Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.

2, 2021

Process Safety Management Strategies and Risk

Assessment
Nina Jildeh1), Mohammed Matouq *2)
1)Qaulity Assurance Consultant, Omnitrade Chaoui, Rshaidat and Masannat, B.O.Box 294 Amman, 11118, Jordan.
2)
Al-Balqa Applied University, Faculty of Engineering Technology, Chemical Engineering Department, P.O. Box 4486, Amman 11131, Jordan.

Abstract

The benefits of achieving excellent process safety prevent or mitigate incidents. Well, the decision-making process has
a benefit on risk reduction. This paper guides how an effective system can be established to develop methods and models
for mandatory safety and a healthful workplace. The success of health and safety management depends on the discipline,
commitment, and participation of all employees to ensure the success of management strategies and ensure the
reduction of significant risks. The sustainability challenges are increasingly by evaluating risk and process safety due to
the differences in the knowledge and experiences. Failure Mode and Effective Analysis (FMEA) combined with risk
management principles provide an overall assessment to express the deviation that might occur in the process before
failure and distinguish the importance of risk factors. This article intended to provide a method for integrating an
organization's safety and health regardless of its size and work contributed to regulations and requirements. The benefits
to implementing this model in the company will show returns in the investment. The main challenges include identification
and discussion of the potential risks, in addition, to the collaborative of researchers between environmental protection
and process system leading to the reliability and better understanding of the existing safety concepts.

Paper type: Review paper

Keywords: safety, health, environmental impact, risks, hazards, process management, ISO.
Citation: Jildeh Nina, and Mohammed Matouq " Process Safety Management Strategies and Risk Assessment" Jordanian Journal of Engineering
and Chemical Industries, Vol. 4, No.2, pp:52-61 (2021).

Introduction

The American Institute of Chemical Engineers (AIChE) created the Center for Chemical Process Safety (CCPS) in 1985 after the
chemical disaster in Mexico and India to prevent major chemical accidents. CCPS provides a series of guidelines and essential practices
for implanting process safety and risk management system to ensure the effectiveness of process safety management (PSM) (Abu Baker
et al., 2017). Nevertheless, many organizations are still challenged within a complex of operational processing plants and management
systems. This could certainly create new risks and hazards. Weaknesses, including lack of awareness about severe chemical hazards
and poor preparation of any hazards, result in victims (Fatemi et al., 2019). According to International Standardization and Organization
ISO 45001, the Occupational Safety and Health Administration (OSHA) requires employees to comply with safety, health standards,
and regulations. The management system aims to prevent work-related incidents/injuries and provide a safe and healthy workplace.
The literature reviewed that European and US safety concepts are considered more advanced and comprehensive than those found in
the Taiwanese construction industry (Chen et al., 2020). Continuously, the organization management should eliminate any hazards
besides improvement of safety performance (Guntzburger et al., 2017; Grossel, 2007). According to regulations and requirements,
organizations and industries seek a new way to improve safety and health management in the work area. The main aim is to reduce risk
and economic failure based on risk analysis and judgment on existing resources and processes. This could become more effective once
consultation and expert analysis of the risks of the entire process life-cycle from the safety point of view for restructuring a new
practical, safe system. Several accidents have occurred over the past decades with significant impact results directly or indirectly in the
environment and human health. Different accidents reflect the efficiency and effectiveness of process safety and risk management
system to prevents and reduce the severity and occurrence of these industrial accidents. It is expected to learn from these accidents and
another industrial failure, reducing the potential catastrophic accidents in the future. Some notable accidents in history have been
addressed in order to learn and improve the existing process safety management system or reduce the impact of the undesirable hazards:

* Corresponding author: E-mail: [email protected] ORCID: https://orcid.org/0000-0002-2497-2117

Received on May 7, 2021; Accepted on July 30--, 2021.
Jordanian Journal of Engineering and Chemical Industries (JJECI), Vol.4, No.2, 2021, pp. 52-61.

