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SGS de Procesos para La Nueva Refinería Talara 12.02.20
SGS de Procesos para La Nueva Refinería Talara 12.02.20
Introduction
This tool focuses on the five industry tenets associated with Vision 20/20. It is intended to help a company assess
its current implementation against Vision 20/20 elements. When multiple parts of a company are assessed, it can
be used to understand the consistency throughout operations and identify opportunities for improvement. It is in
the company's best interest to answer each question critically, in an effort to understand its own progress on the
Vision 20/20 journey, and gain the most value from the tool.
The assessment results are intended to be used internally, as a tool to inform opportunities to better deliver Vision
20/20.
Scoring Guidance
Always - There is evidence that the activity occurs consistently. Any minor gaps are corrected by the established
corporate management system. (weighted as 4 points)
Most of the time - There is evidence that the activity is executed often, but there is room for improvement.
(weighted as 3 points)
Some of the time - These activities occur sporadically and not at a defined or regular interval. (weighted as 2
points)
Infrequent or never - The activity is missing, not followed, or not enforced. There is little to no evidence of its
execution (weighted as 1 point)
Copyright © 2015
Center for Chemical Process Safety of the American Institute of Chemical Engineers
120 Wall St
New York, New York 10005
All rights reserved. This assessment tool may be freely used by companies and facilities which manage hazardous materials
and processes for internal corporate purposes only. Apart from this use, the tool is provided “AS IS”, without warranty of any
kind. In no event shall the copyright holder be liable for any claim, damages or other liability, whether in an action of contract,
tort or otherwise, arising from, out of or in connection with the tool or the use or other dealings with the tool. AIChE and CCPS
are trademarks owned by the American Institute of Chemical Engineers. These trademarks may not be used without the prior
express written consent of the American Institute of Chemical Engineers. The use of this product in whole or in part for
commercial use is prohibited without prior express written consent of the American Institute of Chemical Engineers. To obtain
appropriate license and permission for such use contact ccps@aiche.org, +1.646.495.1371.
March 2015
Cultura comprometida
Los empleados entrenan a otros empleados que se desvían por error del
procedimiento aprobado.
Executives review industry and company incidents and review their own operations for similar hazards.
Executives have personal Process Safety performance goals and objectives (beyond stating metric goals).
Process safety lagging metrics are tracked at the site and company level.
Process safety leading metrics are tracked at the site and company level.
Executives commit a meaningful amount of time personally involved in process safety activities (e.g. risk mitigation planning,
discussing incident investigations, and actively monitoring action item tracking).
Executives and senior managers respond to poor process safety performance with the intent to identify and address root causes.
Executives and senior managers reward good process safety performance and identify learnings to leverage across the site/company.
Executives and senior managers talk knowledgeably about the major hazards and risks at each site (as applicable) and the associated
critical barriers.
Process safety activities are included in annual operating plans and budgets.
The annual report discusses process safety activities and leading process safety metrics.
Executive leadership routinely visits production units and have meaningful discussions regarding process safety related issues with
operations and maintenance personnel.
Executives personally follow-up with site operations and technical personnel regarding potentially significant process safety incidents.
Executives and leadership positively recognize individuals for raising concerns regarding process safety.
Operators and mechanics diligently follow procedures and speak up when they suspect a problem or Most of Some of Infrequent
Always
see an opportunity for improvement. Time Time or Never
Operators and mechanics fully follow and properly complete procedural checklists.
Operators and mechanics freely raise process safety concerns to supervision and management.
Process safety improvements exist or are ongoing based on concerns/suggestions raised by operators/mechanics
Supervisors and managers verify work is done properly, intervene to correct situations, and openly Most of Some of Infrequent
Always
communicate negative news to management. Time Time or Never
Supervisors and managers participate in Management of Change (MOC) and Pre-Start-up Safety Reviews (PSSRs).
The status of incident investigation, audit findings and other process safety related action items is regularly discussed at unit
production meetings.
Unit and plant management conduct regular walk-throughs of the unit, note items of concern or good practice, and personally follow-
up.
Unit managers, engineers and technical specialists routinely dialog with unit operators and mechanics about process safety topics.
Managers and supervisors personally monitor employee conformance with operating and control of work procedures (e.g. hot work).
Managers and supervisors communicate process safety performance to executive management (without modifying to make the
message more positive).
Maintenance work plans include the appropriate action to take if the work does not go according to plan.
Operators and mechanics stop and seek guidance if an established procedure appears wrong, unsafe, or otherwise presents a hazard.
During safety-critical operational steps or phases (e.g., startup of a complex process), an independent “process safety observer” is
present solely to monitor the situation and has authority to intervene.
