Client Background
A mid-sized chemical manufacturing company specialising in the production and recycling of industrial solvents. Located in the UK, the company has been operating for over 20 years and employs around 50 staff.
Client Problem
The company had experienced a series of minor process safety incidents, including a near-miss involving a pressure relief system and a small fire due to an electrical fault.
A routine internal audit revealed gaps in hazard identification, ageing equipment, and inconsistent training.
Though compliant with legal minimums, the company’s Process Safety Management System (PSMS) was fragmented and reactive.
Insights
Improvement Initiative
To address the client's needs comprehensively, we In 2023, following a senior management review and influenced by the CCPS’s “Risk-Based Process Safety” (RBPS) framework, the company launched a comprehensive PSMS improvement program.
The aim was to embed a proactive, risk-based safety culture.implemented a strategic, multistep approach:
The aim was to embed a proactive, risk-based safety culture.implemented a strategic, multistep approach:
1. Commit to Process Safety (Pillar 1: Commitment to Process Safety)
- Leadership training sessions were delivered using CCPS materials.
- A Process Safety Vision was established, with KPIs linked to performance reviews.
- A cross-functional Process Safety Steering Committee was formed.
2. Understand Hazards and Risks (Pillar 2: Understanding Hazards and Risks)
- All P&IDs and Hazardous Area Classifications were updated.
- HAZOP studies were revised using a standardized, documented methodology.
- Layers of Protection Analysis (LOPA) were performed on all high-risk units.
3. Manage Risk (Pillar 3: Managing Risk)
- Mechanical Integrity program was revamped to include risk-based inspections.
- Operating procedures were rewritten for clarity and included safety-critical steps.
- Permit to Work systems were digitised to ensure traceability.
4. Learn from Experience (Pillar 4: Learning from Experience)
- Conducted root cause analysis training for supervisors.
- Developed a lessons-learned database shared across all company sites.
Insights & Results
- 60% reduction in process safety incidents.
- Improved HSE audit scores from 68% to 92%.
- Increased workforce engagement and retention.
By adopting the CCPS’s RBPS framework, the company moved from a reactive to a proactive safety culture. The company’s commitment to continuous improvement, leadership accountability, and structured risk management positioned it as a safer and more reliable operator.