© The author

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

• Nypro Chemical Plant in Flixborough, 1974: Large explosion caused 28 coworkers to be killed and injuries of 36 coworkers.
Upon investigation, leakage of cyclohexane formed a flammable mixture led to an unconfined vapor cloud explosion which
resulted in the ignition for 1 min (Raji, 2014).
• Bhopal in India, 1984: Worst industrial disaster in history, caused by accident release around 40 tonnes of highly toxic and
heavier than air. This incident results in at least 16000 people were killed, and 150,000 to 600,000 suffered injuries (Raji,
2014; Hardy, 2013; Cheremisinoff, 2001).
• Chernobyl Nuclear Disaster in Ukraine, 1986: A Chemical explosion due to uncontrolled graphite fire led to more than 450
radio-nuclides. This accident was officially considered one of the biggest economic catastrophes in history, resulting in
125,000 people who died from cancer, and 1.7 million people were affected directly (Raji, 2014).
• Explosion in Pennsylvania, 1999: Explosion of a vessel containing several hundred pounds of hydroxylamine, which high
chemical concentration and high temperature led to the explosion. This explosion caused four employees and managers to be
killed, four people were injured, and ten buildings were damaged. Upon Chemical Safety and Hazard Investigation Board
(CSB) investigation showed that the company did not collect and analyze the safety information properly before starting the
process and a fault in the design plant (Hardy, 2013).
• Explosion in Delaware, 2001: Explosion due to leakage of sulfuric acid storage tanks resulting in the acidic vapor in the
atmosphere led to the death of one maintenance coworker and injuries of eight coworkers. Upon CSB investigation, the tank
had a history of leakage, and the company has failed to conduct proper identification of the presence of the leakage (Hardy,
2013).
• Explosion and Fire in Florida, 2006: Explosion and fire occurred in a wastewater treatment plant, results in two employees
were killed, and three was severely burned. Upon CSB investigations, the coworkers were using a cutting torch to repair a
roof above the methanol storage tank, igniting vapor from the storage tank and flame back into the tank (Hardy, 2013).
• Fire in Texas, 2007: Fire caused extensive damage to the facility due to a crack in liquid propane pipe, results in shutdown
for months. This accident caused an injury for four people. Upon U.S. CSB investigated that the cracked pipe was not properly
isolated (Hardy, 2013).
• Fukushima Nuclear Disaster in Japan, 2011: A powerful earthquake occurred under the sea about 70 km east of the Oshika
peninsula, resulted in 15,854 deaths, in addition to 3,155 missing people and about 27,000 people were injured (Raji, 2014).
• Explosion in Beirut, 2020: Explosion occurred due to a large amount of ammonium nitrate stored at the port of Beirut, which
results in over 150 were killed, more than 5000 injuries, and 2 billion dollars in property damages and leaving an estimated
300,000 people homeless (Crisis Group, 2021).

Furthermore, the main focus should be on process safety, in which the manufacturing process should be built upon regulations and
customer specifications from specific materials or desired operating processes. The well-designed process was established from data
information to identify the main requirements: raw materials, supplier information, by-process analysis, final product analysis, analytic
equipment maintenance, calibration requirements, packaging materials (containers, labeling requirement), storage and disposal of
containers. The contribution between a complete team of technical operators, engineers, scientists, management, marketing, purchasing,
finance, and clients, results in reducing the likelihood of incidents in and control of process hazards to protect the workplace. Proper
documentation and information about materials and equipment should always be addressed in the manufacturing area, including
personal and material flow diagrams, piping and instrument diagrams (P&IDs), and material safety data sheets (MSDS). The specific
information of the operating equipment should be addressed to ensure the continuity of correct operation and the presence of specific
information, including datasheets for identifying the potential hazards of the process, corrosive materials, physical data, and reactivity
of the process materials, stability analysis of hazardous materials. The emergency shutdown system, senor alarms, and interlocks should
always be checked to ensure the safety process. Considering the catastrophic incidents, the Occupational Health and Safety
Administration (OSHA) enacted in 1994 the Process Safety Management (PSM), aims to prevent incidents through the application of
14 elements based on principles and management systems for knowledge and control of the risks involved in the processes as present
in Figure 1 (Khan et al., 2015). The historical reason for PSM is to prevent any catastrophic accidents in chemical industries, as methyl
isocyanate was released in Bhopal, India, in 1984, which led to the death of more than 3.800 people and more than 100 thousand
injuries, in addition to compensation of 470 million dollars (Raji, 2014).

