INTRODUCTION3EH13EHS.conCHAPTEROUTLINE1.1MANAGEMENT LEADERSHIP19.3EHS.com 3EHTOTAL QUALITY MANAGEMENT 121.10.SAFETY AND ENVIRONMENTAL CONCERNS111.SAFETY-CRITICAL SYSTEMS 13LOSS PREVENTION-1 3112ENVIRONMENT AND SUSTAINABLE DEVELOPMENT 13LARGE SINGLE-STREAM PLANTRESPONSIBLE CARE 131.6.LOSS PREVENTION-21.141.7TOTAL LOSS CONTROL14QUALITY ASSURANCE12Over the last four decades there has developed in the pro-falling trend in personal incidents in British factories,butcess industries a distinctive approach to hazards and fail-about 1960,this fall bottomed out.Over the next decade,ures that cause loss of life and property.This approach isvery little progress was made;in fact there was somecommonly called loss prevention.It involves putting muchregression.Figure 1.I shows the number of fatal incidentsgreater emphasis on technological measures to controland the total number of incidents in factories over thehazards and on trying to get things right the first time.Anperiod 1961-74.The Robens Committee on Health andunderstanding of loss prevention requires some apprecia-Safety at Work,commenting on these trends in 1972,sug-tion of its historical development against a background ofgested that part of the reason was perhaps the increasinglyheightened public awareness of safety,and environmentalcomplex technology employed by industry (Robens,1972).problems,of its relation to traditional safety and also to aAnother important index is that of fire loss.The esti-number of other developments.Selected references onmated fire damage loss in factories and elsewhere in thesafety and loss prevention(SLP)are given in Table 1.1.United Kingdom for the period 1964-74 is shown inFigure 1.2.Figure 1.3 shows the trend of fatal injuries in the1.1.MANAGEMENT LEADERSHIPUnited States from 1992 to 2010.After Clean Air ActBy the mid-1960s,it was becoming increasingly clearthat there were considerable differences in the perfor-mance of companies in terms of occupationalsafety.has shown a decreased trend but still remains larger thanThese disparities could be attributed only to differences4500 per year.in management.There appeared at this time a number ofreports on safety in chemical plants arising from studiesby the British chemical industry of the safety perfor-1.3.SAFETY AND ENVIRONMENTALmance in the US industry,where certain US companiesCONCERNSappeared to have achieved an impressive record.Thesereports included Safety andManagement bytheThere was also at this time growing public awareness andAssociation of British Chemical Manufacturers (ABCM)concern regarding the threat to people and to the environ-(1964,3),Safe and Sound and Safery Audits by the Britishment from industrial activities,particularly those in whichChemicalIndustry Safety Council (BCISC)(1969,9:the process industries are engaged.Taking the United1973,12).The companies concerned attributed theirKingdom as an illustration,the massive vapor cloud explo-success entirely to good managementand this theme wassion at Flixborough in 1974 highlighted the problem ofreflected in the reports.major hazards.This led to the setting up of the AdvisoryCommittee on Major Hazards (ACMH)that sat from1975 to 1983,and to the introduction of legislation to1.2.INDUSTRIAL SAFETY ANDcontrol major hazard installations.Likewise,there was aLOSS TRENDScontinuous flow of legislation to tighten up both on emis-sions from industrial installations and on exposure ofAbout 1970,it became increasingly recognized that thereworkers to noxrous substances at those installations.was a worldwide trend for losses,due to incidents,to riseSimilarly,in the United States,the Bhopal incident asmore rapidly than gross national product(GNP).well as other highly publicized tragedies (Flixborough,This may be illustrated by the situation in the United1974;Seveso,1976;Three Mile Island,1979;Cubato,Kingdom.The first half of the twentieth century saw aFebruary 1984;Mexico City,1984;Houston,1989)Lees'Loss Prevention in the Process IndustriesTABLE 1.1Selected References on Safety and Loss Prevention3EHABCM (n.d./1,1964/3):AIChE(see Appendix 28);Creber (n.d.);IChemE (see Appendix 28):IOSHIC (Information Sheet 15):NSC(n.d/2,4.6,7,1992/1 1);RoSPA (IS/72,IS/106);Ramazzini(1713);Blake (1943);Rust and Ebert (1947):Plumbe (1953):Gugger et al.