Process safety system
What does process safety mean?
Process safety concerns hazards presented by chemicals and processes.
Process safety incidents and accidents are sudden and unplanned, and they involve the release or a potential release of a hazardous substance (e.g. malfunctioning safety systems).
Process safety accidents are explosions or fires caused by chemicals or processes, or leaks of substances hazardous to health or the environment. They potentially have serious consequences related to human health, the environment or property.
Process safety management
Process and occupational safety risks differ from one another from the perspectives of probability and the severity of consequences. Process safety incidents typically have more serious consequences and a smaller probability than incidents related to occupational safety. For example, falling down the stairs has a higher probability and less serious consequences than the breakage of a chemical pipe or the leakage of a toxic substance.
Management systems related to occupational safety focus on occupational safety risk management. Occupational safety management systems alone are insufficient for process safety management – both are important while requiring different expertise.
It is necessary to address process safety in the safety management system – systematic and documented procedures must be in place for it, and all organisational levels must commit to its management. Process safety management is a large system – its understanding and management is essential at each plant supervised by the Finnish Safety and Chemicals Agency (Tukes) at which hazardous chemicals are handled or stored on a large scale.
Tukes process safety system
The term ‘process safety system’ means a management system intended for the management of risks arising from chemicals and processes.
A process safety system can also be called a process safety control system or process safety management system. A process safety system can also be integrated into an economic operator’s general management system, or it can be a separate system applied to activities involving process safety hazards. It is important that the significance of process safety is recognised, and procedures conforming with requirements have been defined for its management.
Tukes has prepared the process safety system model presented on this website. Its purpose is to present key parts of process safety management in easily understandable format.
The Tukes process safety system model was built in the PROTO project carried out by Tukes in 2023. More information about the project is available in newsletters: News for chemicals and LPG supervisors 01/2023 and News for chemicals and LPG supervisors 02/2023 (in Finnish).
The requirements for process safety systems clarify and harmonise the interpretation of chemical safety legislation by Tukes and make it visible for economic operators. The goal is that Tukes and economic operators have a similar view and understanding of the requirements and the procedures defined to comply with them.
The Tukes process safety system model consists of different areas and elements. The areas are based on Government decree 685/2015 (Annex III). The elements describe the key content of each area. The areas and elements of the Tukes process safety system model are:
Organisation and personnel
- Tasks and responsibilities
- Competence management
- Contractor management
Process risk assessment and management
- Process safety information
- Process risk assessment and management
Operation and maintenance
- Safe operation
- Property management
Change management
- Change management
Planning for emergencies
- Internal rescue plan
- Drills
- Communication to the public
Performance monitoring
- Process safety monitoring
- Non-conformity investigation
Audits and reviews
- Audits
- Reviews by senior management
Tukes has defined requirements for each area and element from the perspective of process safety management. An approved procedure has also been recognised for each requirement, representing the method approved by Tukes for meeting the requirement. There may also be other methods to meet the requirements. The requirements and approved procedures are presented on separate pages for each area on this website.
Several companies have previously created standards and guidelines for process safety management.
An economic operator’s process safety system does not have to follow the Tukes model – however, the requirements must be met. Solutions and measures for meeting the requirements may differ depending on the risks associated with a production plant, the scope of operations, and the structure of the organisation.
Tukes maintains the process safety system requirements and approved procedures based on monitoring observations and accident investigations. Any changes will be communicated to economic operators through newsletters. Subscribe to the newsletter (in Finnish).
Addressing the requirements at production plants and in supervision by Tukes
At production plants at which hazardous chemicals are handled and stored on a large scale (facility with a permit, facility with a major accident prevention policy document, facility obliged to provide a safety report), the coverage of the plant’s safety management system must be assessed relative to the requirements defined by Tukes. Tukes recommends that economic operators conduct assessments within the scope of their internal audits.
Tukes conducts periodic inspections at production plants based on the scope of operations and operational risks (risk-based supervision). The process safety system is a key part of the inspections. In its supervision, Tukes requires economic operators to prepare assessments and guides them in the assessment and development of their process safety system.
The Tukes process safety system was completed in December 2023. The preparation of assessments will be part of the next periodic inspection of production plants.
Tukes has prepared a document template (XLSX, 180 kb) for economic operators for process safety system assessments. Veikko Kujala at Tukes ([email protected]) can be contacted regarding all observations and development proposals related to the assessment tool.