Process Risk and Reliability Management

1st Edition

Operational Integrity Management

Authors: Ian Sutton
Hardcover ISBN: 9781437778052
eBook ISBN: 9781437778069
Imprint: William Andrew
Published Date: 9th April 2010
Page Count: 856
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In the last twenty years considerable progress has been made in process safety, particularly in regard to regulatory compliance.  Many companies are now looking to go beyond mere compliance; they are expanding their process safety management (PSM) programs to improve performance not just in safety, but also in environmental compliance, quaility control and overall profitability.  Techniques and principles are illustrated with numerous examples from chemical plants, refineries, transportation, pipelines and offshore oil and gas. 

This book helps executives, managers and technical professionals achieve not only their current PSM goals, but also to make the transition to a broader operational integrity strategy.  The book focuses on the energy and process industries- from refineries, to pipelines, chemical plants, transportation, alternative energy and offshore facilities.  The techniques described in the book can also be applied to a wide range of non-process industries.

The book is both thorough and practical.  It discusses theoretical principles in a wide variety of areas such as management of change, risk analysis and incident investigation, and then goes on to show how these principles work in practice, either in the design office or in an opperating facility.

Key Features

  • Learn how to develop process safety, operational integrity and operational excellence programs
  • Go beyond traditional hazards analysis and risk management programs to explore a company's entire range of procedures, processes and mangement issues
  • Understand how to develop a culture of process safety and operational excellence that goes beyond simple rule complience


Managers and technical staff in the oil and gas industry: refineries, pipelines, transportation, offshore facilities.
Managers and engineers in the process industries.

Table of Contents

Chapter 1 - Operational Integrity Management
Operational Integrity / Excellence
Process Safety Management
Major Events
Example 1 - Facility Design
Example 2 - Process Flow
Example 3 - Heat Exchanger
Example 4 - Risk Management Workflow
External Standard
Risk Analysis Plan and Implement
Audit / Deltas
Success / Continuous Improvement
Fundamentals of PSM
Safe Limits
Set Point Values
Operating, Safe and Emergency Limits
Performance / Risk Based
Process - Not Occupational - Safety
Measurement Strategies
Involvement and Thoroughness
Definition of Process Safety Management
Health, Safety & Environmental Programs
Environmental / Sustainability
Quality Management
Statistical Process Control
ISO 9000 / 14001
Six Sigma
Consequence / Likelihood
Bow-Tie Method
Presence of Persons
Single Contingency Events
Economies of Scale
Subjective Nature of Risk
Degree of Control
Familiarity with the Hazard
Direct Benefit
Personal Impact
Natural vs. Man-Made Risks
Recency of Events
Perception of the Consequence Term
Comprehension Time
Quantification of Risk
Predicted Frequency
Likelihood and Failure Rate
Error / Statistical Significance Confidence
Failure / Fault
Independence and Randomness
Acceptable Risk
As Low as Reasonably Practical - ALARP
De Minimis Risk
Citations / "Case Law"
Indexing Methods
Risk Matrices
Consequence Matrix
Worker Safety
Public Safety and Health
Environmental Impact
Economic Loss
Frequency Matrix
Risk Matrix

Chapter 2 - Culture and Employee Involvement
Elements of Culture
On-Going and Consistent
Words and Action


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© William Andrew 2010
William Andrew
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About the Author

Ian Sutton

rIan Sutton is a chemical engineer with over thirty years of experience in the process industries. He has worked on the design and operation of chemical plants, offshore platforms, refineries, pipelines and mineral processing facilities. He has extensive experience in the development and implementation of process safety management and operational excellence programs. He has published multiple books including Process Risk and Reliability Management, 2nd Edition and Offshore Safety Management, 2nd Edition, both published by Elsevier.

Affiliations and Expertise

Principal, Sutton Technical Books