1 Process safety management in terms of ISO 31000

Process safety is defined as an integral part of process development and manufacturing to define risk identification, risk analysis, risk
assessment, risk evaluation, and consultation for critical decision making (Khan et al., 2015). Process safety is expressed in terms of
ISO 31000 to manage the risk/safety and economics based on decision making and design improvement, as presented in Figure 2

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

Fig. 1 Principles of management systems based on 14 elements for controlling Fig. 2 Risk ISO 31000 Management Process.
the risks involved in the processes. Source: Pacheco and Souza, 2018

By implementing the principle of risk management system, the

obtained model provides organizations with an analysis of how
the design process influences safety. It also provides ideas for
improving the existing operating system and measuring future
performance through communication with expertise. The
effectiveness of regulations on process safety systems involves
a complete understanding of equipment and the concept of
critical hazardous systems (Halim and Mannan, 2018).
Predicted accidents should be modeled and structured depends
on the overall life-cycle process to prevent serious injuries and
incidents. Figure 3 shows a process flowchart for an
organization focused on process-safety performance and
personal behavior to identify the effectiveness of process safety
the potential risks based on collecting information through
observations, facts, experiences, and assumptions. The analysis
of risk provides a quantitative and qualitative estimation of each
identified risk. Based on identifying, analyzing, and treating the
risks, the organization would make decisions depending on the Fig. 3 Process flowchart for organization focused on process-safety
performance and personal behavior to identify the effectiveness of
situations that are subjected to change by monitoring and process.
reviewing the effectiveness of the risk management framework.
In addition, the view of compliance and consultation within rules and specifications helps resolve problems, customer satisfaction
within high-quality management. Within variation of process parameter and personal behavior for continuous improvement, this
variation should be anticipating and acceptable otherwise, and it is called deviation. Center for Chemical Process Safety (CCPS)
mentioned that risk-based process safety provides a helpful tool and essential guidance on design process management, correcting the
presence system, and improving the practices of the safety management system (ISO 45001, 2018). Good documentation is highly
required to minimize the potential risk of personal and process safety of an organization. For example, a coworker falling from a ladder
is not reported or an incident of a coworker falling from a juke is not reported. An incident caused by a failure in the processing unit is
reported immediately. However, all the incidents should be highly reported to distinguish the safety of the equipment and materials
workplace. Reporting criteria should be reported immediately to prevent any difficulty in controlling the incident. Failure to follow
instructions and safety work-area results in critical safety issues summarized in Table 1, which presented severe incidents and
corresponding consequences of the accidents as sickness, death, and disability for life.

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

Table 1 Industrial accident and the corresponding failure identifications, evaluation, treatment, monitoring and review
Industrial Risk Identification Risk Risk Evaluation Risk Treatment Monitoring and Review References
Sectors Analysis
(Low,
Medium,
High)
Steam, hot
Technical and
condensate, gases, continuous
compressed air, communications with
Reactors, tanks, increase of contractors and Mechhoud et
Continuous maintenance
pipes, boilers, temperature, increase suppliers. al, 2016;
of mechanical equipment
cooling towers, of pressure. Continuous checking Ebrahimi et
Petrochemical Continues training for
refrigeration systems, Medium to Serious harmful and maintenance the al., 2021;
and refining safety issues
spillage, interlocks High performance of the Damnjanovic
production effects on human Continuous maintenance
and emergency machinery and Roed,
health and of emergency interlocks,
shutdown systems, Alarms are provided 2016, Fatemi
environment such as emergency equipment
fire and explosion for any changes in the et al., 2019
respiratory distress, process
eye and skin Inspecting the fire
irritation protection facilities
Improper design
issues/ inappropriate
Contamination of Improve the Continuous monitoring
operational Analouei et
surface water from separation process to of the operation
management, al., 2020; Loi-
Wastewater excess nutrient, reduce the treatment plant and
Medium to bacteria in an Plich and
treatment operational/ concentrations of review process to ensure
High activated sludge Zakzewska,
plants mechanical pollutants the effectiveness in
chamber, 2020; Carroll
malfunctions, Improve technologies providing suitable risk
environmental et al., 2006
ecological hazard lines devices migration
pollution with
chemicals
Fundamental
thermochemical
calculations are
performed for better
Increase of
understanding of the
temperature, increase
hazard as oxygen
Uncontrolled of pressure, gas
balance, heat of
chemical reaction evolution Review of process safety
reaction, maximum
resulted in the release Serious harmful awareness, review of Fatemi et al.,
Chemical Medium to pressure/rate of
of toxic vapors from effects on human employees awareness for 2019; Mannan
Industries High pressure rise,
reactors, tanks, health and plant hazards and safety et al., 2015
temperature rise,
leakage system, fires environment such as regulations
reaction rate constant,
and explosions respiratory distress,
computer programs,
eye and skin
screening tests as
irritation
incompatibility tests,
thermogravimetric
analysis, differential
scanning calorimetry
Review the required
Failure in mechanical Continuous training
Corrosive-vapors, training of employees Langermann,
Laboratory- Medium to integrity and material and regulations to
electrical-contacts, with respects to safety 2009
scale incidents High compatibility, lack of wear safety glasses,
exothermic reaction and emergency
technician experience lab coats and gloves
regulations
Review and evaluate the
data to maintain safety
Incidents that is no
and efficiency of
direct contact to Injury, disabilities,
Emergency handling procedures, WHO, 2018;
chemical or process Medium to loss of life, property
Others preparation and review of the various DeCoyet et
as office building High damages results in
handling procedure active as fire hydrant, al., 2006
fire, earthquakes, economic losses
portable fire
war, floods situations
extinguishers and
sprinkler
Continuous checking
Storage of active -Improper storages and maintenance the
pharmaceutical condition according performance of the
ingredient and to the supplier machinery Review of process safety
Patel et al.,
chemical specifications Alarms are provided awareness, review of
Pharmaceutical Medium to 2019;
components, -Power failure to the for any changes in the employees awareness for
Industries High Chavda et al.,
uncontrolled refrigerators or set-point plant hazards and safety
2015
temperature and conditioning system temperature/humidity regulations
relative humidity, -Damage in the Trained employee to
machinery failure operational machine keep monitoring