(1954);Guelich (1956):Harveyand Murray (1958):Armistead (1959):Coates (1960):Thackara et al.(1960):ILO(1961,1972):Meyer and Church (1961):AIA(1962):Devauchelleand Ney (1962);Ducommun (1962);Shearon (1962);Kirk and Othmer (1963-,1978-,1991-);Simonds and Grimaldi (1963);Gilbert (1964);Vervalin (1964a,1973a,1976c,1981a,b,1983);G.T.Austin (1965a);Christian (1965);H.H.Fawcett(1965a,1981,1982a,1985);H.H.Faweett andWood (1965,1982):Gagliardi(1965):Gilmore (1965):Gimbel (1965a):Gordon (1965):Kac and Strizak (1965):Voigtlander (1965);Emerick (1967)FMEC (1967):MePherson (1967):Sands and Bulkley (1967):Tarrants (1967):Badger (1968):J.E.Browning (1968):CBI (1968):Fowler andSpiegelman (1968);Leeah(1968-);Packman (1968);Berry (1969,1977):Everett(1969):Handley(1969,1977);Klassen (1969,1971,1979);Maas(1969)Northeott (1969)Davidson (1970.1974:Hearfield (1970.1974.1976):D.L.Katz(1970:MCA (1970-/18):Queener (1970):N.T.Freeman1985a,1986g,1987i1988,1990d1991k,1994LPB120,1998,2000,2001,2009:Rodgers(1971 )Tye and0yet(171Hmmr(1972hR.Y.Levine (1972b):SCI (1972);Burns(1973);CAPITB(1973/1,1975 Information Paper 16);Holder (1973);Kinnersley (1973);Kirven and Handke(1973):Ludwig (1973a,b);Orloff(1973)Socicty of the Plastics Industry (1973):Widner (197):C.A.J.Young (1973):Buschmann (1974):CritchfieldGardner and Taylor (1975);Institute of Fuel (1975);D.Petersen (1975,1982,1984,1988a,b,1989);TUC (1975,1978,1986);Bean (1976a,b);D.B.1978);Barbieriet al (1977);Blohm (1977);IP (1977):J.Jones (1977);Leuchter (1977):Lugenheim (1977);McCrindle(1977,1981);D.Nicolaescu(1977):Rogojina(1977):Sisman and Georghiu (1977):Wakabayashi(1977):Webster (1977);Allianz Versicherung (1978);M.E.Green (1978,1979);Napier(1978,1980);Anon.(1979d);BASF (1979);Birkhahn and Wallis (1979):M.Hagenkotter (1979);Kerr (LPB 251979);R.King and Magid(1979):Menzies and Strong (1979);Peine (1979):Schaeffer (1979):Schierwater (1979):H.Clarke (1980);Heinrich et al.(1980):M.R.V.Krishnan andJ.Ganesh(1980):Kumar et al.(1980);Spiegelman (1980)Srinivasan et al (1980):Wells (1980);G.Choudhary (1981);McCrindle (1981);Teja(1981)AGA (1982/7);Laitinen (1982);Ormsby (1982,1990):Carter (LPB 50 1983):W.B.Howard (1983,1984,1985,1989);Parmeggiani (1983);RidleyDnV (1987 RP C201):Romer (1987):Scheid (1987):Hovos and B.M.Zimolong (1988):Kharbanda and Stallworthy (1988):;Carson and MumfordRenshaw (1990):R.Du pont,L.Theodore,and J.Reynolds(1991):L.Hunt (1991);McQuaid (1991);Rasmussen (1991):Whiston (1991);Pasmanet al.(1992);Andrews (1993);Fisk and Howes (1993);Cullen (1994);Donald and Canfer (1994);M.Richardson (1994);Rosenthal and Mannan (2000);Schupp et al (2002);Manman et al (2003)Sanders (2005):Mannan (2005):Knegteringand Pasman (2009);Crowland Louvar (2011)Total loss controlBSC (n.d/6,7):Heinrich (1959);Bird (1966,1974);Bird and Germain (1966,1985);Gilmore (1970);Goforth (1970);J.Tye (1970):J.A.Fletcherand Douglas (1971):Webster (1974,1976);Anon.(1975 LPB 4,p.1):Hearfield (1975)D.G.King (1975);EE.Davis (1976);Ling (1976,1979);D.H.Farmer (1978);Planer (1979);Heinrich,Petersen,and Roos (1980);Dave (1987)Safety,health and environmentBerkey,Dowd,and Jones(1993);J.L.Hawksley (1993b).Walk (1993)Company policiesomAalbersberg (1991);Auger (1993):Whiston (1993)Responsible careCIA(RC51.RC52:1990 RC23.Product stewardshipRausch (1990)3EHOrganizational initiativesIChemE:Hancock (1983):Street,Evans,and Hancock (1984)CEFIC:Jourd (1990)EPSC:Anon.(1992 LPB 103):Anon.(1993 LPB 111):EPSC (1993):Anon.(1994 LPB 115):Hancock (1994 LPB 120)Organization guidesContractorsTerminologyIP (Oil Data Sht 3):Harvey (1979b):Burgoyne (1980);W.Berthold and U.Loffler (1981):V.C.Marshall (1981a,b,1990c):A.E.Green (1982):Kletz(1983c,1984:IChemE(1985/78,192/ACDS(1991)BS(Appendix 27 Glossaries);CCPS(2005)BibliographiesCommonwealth Department of Productivity (1979);Lees (1980b);Vervalin (1981a,b);Lees and Ang(1989)CritiquesWallick (1972):Commoner (1973);L.N.Davis (1979,1984)Other related fieldsPugsley (1966)Ingles (1980;civil engineering):Thurston(198aviation):BJ.Garrick and S.Kaplan (1982);V.M.Thomas (1982):Grigoriu (19843EH