Process Safety Performance Indicators in Chemical Industry – What Makes It a Success Story and What Did We Learn So Far?

Abstract

Latest with the publication of the Baker Report (2007) triggered by the Texas City tragedy, it became obvious to the chemical industry that process safety leadership and incorporation of process safety into management decisions cannot be achieved without measuring and reporting process safety performance. To sustainably maintain and continuously improve process safety culture it is at the same time essential that process safety performance indicators (PSPIs) are meaningful and easy to understand for the entire organization from shift operators, plant engineers and plant managers to the top management.
Bayer MaterialScience initiated its process safety performance indicator program several years ago. After piloting in selected plants it was globally rolled out and implemented. Factors supporting the successful implementation were face-to-face meetings with Production and Technology (P&T) managers, incl. plant managers and engineers in most of our facilities explaining the concept and the full integration of the selected indicators into the existing management system and software as far as possible.
The selected performance indicators are reported to the BMS management and discussed in safety meetings. The Bayer MaterialScience community of plant and process safety experts is regularly reviewing and analysing data to further improve consistency and reporting efficiency but also discussing options for further PSPIs as well as measures to improve process safety performance.
This paper provides insight in the system of PSPIs developed at Bayer MaterialScience as well as in major conclusions drawn and actions taken to maintain and improve excellence in process safety.