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

2 Strategies to prevent and control the risks

Major regulatory elements of process safety management (PSM) as published at 29 CFR 1910.117 includes employee’s, information
of process safety, analysis of process hazard, operating procedures, training, contractors, pre-sat-up safety, mechanical integrity,
management of change, incident investigation, emergency planning and response, compliance audits and trade secrets as presented in
Figure 4 (Langermann, 2009). Furthermore, risk description associated with a set of hazards is considered an important aspect is
comprising scope, procedures, personal qualifications and successful training program, schedule and deadlines, management auditing,
and review. By analyzing these risks, the approach result provides quantitative and qualitative consequences to correct/ improve
activities of management process safety. Failure Modes and Effects Analysis (FMEA) is a statistical tool that identifies all the possible
failures that might occur in the design, manufacturing, or assembly process and the consequences of those failures. FMEA can also
analyze the history of organizational data (Nuchpho et al., 2014). Despite the simple concept of FMEA, the variation in the complex
processes should be taken into consideration to ensure quality and safety, and this must include a complete understanding of the type
of failure modes, cause or effect, risk assessment, type of control, process versus design, and interactions between structures. Each
potential failure is corresponding to various scaling values related to severity, occurrence, and detection. In the later stage of FMEA,
Risk Priority Number (RPN) is determined by multiplying three
scaling values, which provides valuable tools to evaluate and
determine risk for each risk.

Table 2 presents a simple FMEA worksheet to understand the

principle of managing the risk. The actual FMEA worksheet
contains more details, including several failures. The framework
starts by providing all the potential risks that might occur in the
unit operation, followed by evaluating each failure in severe
occurrence and the potential to detect the failure before
occurrence. Therefore, well-communication protocols between
employees and consulting sectors maintain a well-established
process safety management system.

Fig. 4 Process safety management as established by 29 CFR 1910.117.

The first step in conducting FMEA is to build a model table that
refers to all the possible potential failures in terms of equipment failure and functional failure (Potential Failure Modes). The second
step is by describing the impact of each failure on the process (Potential Failure Modes Effects) within the severity of the failure.
Identify the causes of the failure (Potential Failure Causes) within the possibility of occurrence. The third step is describing the
prevention action and process control for each failure (Current Controls). In the final stage, Risk Priority Number (RPN) is measured
to provide information’s referring to the risks factors for implementing ideas to prevent these failures from an occurrence during the
earliest conceptual design stages and continuous improvement throughout the process life-cycle (Sadaqat et al., 2018; Picardi et al.,
2004). For implementing a successful model, a team of skilled people with different diverse knowledge about the process is collaborated
to identify all the possible risks, including scientists, engineers, manufacturing, testing, maintenance, suppliers, marketing, and
customer services.
Table 2 Typical Failure Modes and Effects Analysis (FMEA)
Potential
Numb

