Take the FUN out of Process Safety
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Safety Take the FUN Out of Process Safety Peter Lodal, P.E. Process safety can be approached in many different Eastman Chemical Co. ways. This article provides an unconventional way of looking at process safety that ties together wide-ranging ideas from seemingly disparate fields. s chemical engineers, we often think of process has all the other ingredients needed for happiness.” safety in terms of process hazard analyses, risk I believe this principle can be extended to understand Aassessments, layers of protection, personal pro many other things, among them, process safety. To para tective equipment, and the like. This discussion of process phrase Tolstoy: Successful chemical processes are all alike; safety borrows concepts from a wide range of areas, some of every unsuccessful chemical process fails in its own way. which have nothing to do with chemicals, chemical engi This statement implies that a successful chemical process neering, or process safety. Ideas from Leo Tolstoy, clinical must succeed at multiple things simultaneously — that is, psychologist Aubrey Daniels, and the German economist all successful chemical processes look alike in the sense E. F. Schumacher, among others, are tied together in this that they all succeed at the same things. This suggests some unconventional exploration of process safety. essential elements of a successful chemical process — things that all must go right for a process to succeed in the Leo Tolstoy and Anna Karenina long term: An unusual character for an article on process safety, Leo • the process must be thermodynamically possible Tolstoy sets the stage for this discussion. Although Tolstoy • the process must be sustainable, in that it: died in 1910, just two years after the founding of AIChE, w meets a market need he articulated a concept in his novel Anna Karenina that we w meets some minimum financial criterion will consider as we begin our journey. The opening sentence w has a consistent supply of raw materials of the seminal novel reads: “Happy families are all alike; w receives intellectual property protection every unhappy family is unhappy in its own way.” • the process must be legally acceptable, in that it: That famous line led Jared Diamond to coin the phrase w is not specifically illegal or criminal the Anna Karenina Principle (AKP) in his book, Guns, w meets applicable regulatory requirements Germs and Steel: The Fates of Human Societies (1). Dia • the process must be socially acceptable, in that it is: mond extends this principle to evolutionary biology and w safe (i.e., it does not hurt people) the success or failure of civilizations: w clean (i.e., it does not adversely affect the “By that sentence, Tolstoy meant that, in order to be environment). happy, a marriage must succeed in many different respects: Applied to process safety, the Anna Karenina Principle sexual attraction, agreement about money, child discipline, says that safety is just as important — no more, no less — religion, inlaws, and other vital issues. Failure in any one as sustainability and legal acceptability to the success of of those essential respects can doom a marriage even if it a chemical process, as all successful chemical processes * This article is based on a paper presented at the AIChE Annual Meeting, have to succeed at all of these elements consistently, if Oct. 28–Nov. 2, 2012, Pittsburgh, PA. not simultaneously. This conclusion necessitates a cultural 26 www.aiche.org/cep February 2014 CEP Copyright © 2014 American Institute of Chemical Engineers (AIChE) change, not only on the part of business managers, but on • timing — will the consequence occur immediately (I) the part of process safety professionals as well. or at some time in the future (F)? • probability — is the probability of the consequence A cultural change occurring certain (C) or uncertain (U)? In its report “Corporate Governance for Process Safety: • type — is the consequence positive (P) or negative (N)? Guidance for Senior Leaders in High Hazard Industries” (2), Thus, consequences can be Immediate, Certain, and the Organisation for Economic Cooperation and Develop Positive (ICP), or Future, Uncertain, and Negative (FUN). ment (OECD) describes the importance of safe operation: The vital cultural change requires that the FUN be “Safe operation and sustainable success in business taken out of process safety. The consequence of taking cannot be separated. Failure to manage process safety can the FUN out would be that process safety incidents are never deliver good performance in the long term, and the prevented early, and willingly, because the managers mak consequences of getting control of major hazards wrong ing resource decisions clearly see the immediate, certain, are extremely costly.” and positive benefits of investing in projects that result If effective process safety management is so beneficial, in improved process safety. The consequences of leaving why do leaders not