Many catastrophic accidents and irreversible environmental pollution have occurred in the petrochemical industry, most of which are caused by human factor errors. Therefore, sustainable safety development is one of the main tasks of petrochemical industry. Behavior-based safety (BBS) management is an effective means to improve human factor errors and reduce accidents. Previous BBS literature studies mainly focused on single method, while rarely combined with other quantitative technical methods. This study proposes an extended BBS approach that combines the application of fuzzy analytic hierarchy process (FAHP) and fuzzy comprehensive evaluation (FCE) to assess sustainable safety performance of a petrochemical industry. By using the FAHP for design and prioritizing the behavior factors to develop a BBS program and provide a guidance for the safety managers and employees on site. The FCE method is applied to evaluate the sustainable safety performance and this method is a new application of BBS management. To verify the validity of the proposed framework, the FCE results before and after BBS management are compared. The results show that the approach has a positive effect on human factor errors, accident reduction and sustainable safety development. This paper supplements the knowledge system of BBS program in terms of method and carry out two respects and provides leaders with guidance on sustainable safety development.