of training providers specialising in PSM. All related course materials and training
personnel have been subject to a rigorous review, with the assessment process led by the
Skills Academy and industry representatives from the Expert Panel, to ensure PSM course
delivery standards fully meet the requirements of the agreed Training Standards.
An evaluation by the PSM Expert Panel in March 2013 found that the core principles and
content of the Process Safety Leadership for Senior Executives remain valid, with no
significant or detailed changes being required at this time.
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The original targets established within “The UK Strategy for skills in Process Safety
Management 2012 – 2014, A skills blueprint for industry” were based on the number of
Top-Tier and Lower-Tier COMAH sites falling within the traditional process industry footprint.
The evidence to date is that there has been an enthusiastic take up by a small but significant
number of COMAH and other major accident hazard sites, with participation extending
beyond the traditional Process Industry into other areas of industry including the Oil & Gas,
Energy & Utilities, Explosives, and Distillery sectors.
PSM Project Performance to April 2013
Actual
(Target)
2012 2013 2014
Top Tier COMAH companies bookings
(incl. multiple sites)
94
(120)
136
(145)
(170)
Lower Tier COMAH companies bookings + non COMAH
(incl. multiple sites)
41
(60)
102
(120)
(180)
Number of participants booked on PSL courses
508
(350)
699
(525)
(650)
Number of participants booked on PSMF courses
88
(150)
373
(350)
(650)
Number of process operators trained * (0) (360) (1600)
Number of people licensed as PSMO Trainers * (0) (40) (100)
*PSMO not launched until April 2013
Employers are now beginning to invest in both the Process Safety Leadership and Process
Safety Management Foundations awareness training and over 1000 individuals having
completed or booked to participate in these courses. A number of employers have also
expressed interest in implementing the Process Safety Management for Operations training.
A significant proportion of the membership of the participating trade associations (CIA, UKPIA
and TSA) has engaged in the PSM programme, and the support of these trade associations
and their members has been a major contributing factor to the steady growth of the
programme to date.
Project Board members have delivered regular updates on the programme objectives,
reporting progress at national and regional events, seminars and conferences, with the CIA
and the Skills Academy hosting a well-attended seminar to disseminate the findings of the
investigation into the Macondo Deepwater Horizon blow-out in August 2012.
The sobering fact remains however, that with circa 1000 Top-Tier and Lower-Tier COMAH
sites, circa 300 Sub-COMAH sites, and many other High Hazard sites and operations falling
outside the scope of COMAH, there is still a significant amount of work to be done to engage
and raise Process Safety awareness within the wider industry.
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The PSM Project Board priorities
The PSM Project Board is fully committed to continuing to promote the take up of PSM
awareness training across the high hazard industry sectors.
During a Project Board review of the programme in consultation with Judith Hackitt, the Chair
of the HSE in November 2012, it became clear that there is a real need to increase
programme engagement, with a significant concern being raised that the senior executives in
many high hazard sites remains ‘unconverted’, do not have a strong enough awareness, nor
fully understanding their leadership role for developing an effective process safety
management culture within their business.
As a result of this review, the Project Board has agreed to expand its focus beyond the
traditional process industries and widen engagement to include the membership of trade
associations that support other high hazard industries, with their ongoing priorities to be:
To widen engagement across industry sectors and increase the take up of PSM
awareness raising courses in Top-Tier COMAH sites, extend awareness raising into
Lower-Tier COMAH and other High Hazard sites and operations across the UK, and
increase the numbers of leaders, managers and operations personnel participating in
PSL and PSMF and PSMO training.
To support the development of tools and services supporting COMAH site operators to
demonstrate the effectiveness of their Process Safety training, including enabling
employers that so choose, to benchmark their internal training to PSM Training
Standards.
To encourage employers to access other relevant high quality specialist PSM
programmes that will contribute to the embedding of Process Safety competence
within their organisations.
To increase the opportunities for employers to share good practice in process safety
management training through the facilitation of and participation in regional and
national meetings, conferences and workshops.
Support the launch of the Process Safety Management for Operations training
standard by the Skills Academy to assist employers in cascading their learning
throughout their organisation to embed the lessons learned, to ensure all personnel
are able to understand the significance of their contribution to controlling major
hazard risk.
To emphasise the sustainable nature of PSM Initiatives at every opportunity. As with
other continuous improvement initiatives, this is a never-ending journey.