Potential Failure Potential Failure Likelihood Current Detectabi Risk Priority

Severity Failure Remarks
er

Mode Modes Effects Occurrence Controls lity Number

Causes
1
..

n
Rank the failures from one to ten based on the severity of the consequences of failure
Rank the failures from one to ten based on how frequently it is likely it is to occur
Rank the failures from one to ten based on the chances that it will be detected before it occurs
Calculate the RPN for each failure by multiplication of Severity, Occurrence and Detection

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

Rating is usually done on a scale of ranges from 1 to 10. They depend on the severity of the failure, the probability of occurrence, and
the probability of detection. The highest RPN number
depending on the severity effect of the failure and the urgent
correction actions.
By Applying the FMEA model for all process failures and
measuring the RPN number, the detected value of potential
risk helps in reducing the likelihood of a specific failure or
mitigating the consequences. Figure 5 presents how the
potential occurrence of the risk failure is reduced after
implementing FMEA within high severity of the risk and
detectability on the process. Therefore, this model provides a
knowledge’s on which risk is the most serious, which has a
substantial negative impact on employees and organizations,
indicating that the highest risk value should be controlled first.
This model also helps in reducing the impact of risks by
reviewing/writing standards of procedures that cover the
safety of process in terms of accidents, shutdown emergency, Fig. 5 Potential occurrence of the risk failure is reduced after implementing
deviation emergency, emergency operation, emergency action FMEA within high severity of the risk and detectability on the process.
plan for entire facilities including plans, maps, and assembly points. As discussed above, the essential integration of management
system boundaries, as illustrated in Figure 6, enhances participation and engagement with coworkers and consultation sectors to
provide safe and healthy working process conditions by preventing workplace injury and ill-health. This integration can be built up
within the management concept of the Plan-Do-Check-Act model, which describes the organization's objectives and monitoring the
performance. Management integration systems cover risk identification/awareness, risk assessment/control, emergency response,
performance improvement (Yoltarelli et al., 2018; Patal and Deshpande, 2017; Gidey et al., 2014).

Furthermore, the Center for Chemical Process Safety (2011) has

reported that sleeping disorders, alertness, and physiological
fatigue have a huge impact on decision-making, resulting in
potential risk. In addition, extended working shifts and overtime
are also assigned as a cause for risk. Industries should implement
operational regulation strategies to prevent any catastrophic
incidents through audits, inspections, coworker training, safety
culture, and system improvement (Fatemi et al., 2019). An
adequate process safety could indicate the performance of process
safety when an accident is most likely to occurs, which enables
the organizations to implement corrective actions by:
• Schedule annual audit and define the scope of the
annual audit policy Fig. 6 Typical integration between management systems and typical Plan-Do-
• Discuss the annual audit report with expertise to Check-Act model.

ensure an adequate atmosphere for safety

• Define the procedures to resolve hazards related to risk and the time frame to resolve the problem
• Reduce the potential risk of accidents in the workplace, claims, business reputation, and costs
• Define the restart-up of the unit operation after resolving the issue or restart portions of the unit operation related to the
safety phases
• Review and checkout the process after resolving the hazards
• Commitment to protect employees, clients, and visitors from any presence of incident
• Continuous and successful training demonstrating skills and knowledges for process safety management to prevent any
significant hazards and recovery from accident circumstances
• Learning from experiences and learning from other industrial failures provide an opportunity for improvement by
monitoring practical internal and external resources of information
Companies who would commit to the above engagement system firm a severe and successful environmental protection for employees,
clients, and visitors, which demonstrates the success of the company in the competitive market.