Employees coach other employees who mistakenly deviate from the approved procedure.
Operators follow operating procedures as written; ‘work-arounds’ outside of the management system are not used.
All employees can describe their roles and responsibilities in maintaining barriers to prevent major accidents.
The management system is documented, readily accessible by all employees, and easily used to access process safety content.
Management system includes all 20 elements of CCPS’s Guidelines for Risk Based Process Safety.
Management system includes all process safety elements required by local regulations.
Management system is not solely at the company level; rather, it cascades from a corporate system to regional requirements to site
activities.
The management system defines how operations are conducted at the workplace and promotes safety Most of Some of Infrequent
Always
in design, operations, and maintenance. Time Time or Never
The management system defines the process safety-related activities that are conducted (e.g. hazard identification, MOCs, incident
investigation, and action item tracking).
The management system refers to specific tools used to perform process safety related activities (e.g. hazard identification, MOCs,
incident investigation, and action item tracking).
Managers have a structured management review process (see CCPS’s Guidelines for Risk Based Process Safety) for process safety
elements and generate actions to address identified issues.
The management system ensures employees are assigned to roles based on their competency to perform the tasks expected of that
role.
Incident investigations methods are appropriate for the incident severity (actual or potential).
The management system terminology reflects the current organizational construct and titles.
The management system has a mechanism that encourages and makes it easy for all employees to identify opportunities for
improvement in the management system.
Average score #DIV/0!
Employees that can impact process safety performance receive formal training on relevant industry standards, their content and use.
Companies also identify, document, and diligently follow a set of standards applicable to existing Most of Some of Infrequent
Always
equipment. Time Time or Never
Standards (internal or common industry standards) for existing fabricated equipment, such as pressure vessels,
piping, and tanks, are clearly specified and readily available.
Standards (internal or common industry standards) for existing equipment such as furnaces, compressors, relief
valves, and instrumented control systems, etc. are clearly specified and readily available.
Where a process exists for approval of deviations from standards for existing equipment, it requires a risk assessment and approval
from an appropriate level of management.
A process exists (i.e. audits or other assessments) to evaluate conformance to standards for new equipment.
A process exists (i.e. audits or other assessments) to periodically verify that existing (aging) equipment is fit for service.
If gaps are found between standards for existing equipment and actual equipment in the field, actions are developed and tracked to
completion to ensure conformance.
Managers and supervisors reward excellent conformance with standards and practices.
Managers and supervisors correct poor conformance with standards and practices.
As industry standards evolve, companies codify significant new learnings in their identified standards Most of Some of Infrequent
Always
for existing (and new?) equipment. Time Time or Never
A system exists to periodically review, update and re-issue internal standards for existing equipment.
Employees routinely access technical resources via experts, documented guidance, or coursework.
Competency profiles are established for progression in disciplines that can impact process safety performance.
Employee performance plans include specific developmental expectations related to a process safety competency profile.
Engineering design and modification work is verified at a level of rigor commensurate with the risk.
Engineers and technical specialist are trained in discipline standards and codes relevant to their role and responsibilities.
There are examples of operators or maintenance personnel stopping work when it has gone outside of preapproved plans.
Average score #DIV/0!
Managers are competent to engage field personnel in a conversation about process safety hazards and barrier/safeguard
management.
Managers provide access to technical expertise/resources and provide time for technical development.
There are examples of learnings from external incidents being implemented locally.
There are examples of learnings from industry benchmarking related to process safety being implemented locally.
The site/company is actively involved in industry associations and standard setting bodies to ensure that process safety management
systems are consistent with current industry practice.
The site/company uses an incident investigation methodology that results in root cause identification.
Exceedances of safe operating limits and challenges to safety systems are treated as near misses and prompt action for follow-up.
Incident and near miss investigations identify root causes, including human factor and leadership-based root causes.
Incident and near miss investigation root causes identify potential problems in management systems.
Near miss and incident tracking systems capture the potential worst credible consequence.
Near misses are investigated to the level of the potential worst credible consequence.
Incident characteristics (e.g. frequency, root cause) are captured and analyzed for trends and learnings.
The company culture encourages the identification of incident learnings that are shared across the company.
Process incident investigation status, findings, and action items are regularly discussed at unit production meetings.
Learnings from significant events are communicated regularly and never forgotten.
Third, embed the learning in standards or practices, and check if existing equipment or processes Most of Some of Infrequent
Always
require modification Time Time or Never
The company incorporates learnings (from internal/external incidents, changes in industry standards, new technology development,
recognized good practices) into internal standards.
Action items from learnings applicable to existing equipment are issued and resolutions are tracked to completion.
