Process Safety Metrics for Incident Prevention and Performance Enhancement

Process safety metrics are measures that are used to evaluate and track the performance of a facility’s process safety management (PSM) program. By tracking these metrics, organisation can identify areas where their PSM program is effective and areas where it needs improvement. This information is then used to make informed decisions about safety investments and to prioritize corrective actions.

One of the key benefits of process safety metrics is their ability to provide a comprehensive picture of the safety health of an organization. These metrics encompass a wide range of aspects, including leading and lagging indicators, performance indicators, and compliance with safety regulations.

Types of Process Safety Metrics (Or Process Safety Performance Indicators)

There are a number of different types of process safety metrics that can are used to measure performance. These are also referred to as Process Safety Performance Indicators.

One of the key elements of process safety performance indicators is the use of key performance indicators (KPIs). These KPIs serve as measurable parameters that provide a quantitative or qualitative measure of the organization’s safety performance.

Some common process safety KPIs include:

• Incident rate: The number of incidents per unit of time, such as per year or per 100,000 hours worked. This metric can be used to track trends in process safety performance over time.
• Fatality rate: The number of fatalities per unit of time. This metric is a more severe measure of process safety performance than the incident rate.
• Injury rate: The number of injuries per unit of time. This metric is less severe than the fatality rate, but it is still an important measure of process safety performance.
• Total cost of incidents: The total cost of all incidents, including the cost of property damage, lost production, and medical expenses. This metric is a comprehensive measure of the economic impact of process safety incidents.
• Near- miss rate: The number of near misses per unit of time. Near misses are events that could have resulted in an incident but did not. Tracking the near-miss rate can help to identify potential hazards and prevent future incidents.
• Hazard identification rate: The number of hazards identified per unit of time. This metric can be used to track the effectiveness of hazard identification programs.
• Risk assessment rate: The number of risk assessments performed per unit of time. This metric can be used to track the effectiveness of risk assessment programs.
• Corrective action rate: The number of corrective actions taken per unit of time. This metric can be used to track the effectiveness of corrective action programs.

In addition to these metrics, there are a number of other metrics that can be used to measure process safety performance. The specific metrics that are used will vary depending on the industry and the specific hazards that are present.

What are the leading and lagging metrics in the process safety industry?

According to the American Institute of Chemical Engineers (AIChE), there are several metrics that companies should consider to evaluate their process safety performance. CCPS formed a committee to publish a Guideline defining uniform metrics that could serve as a global standard, in 2006. The committee have published recommendations for leading and lagging PSM performance metrics.

Leading Indicators and their role in proactive hazard identification

By utilizing leading indicators, organizations can take a proactive approach to identify potential hazards before they result in process incidents. Leading indicators can include risk assessments, near-miss reporting, and safety culture surveys. These metrics help organisation identify trends, spot potential weaknesses, and take preventive measures to mitigate risks.

Leading Indicators:

1. Risk Assessments: Measuring potential hazards and identifying risks before they result in incidents.
2. Near-Miss Reporting: Reporting incidents or situations that did not result in harm but had the potential to cause an incident.
3. Safety Culture Surveys: Assessing the attitudes, beliefs, and behaviours of employees towards safety to identify areas for improvement.
4. Safety Training: Measuring the effectiveness and completeness of safety training programs.
5. Emergency Response Drills: Conducting regular drills to test the organization’s preparedness and response to process safety incidents.
6. Process Hazard Audits: Evaluating the effectiveness of hazard identification and risk management processes.
7. Process Safety Inspections: Regularly inspecting process equipment and procedures to identify and address potential safety hazards.
8. Management of Change Review: Assessing the impact of changes in processes, equipment, or personnel on process safety.
9. Safety Meetings: Holding regular safety meetings to discuss safety concerns and promote open communication.

Lagging Indicators and their use in analyzing past incidents

On the other hand, lagging indicators are reactive measures that look at incidents that have already occurred. Lagging indicators can include injury rates, accident investigations, and incidents related to process safety. While lagging indicators are important for understanding past incidents and patterns, they mainly serve as a way to learn from mistakes and improve future safety measures.

Lagging Indicators:

1. Incident Rates: Measuring the number and frequency of incidents, injuries, and near misses.
2. Lost Time Incidents: Tracking incidents that result in employees missing work due to injuries.
3. Severity of Incidents: Evaluating the severity of incidents based on the extent of injuries or damages.
4. Compliance with Safety Regulations: Assessing the organization’s adherence to safety regulations and standards.
5. Process Safety Audits: Conducting audits to evaluate the effectiveness of process safety management systems.
6. Safety Observation Reports: Documenting observations and concerns related to safety during routine work.
7. Corrective Action Completion Rate: Tracking the rate at which corrective actions are recommended after incidents or audits are implemented.
8. Safety Procedural Compliance: Assessing the adherence to established safety procedures and protocols.

It is important to note that the specific leading and lagging indicators used may vary depending on the industry, organization, and specific processes involved. These indicators should be selected and tailored to best reflect the organization’s unique safety risks and priorities.

Regular monitoring and analysis of leading and lagging indicators allow organizations to proactively manage risks, continuously improve safety performance, and prevent incidents.

Examples of Process Safety Metrics in Various Industries

Process safety metrics is extremely important in various industries, including chemical manufacturing, oil and gas, and pharmaceuticals. These metrics help organizations identify, monitor, and manage process safety risks to prevent incidents and improve safety performance.

Here are some examples of process safety metrics utilized in these industries:

Chemical Manufacturing:

• Number of Process Safety Incidents: Tracking the frequency and nature of incidents related to chemical processes, such as leaks, spills, or explosions.
• Process Safety Risk Assessments: Conducting thorough and regular risk assessments to identify potential hazards and assess their associated risks.
• Compliance with Safety Procedures: Evaluating the adherence to established safety procedures and protocols during chemical manufacturing processes.
• Process Safety Management System Audits: Assessing the effectiveness of process safety management systems through audits and inspections.

Oil and Gas:

• Process Safety Leading Indicators: Monitoring leading indicators such as near-miss reporting, safety training completion rates, and safety culture surveys.
• Process Safety Incident Rate: Measuring the number of incidents per million hours worked to track the safety performance within the oil and gas industry.
• Safety Observations and Corrective Action Completion: Documenting safety observation reports and tracking the completion of corrective actions to address identified issues.
• Asset Integrity Metrics: Monitoring the integrity and reliability of critical assets such as pipelines, storage tanks, and pressure vessels.

Pharmaceuticals:

• Compliance with Good Manufacturing Practices (GMP): Assessing adherence to established GMP guidelines to ensure the safety and quality of pharmaceutical manufacturing.
• Process Safety Incident Investigations: Conducting thorough investigations of any process safety incidents to identify root causes and prevent recurrence.
• Training and Competence: Evaluating the effectiveness and completeness of process safety training programs for pharmaceutical manufacturing personnel.
• Environmental Impact Metrics: Monitoring and reducing the environmental impact of pharmaceutical manufacturing processes, such as waste generation or emissions.

Benefits of Using Process Safety Metrics

There are a number of benefits to using process safety metrics. These benefits include:

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