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

3 The framework of industrial accidents and the prevention mechanisms

In order to control and prevent the presence of accidents and hazard risks during the processing plant, a feedback model on the process
control is determined by continuous observation and data evaluation to maintain the safety of the process management system. Every
chemical process has a certain amount of risk associated with its specific activity; usually, risks may be too high in the presence of
additional factors as fire and multiple exposures. However,’’Acceptable Risk’’ should be identified during the design stage to minimize
the process's economic constraints and acceptable regulatory risk standards. Figure 7 describes the overall identifications for estimating
the risk. The concept is used to define risks based on the information and frequency of predicted incidents. Several questionnaires
should be applied through the design stage based on knowledge’s and previous industrial failure related to the process. What is the
factor of a safe work environment and resources? The acceptability of the final framework model depends on all the parameters that
directly and indirectly affect the process. A lack of resources and understanding of science and engineering through risk assessment
could lead to incidents. Implementing training and teaching workers on managing and controlling the presence of any risks during the
operations of machines and equipment will be an essential step in controlling the risk of dangers, with a continuous inspection and
validation of the machines to ensure the safety of the used machines. Applying safety regulations in industries is intended to prevent
any major incidents that might cause danger to human/environmental during industrial activities in various procedures and methods.
By maintaining the safety and effectiveness of the process control, the desired target is efficiently stable, corresponding to the safety
policies as recommended from Occupational Health and Safety Management System ISO 45001 and ISO 14001. This significantly
helps to improve the overall safety performance. The assessment structure proposed on safety management, which attempted to
characterize the relationship between physical/technical elements (equipment, facilities, guard’s protection, helmets, shoes, safety
glasses), community element (education, skills, knowledge’s, expertise, managers, leaders), and external relative/social element
(law/regulations, safety, budget). This model utilizes the relationship between various elements among the vital success of constructing
safety professionally.

Fig.7 Overall identifications for estimating the risk.

Figure 8 shows a model process in which engineers and quality assurance workers measure the actual quality of the entire process,
starting from the input to the actual desired output. A variation or deviation between the actual target and the desired target is highly
dependent on the processing system, skills, knowledge’s, regulations, and economic aspects. The primary role of collaborations between
various industrial sectors is to provide a sustainable workplace and equilibrium state coupled with safety policy regulations. Therefore,
continuous training and education of workers and managers regarding safety performance increase the ability to undertake any presence
of accident, hence protecting the lives of workers in industrial accidents and reducing costs as mentioned at center for chemical process
safety in the year 2011.

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

Fig. 8 Schematic methodology diagram designed for proposed dynamic industrial accident associated with influential factors to prevent risk and enhance the
productivity and safety management

The ‘’Key success factor’’ term is considered a unique element to complete the organization's goal. Chen et al. (2020) defined KSF as
a ‘’set of positive activities and results which signifies that a manager has realized their goals and objectives’’. Commitment to project
safety management through comprehensive communications between sectors, which display a significant impact in implementing and
measuring the effectiveness of the quality and professional training process planning (Chen et al., 2020). Ismail et al. (2012) stated that
safety management and personal protection equipment are based on the awareness of workers. In addition, the improvement principle
and update of the current safety system based on the overall point of view of consultation and engineers, process life-cycle analysis,
external climate to ensure the sustainability of the process (Mannan et al., 2015). Figure 8 presents the methodology framework in
understanding the scope and target of the process cycle from the impact of raw materials, manufacturing process, maintenance,
disposal/recycling, and distribution of the final product and the external environmental interpretation on the significant improvement
of the safety process. The uncertainty of identifying the potential risks in the process resulted in management failure and personal
errors. For reducing such failure and losses, a contribution between various principles and management approaches as PDCA and
FMEA provides a fundamental framework to ensure control and improve continuous safety system. This assessment structure
methodology defines the concept of life-cycle process identifies the potential risk of process failure due to technology failure, human
failure, management system failure, equipment failure, external circumstances, and natural phenomena. The provided information and
data analysis would support the managers for strong decision-making by minimizing the real estimation time. Hence, reducing the
possible losses and maintain the stability of company investment.

Conclusions
Failure Mode and Effects Analysis (FMEA) and Plan-Do-Check-Act (PDCA) cycle models could be conducted in any organization,
which adds quantitative and qualitative value for improving the process life-cycle and protecting organizations from the organization
any possible hazards. Analysis of these hazards in the processing unit is evaluated based on different criteria through visualization and
experiences that aimed to identify the source of failure regardless of workplace complexity. This approach enables the organizations to
implement all the required corrective actions to eliminate these risks, increase the profit investment, and ensure workplace safety. The
incorporations between management systems and various sectors assure a successful, strong decision-making by reviewing and
monitoring the action plans.

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Jordanian Journal of Engineering and Chemical Industries (JJECI) Review Paper Vol.4 No.2, 2021

Nomenclature

AIChE =American Institute of Chemical Engineers [-]

CCPS =Center for Chemical Process Safety [-]
CSB =Chemical Safety and Hazard Investigation Board [-]
FMEA =Failure Modes and Effects Analysis [-]
RPN =Risk Priority Number [-]
OSHA =Occupational Safety and Health Administration [-]
PDCA =Plan-Do-Check-Act [-]
PSM =Process Safety Management [-]

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