Lessons learned are discussed during HAZOP and other risk analysis studies.
Total
Total
Industry Tenet Average Evidence
Score
Score
Executives personally and visibly lead process safety. #DIV/0!
#DIV/0!
Operators and mechanics diligently follow procedures and speak up when they suspect a problem or see an #DIV/0!
opportunity for improvement.
Committed Culture
Supervisors and managers verify work is done properly, intervene to correct situations, and openly #DIV/0!
communicate negative news to management.
All employees and contractors commit to “do it right” and have a plan for when it goes wrong. #DIV/0!
All employees must clearly understand their role in managing process safety. #DIV/0!
#DIV/0!
The management system defines how operations are conducted at the workplace and promotes safety in #DIV/0!
Vibrant Management Systems design, operations, and maintenance.
The management system is agile and continually improved. #DIV/0!
Companies identify, document, and diligently follow standards for new equipment. #DIV/0!
#DIV/0!
Companies also identify, document, and diligently follow a set of standards applicable to existing equipment. #DIV/0!
As industry standards evolve, companies codify significant new learnings in their identified standards for #DIV/0!
existing (and new?) equipment.
Intentional competency development includes understanding competency expectations, providing #DIV/0!
#DIV/0! educational resources, and allowing time for people to build competency.
Intentional competency development applies to all levels in the organization. #DIV/0!
We learn from accidents, near misses, industry benchmarking, and success stories. #DIV/0!
#DIV/0!
First, identify the learnings and recognize the value in sharing it with others. #DIV/0!
Second, use a system to efficiently share learnings, without overwhelming the organization. #DIV/0!
Third, embed the learning in standards or practices, and check if existing equipment or processes require #DIV/0!
modification
Assessment Tool
Overall Results
Committed Culture
4.0
2.0
0.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
re s t
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ltu te
m ar m
Cu s nd op
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itt en to De
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m em ce nc
y
Co ag en te
an her pe
tM Ad m
an ed Co
br lin al
Vi ip io
n
sc nt
Di te
In
Assessment Tool
Detailed Results
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Committed
Culture
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Vibrant
Management
12.0 Systems
10.0
8.0
6.0
4.0
2.0
0.0
Disciplined
Adherence
4.0
to Standards
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Intentional
Competency
4.0
Development
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Enhanced
Application & Sharing
of Lessons Learned
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
He leido la introducción al cuestionario y me comprometo a
completarlo bajo las condiciones descritas
SI
Información general
A ¿Año de nacimiento? 19 20
B Usted es Hombre Mujer
C ¿Tienes un puesto directivo, por ejemplo, gerente supervisor?
No Si. ¿Cúal?
Muy en
En desacuerdo De acuerdo
desacuerdo
Muy en
En desacuerdo De acuerdo
desacuerdo
Muy en
En desacuerdo De acuerdo
desacuerdo
Muy en
En desacuerdo De acuerdo
desacuerdo
Comentarios:
a5r a6 a7 a8r a9r a10 a11 a12 a13r a14 a15r a16 a17 a18r a19 a20 a21r a22 a23 a24
2 4 3 1 2 2 1 2 1 3 1 2 3 2 2 3 1 2 3 2
4. Workers' safety 5. Workers safety priority and risk 6. Safety communication , lerning and 7. Workers trust
commitment non-acceptance trust in co-workers safety competenece safety sy
a25r a26r a27 a28r a29r a30r a31r a32r a33 a34r a35r a36 a37 a38 a39 a40 a41r a42 a43 a44
1 2 3 1 2 2 1 1 3 2 1 3 2 4 1 3 1 2 3 3
7. Workers trust in efficiency of
safety systems
Dimension scores - calculated automatically!!
Dim6 - Peer safety
Dim1 - Management
Dim2 - Management
Dim3 -safety
Management
Dim4 -safety
Worker
Dim5 - Workers'
communication,
Dim7
safety
- Workers'
priority
learning,trust in
a45r a46 a47r a48 a49r a50 Comments priorityempowerment
and ability
safety justice
safety commitment
and riskand
non-acceptance
trust
efficacy
in safety
of safety
abilitysyste
2 4 1 3 2 4 Item C=Manager; "Th3.44 2.57 2.83 3.17 3.43 2.75 3.43
3.44 2.57 2.83 3.17 3.43 2.75 3.43
These mean dimension scores are shown in the diagram
.
.
own in the diagram
NOSACQ-50 results
Dim1 - Management safety
priority and ability
Scale 1 (poor) til 4 (good)
3.8
3.6
Dim7 - Workers' trust in the Dim2 - Management safety
efficacy of safety systems 3.4 empowerment
3.2
3.0
2.8
2.6
2.4