March 2011

Bonus Report: Plant Safety

Process safety: Blind spots and red flags

Improving safety for organizations involve more than technological solutions; understanding processes and plant interactions are a must

Shephard, T., Mustang Engineering Inc.

The Process Safety Management (PSM) regulation 29 CFR 1910.119 was developed in response to a series of major accidents. These same events led to the creation of the safety instrumented system (SIS) standard, ANSI/ISA-84.00.01-2004 Part 1 (IEC 61511-1 Mod). Both provide a wholistic, lifecycle approach to the design, operation and maintenance of SIS and facilities. Plant safety improves when these programs are implemented, although accidents can still occur. From studies of major accidents, most result from the simultaneous occurrence of multiple and seemingly minor errors and “incidents” that interact in complex and unforeseen ways.1 PSM and ANSI/ISA 84.00.01 are similar in that

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