practice it in the short term? Many have FUN in is that skeptical decisionmakers may choose to not asked different versions of this question in other venues: make an investment because they cannot see its benefit. • Why do people smoke? • Why do people use drugs? Changing our thinking • Why don’t people wear seat belts? Taking the FUN out of process safety will necessitate • Why don’t motorcyclists wear helmets? a change in the way most chemical engineers think. The answers to all of these questions rest on a behavioral E. F. Schumacher, a German expatriate who lived in Eng fact that some would rather ignore: There is often a short land, describes two types of thinking in his influential book, term benefit for not doing what will benefit us in the long Small is Beautiful: Economics as if People Mattered (4). term. For example, smoking and drug use produce short These modes of thinking, as defined by the British psycholo term pleasure for the users. In the same vein, minimizing gist Liam Hudson, are convergent and divergent. process safety can produce tangible short-term benefits (e.g., Convergent thinking involves finding the one unique profits, bonuses, and promotions) to the nonpractitioners. solution to a problem by analyzing material from a variety Thus, we must overcome a huge cultural hurdle. of sources. This kind of thinking is particularly appropriate Cultural changes require behavioral changes. There in science, math, and engineering. Divergent thinking, on fore, some behavioralbased safety principles must be the other hand, starts with a single goal (or stimulus) and applied to process safety. How do we apply a behavioral theorizes multiple successful outcomes that might result model appropriately to process safety, without losing focus from the same starting point. This type of thinking is more on the unique aspects of process safety? suited to artistic pursuits. According to Aubrey Daniels (3), a clinical psychologist To succeed at taking the FUN out of process safety, we and founder of Aubrey Daniels International, an Atlanta have to think divergently. Divergent thinking is needed to based company that applies scientifically proven laws of break the stereotypical thereisonlyonecorrectsolution human behavior to improve business performance: mindset that engineers often have. “People are the most important element of every orga One way to do this is by taking a different look at the nization. With the complex challenges facing American familiar, because the answer may depend on things that business leaders every day, the science of human behavior do not directly deal with process safety. After the end of cannot be ignored. Rather, it must be the starting place for World War II, General Dwight D. Eisenhower, Supreme every decision we make, every new technology we apply, Allied Commander in Europe who went on to become U.S. and every initiative we employ.” president, was asked what weaponry was the most critical At the core of Daniels’ approach is the ABC Model, in the successful invasion of Europe. His answer was (5): where A stands for antecedents, B for behaviors, and C for “Four … pieces of equipment that most senior officers consequences. Antecedents create favorable circumstances came to regard as among the most vital to our success in for a particular behavior to occur once. Consequences are Africa and Europe were the bulldozer, the Jeep, the 2½ton the outcome of a behavior. Daniels suggests that con truck, and the C47 airplane. Curiously enough, none of sequences, perceived or previously experienced, play a these is designed for combat.” significant role in managing future behavior (i.e., shaping Just as Eisenhower attributes his war success to items decisionmaking behavior). not typically thought of as weapons, I believe nontraditional Consequences can be characterized by three dimensions: ideas will contribute to process safety. Article continues on next page Copyright © 2014 American Institute of Chemical Engineers (AIChE) CEP February 2014 www.aiche.org/cep 27 Safety Take the FUN out of process safety benefits of investing in process safety projects. This creates This new way of thinking can be used to discuss the a positive perception for management. FUN elements introduced earlier. One way to look at process safety through a different lens is to tie it to reliability — a Continue to seek solutions metric and its associated techniques that keep the plant An article on nuclear power in The Economist (6) running and that are not normally associated with process included the following statement: “Safety requires more safety. Process safety and reliability are at opposite ends of than good engineering. It takes independent regulation, the same risk continuum — reliability deals with higher and a meticulous, selfcritical safety culture that endlessly probability, lowerconsequence events, whereas process searches for risks it might have missed.” safety addresses the lowprobability, highconsequence This endless searching applies to process safety and is at events.