14 Tips for Process Safety Management

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www.verde.co.in Process Safety lack of awareness could be costlier than you thought Are your process safety risks under control?

description

Process Safety Management (PSM) is a concern in any of the industries who store, handle and process hazardous chemicals & gases. The risks related to process safety are often managed in an isolated way. This presentation will help organisations to manage process safety risks in a more structured fashion.

Transcript of 14 Tips for Process Safety Management

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Process Safety lack of awareness could be costlier than you thought

Are your process safety risks under control?

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about the presentation

Process Safety Management (PSM) is a concern in any of the industries who store, handle and process hazardous chemicals & gases. The risks related to process safety are often managed in an isolated way. This presentation will help organisations to manage process safety risks in a more structured fashion.

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Now on the subject:

Process Safety

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What is Process Safety Management System?

The Process Safety Management System is a comprehensive management system that proactively avoids incidents in the hazardous industries like chemical plants, oil and gas installations, fertilizer, pharmaceutical, explosives and that handle, store or process toxic or flammable chemicals.

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Process Safety Management System integrates different aspects of risks in a facility and puts them under the control of a management system.

By establishing a risk based awareness of the safety impacts of technology, personnel and the management, the system provides a dynamic environment for continual improvement.

Process Safety Management System

Input Output Process

Resources - Equipment - Infrastructure - Human Resource

Controls - Quality / Productivity - Safety

14 Elements of Process Safety Safe

ty

Pro

cess

Man

age

me

nt

Plan

Do

Check

Act

• Process Industries like O&G, Fertilizer, Pesticides, Chemical, Pharmaceutical, Explosives etc.

• Processes in any other industry

Applicability Storage Handling Emissions / Waste Utilities

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14 ELEMENTS

of Process Safety

Element 1: Employee participation

Element 2: Process Safety Information

Element 3: Process Hazard Analysis

Element 4: Operating Procedures

Element 5: Safe work practices

Element 61: Contractor control

Element 7: Training

Element 8: Pre-Start up Safety Review

Element 9: Mechanical integrity

Element 10: Management of Change

Element 11: Emergency response planning

Element 12: Trade secrets

Element 13: Incident Investigation

Element 14: Compliance audits

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These 14 elements follow a simple management system

framework

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Hazard Information

from Employees

Process Safety

Information

• Hazard Identification

• Risk Assessment

• Prioritization

Hierarchy of Controls:

• Elimination

• Substitution

• Engineering Control

• Admin Control

• PPE

• Operating procedures • Safe work practices • Contractor control • Training • Pre-Start up safety

Review • Mechanical integrity • Management of change • Emergency response

planning • Trade secrets

Element # 1

Element # 2

Element # 3 Element # 4 - 12

Set Controls Process Hazard Analysis

Compliance Audits

Element # 13

Incident Investigation

Element # 14

Plan Do Check & Act

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Action Points Develop a written plan of action to implement the employee participation required by PSM.

Consult – provide platforms to share their views, advices, suggestions, alerts

Involve people in hazard identification and analysis process

Provide access to safety information

… 1

Employee Participation

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Process Safety Information: … 2

a compilation of written process safety information that helps to identify and

understand the hazards posed by those processes involving highly hazardous

chemicals.

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Process safety information

must include : Hazards of the highly hazardous chemicals in the

process shall consist of at least the following:

• Toxicity

• Permissible exposure limits

• Physical data

• Reactivity data

• Corrosivity data, and

• Thermal and chemical stability data, and

hazardous effects of inadvertent mixing of

different materials

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• A block flow diagram or simplified process

flow diagram,

• Process chemistry

• Maximum intended inventory

• Safe upper and lower limits for such items as

temperatures, pressures, flows or

compositions, and

• An evaluation of the consequences of

deviations, including those affecting the safety

and health of employees

Information on the technology of the process

must include at least the following:

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Methods • What-if

• Checklist

• What-if/checklist

• Hazard and operability study

(HAZOP)

• Failure mode and effects analysis

(FMEA)

• Fault tree analysis

• An appropriate equivalent

methodology

Process Hazard Analysis identifying, evaluating, and controlling the hazards of

processes involving highly hazardous chemicals.

… 3

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Tasks and procedures related to the

covered process must be appropriate,

clear, consistent, and most importantly,

well communicated to employees.

