James VanOmmeren

So we all have been implementing process safety metrics—what next?

Industry over the last two to three years has put a lot of effort into implementing Process Safety Metrics. This is a good practice but, now that we have metrics data, how are we utilizing them to improve process safety performance? Air Products has been monitoring process safety performance for the last five years using combined Center for Chemical Process Safety and American Petroleum Institute RP 754 metrics. This article will highlight the approach we have applied, both through our lagging and leading indicators, to drive our process safety performance improvement programs. It will review the programs we initiated, leading indicators we identified, and how it also helped to improve our process safety culture. This article will also look at the importance of measuring severity and its impact in driving leadership behaviors. We will also discuss future opportunities to improve process safety performance via metrics analysis and follow‐up initiatives.

Silane gas venting/treatment lessons learned and best practices†

Silane (SiH4) is a pyrophoric gas that requires special equipment and handling precautions to manage safely. Unfortunately, many users have had various serious accidents with SiH4 equipment since popular inception of the gas in the late 1960s for semiconductor manufacture, including at least eight fatalities and many injuries. SiH4 usage is growing tremendously worldwide in various industries, including semiconductor, flat‐panel display, photovoltaic cell, and specialty glass manufacturing. Significant uses of SiH4 also require systems with the capability to safely vent or treat SiH4 gas—such as residual venting during container changes or emergency venting. Six hazards associated with venting and treating SiH4 gas are presented in detail. Each hazard is illustrated by an actual venting incident and resulting lessons learned are discussed. Preferred venting and treatment solutions are detailed and a silane disposal system design work process is presented. Although the article is specific to pure SiH4, it has relevance to both venting and treatment of pyrophoric gases and flammable gases that possess relatively low‐ignition energies.

One company's near miss program–successes, learning, and improvements

Process safety events (or near misses and incidents) are key indicators of a companys process safety performance. The goal in reporting and evaluating near misses is to improve operators’ hazards awareness by recognizing unsafe conditions and acting on less‐severe Tier 3 near miss events before they escalate into more severe Tier 1 and Tier 2 type process safety incidents. Near miss analysis can also be used to identify themes and trends that a company should focus on to improve process safety risk management at their facilities.