Risk Based Process Safety Program in R & D Facility | AIChE

Risk Based Process Safety Program in R & D Facility


Conference Presentation

Conference Type

AIChE Spring Meeting and Global Congress on Process Safety

Presentation Date

April 12, 2016


30 minutes

Skill Level




Research & Development facility comprises of pilot plants & laboratories which are designed & constructed to perform new experiments/advancement processes to investigate the critical aspects of process, which will be replicated into the commercial Processes/plants. There may be a general perception that the R & D facilities are less hazardous, safer than the commercial plant & they don’t require the same precautions/safety management systems as commercial plants. However with the new, unknown & changing technology, numerous unknown chemicals, less information about the material & processes, frequent modifications for experiments, lack of waste characterization, limited automatic safety interlocks make R & D, a complex system. This complexity & Flexibility in R & D leads to significant hazard potential that can cause injuries, fatalities, property damages & environment excursions. Therefore it is a very challenging task for R & D organizations to develop a comprehensive & standardized set of Process safety program covering all potential scenarios which may lead to process safety incidents.

This paper attempts to provide a risk based process safety program for R & D facilities based on its four pillars which certainly helps to understand the potential Hazards & their identification, assessment & mitigation pathway in R & D Facility which are mentioned below,


  • Commitment to Process safety.
    • Management commitment towards Process Safety
    • Operation consistent with Standards & Procedures
    • Employee involvement
  • Understanding of Hazard & Risk.
    • Design safety Review
    • Hazard Identification & Assessment
    • Process Information/knowledge
  • Managing risk.
    • Safe Work Practices & Operating Procedures
    • Management of Change
    • Emergency Response Planning & Management
    • Training & Performance Assurance
  • Learning from the past incidents.
    • Incident Investigations
    • Learning from past incidents
    • Auditing
    • Management review

Risk Based Process Safety Program is providing the structured, strategic, Functional & Technical baseline to R & D Facility to achieve sustainable safety.


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