Steps for each operating phase:

• Initial start up

• Normal operations

• Temporary operations

• Emergency shutdown,

• Emergency operations

• Normal shutdown and

• Start up following a turnaround or

after an emergency shut-down

4 Operating Procedure

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Operating limits: • Consequences of deviation, and steps required correcting or

avoiding deviation. Safety and health considerations

• Properties of, and hazards presented by, the chemicals used in the

process

• Precautions necessary to prevent exposure, including engineering

controls, administrative controls, and personal protective equipment

• Control measures to be taken if physical contact or airborne

exposure occurs

• Quality control for raw materials and control of hazardous chemical

inventory levels; and

• Any special or unique hazards

• Safety systems (e.g., interlocks, detection or suppression systems)

and their functions

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The employer must develop and implement safe

work practices to provide for the control of hazards

during work activities such as

• Lockout / tagout

• Confined space entry

• Opening process equipment or piping; and

• Access control over entrance into a facility by

maintenance, contractor, laboratory, or other

support personnel

These safe work practices must equally apply both

to employees and to contractor employees.

5 Safe work practice

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Contractor Control 6

PSM includes special provisions for contractors and their employees to emphasize the importance of everyone taking care that they do

nothing to endanger those working nearby who may work for another employer.

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Training:

• Initial Training

• Refresher Training

Training Documentation is important

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Prior to the introduction of a highly hazardous chemical to a

process, the pre-start-up safety review must confirm that the

following:

• The constructions and equipments are in accordance

with design specifications

• Safety, operating, maintenance, and emergency

procedures are in place and are adequate

• A process hazard analysis has been performed for new

facilities and recommendations have been resolved or

implemented before start up, and modified facilities

meet the management of change requirements; and

• Training of each employee involved in operating a

process has been completed

8 Pre Start up Safety Review

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Mechanical Integrity:

• Pressure vessels and storage tanks

• Piping systems (including piping

components such as valves)

• Relief and vent systems and devices

• Emergency shutdown systems

• Controls (including monitoring

devices and sensors, alarms and

interlocks); and

• Pumps

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Management of change

These written procedures must ensure

• The technical basis for the proposed change

• Impact of the change on employee safety and

health

• Modifications to operating procedures

• Necessary time period for the change, and

• Authorization requirements for the proposed

change

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Use of a

‘Problem Solving Technique’

Incident

Investigation

Incident Accident Near Miss

Correction Corrective Action Preventive Action

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Emergency Planning & Response 12

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• Identification of possible emergency situations

• Emergency preparedness plan

• Training of people

• Practice

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Compliance Audit 13

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Establish a process of evaluated

compliance with the provisions of PSM

Planned & conducted at regular

intervals

Conducted by Trained and competent

auditors knowledgeable in the process

Documented process

Management attention and actions on

findings

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No requirement to enter

into confidentiality

agreements to not disclose

the information

14 Trade Secret

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• Proactive management system

• Safer workplace for employees

• Reduced risk

• Compliance with industry codes, standards

and practices

• Reduces downtime and losses

• Reduces risk to nearby communities

• Continual improvement

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This is a

knowledge

initiative

About the author:

Saikat Is the CEO and Chief Mentor of Verde Ventures, it provides consulting and advisory services in the field of business management. He is heading the company’s technical team. He is a mechanical engineer by profession and worked in manufacturing industries, service industries and engineering infrastructural projects. Saikat has expertise in areas like Sustainability (Occupational Health & Safety, Environment Protection Corporate Social Responsibility) and Business Excellence (Management Systems, , Training and Human Capital Development). Saikat is a trainer, speaker and assessor with 23 years of rich experience in capacity development, training, assessment and certification of more than 800 organisations worldwide. He has worked with 200+ organisations globally on Occupational Health & Safety, Process Safety, Behaviour Based Safety, OHS Management System development, OHS Risk Management and training. Saikat is Lead Tutor for OHSAS 18001 and participated in 300+ safety audits across industries.

Saikat can be reached at [email protected]

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What Verde does?

Verde is an international advisory firm involved in the field of Responsible Business, Business Excellence and Risk Management.

1 Assessment

Identifying the gaps in a system against standard(s) and requirement. to meet compliance and facilitate improvement.

2 Consulting

Supporting & handholding organisations to solve their problems and to meet the gaps identified during the assessment or any other audit.

3 Training

Empowering people to perform their duties effectively and efficiently.

4 Assurance

& Certification

Ensuring that a process, product, or service meets relevant technical standards and fulfils relevant requirements.

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Verde services in

Occupational Health & Safety

• Safety Audit

• Safety Management System

• Ergonomic

• Electrical Safety

• Accidental Investigation

• Safety Legal

• Fire Risk Assessment

• OHS Due Diligence

• Behavior bases safety

• Safety Management System Maturity Assessment

Safety, Health & Environment

People Excellence Food Safety

Social Compliance

Quality & Business Excellence

Information Security

Sustainability

Risk Management