Undertake an evaluation of the Process Safety Management Foundations training
standard in late 2013
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Increasing awareness of Process Safety Management.
'Major hazard risks are ever present at COMAH sites and can only be effectively
controlled by a Process Safety Management System that receives continuous
attention and focus.
Major hazard risk management is not the preserve of health and safety specialists
within an organisation.
Understanding those hazards and risks is a core part of everyone's day to day
responsibilities'
Ian Travers, Head of Chemical Industries Strategy Unit, HSE and PSM Project Board member
Support and guidance for employers on the Process Safety Management programme
objectives is available from any of the Project Board or Expert Panel members, and advice on
programme delivery options through the National Skills Academy Process Industries.
Trade associations and membership organisations representing high hazard industries are
invited to participate in the PSM Project Board to help shape the ongoing development
priorities and future objectives, to support their membership in achieving performance
improvements in process safety management.
Interested parties should contact:
Neil Smith
Skills Development Director
National Skills Academy Process Industries
Email: n.smith@process.nsacademy.co.uk
To learn more about the availability of courses and how they can be delivered flexibly to meet
your individual company requirements, contact your trade association or call the Skills
Academy on 0845 607 0140 / email industry@process.nsacademy.co.uk
THE UK STRATEGY FOR SKILLS IN PROCESS SAFETY MANAGEMENT 2012 – 2014: A SKILLS BLUEPRINT FOR INDUSTRY PROGRESS REPORT APRIL 2013
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With thanks to the members past and present of the PSM Project Board and Expert Panel that
have actively supported the development of the Process Safety Management training standards.
PSM Project Board
Allan Laing (Chair)
Alan Marsh
Bud Hudspith
Chris Hunt
Daren Smith
Dave Topliffe
David Brown
Gary Conroy
George Ritchie
Gordon Grant
Hugh Bray
Ian Travers
James Murdock
Jenny Clucas
Joanna Woolf
Karen Russ
Lee Rounds
Malcolm Sarstedt
Martyn Lyons
Neil Smith
Paul Merrick
Philip Jones
Phil Scott
Steve Elliott
Steve Hatton
Steve Scott
Pentagon Speciality Chemicals Ltd
Lucite International UK Ltd
Unite the Union
United Kingdom Petroleum Industry
Association
SABIC UK Petrochemicals
Shell UK Ltd
IChemE
Lotte Chemicals UK Ltd
Sembcorp
INEOS Manufacturing Scotland Ltd
Tank Storage Association
Health & Safety Executive
Cogent SSC
Cogent SSC
Cogent SSC
Health & Safety Laboratory
Covance Laboratories
Unilever
Tank Storage Association
National Skills Academy Process
Industries
IMechE
National Skills Academy Process
Industries
Chemical Industries Association
Chemical Industries Association
BASF UK & Ireland
Lotte Chemicals UK Ltd
PSM Expert Panel
Phil Scott (Chair)
Alan Flynn
Amanda Cockton
Andrew Hudson
Bud Hudspith
Charles Stuart
Dave Smith
Dave Topliffe
Gareth James
Gary Cramb
Gary Machin
Gary Pilkington
Gerry Brennan
Graeme Ellis
Hilary Wright
Ian Ogilvie
Ian Moores
John Reynolds
Julian Hought
Martin Griffiths
Mick Harrison
Paul McCulloch
Peter Davidson
Phil Bather
Ron Wood
Steve Leigh
Steve Wheat
Chemical Industries Association
Pentagon Speciality Chemicals Ltd
Health & Safety Executive
Hudson Consultants
Unite the Union
Nustar Energy
Murphy Oil
Shell UK Ltd
Process Industry Consulting
Syngenta
Johnson Matthey
APEX/IChemE
ABB Consulting
ABB Consulting
Briar Chemicals
Dow Corning
Cogent SSC
Reynolds Training Services
HFL Risk Services
Solvay
UM Group Ltd
E.ON
United Kingdom Petroleum Industry
Association
Cogent SSC
Unite the Union
Croda
E.ON
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National Skills Academy Process Industries, 5 Pioneer Court,
Morton Palms Business Park, Darlington, DL1 4WD.
T: 0845 607 0140 E: enquiries@process.nsacademy.co.uk
F: 01325 740 901 W: process.nsacademy.co.uk