A Total Safety Management framework in case of a major hazards plant producing pesticides

•Total Safety management framework in the process industry.•Common Operational Picture for process safety.•A tool for Total safety management.•An illustrative application in dichloropropene storage tanks with flammable substances. The aim of this paper is to present the framework for Total Safety Management through its application to a major hazards chemical plant, namely a pesticides producing unit. This framework was developed within the European Project entitled “Total Operation Management for Safety Critical Activities” (TOSCA) aiming at an innovative approach able to integrate and enhance safety, quality and productivity. The cornerstone of this framework is the “Common Operation Picture” notion, which involves a useful synthesis of the unit risk assessment, with the intention to provide understandable information to the relevant stakeholders and decision-makers. This framework has been applied to the storage area of a hazardous substance called dichloropropene, a flammable material used for pesticides production. The Fault Tree and the Bowtie methods have been used for the risk assessment of various accidental releases from the dichloropropene storage tanks. Production data, safety barrier information and results of risk analysis are stored in a database linked with accident sequences visualization tools.