Abstract
Process operators face competing demands to maintain process safety, while at the same time meeting production targets. Since June 2015 the Seveso III directive replaces Seveso II with stricter standards for inspections by notified bodies and more effective enforcement of the rules for managing safety.
Inspectors look for evidence of good practice in process safety, with reference to IEC 61511 as the benchmark. Many experienced operators of hazardous process plants already manage safety to some extent. However, IEC 61511 calls for structure and planning, to ensure that nothing goes un-checked. Records should show that plans were followed and any resulting corrective actions completed. Producing documents to show functional safety is well-managed can be challenging, when the inspector calls.
Five key areas are investigated, and opportunities for improvement are explored. Three of these topics relate to the operational phase of the safety lifecycle, which is applicable to all plants, regardless of age, or of safety instrumented system (SIS) technology in use: Safety Requirements Specification (SRS), Technology Selection, Management of Safety System assets, Planning for Proof Test and Inspection, Management of overrides. Suggestions for improvements are made and thought-provoking impulses are given for each of the key areas resulting in a set of recommended best practices that are likely to improve safety at any plant without causing the need of major investments.
