Introduction to Process Safety Management (PSM) of Highly Hazardous Chemicals

Introduction toIntroduction toProcess Safety Management (PSM)Process Safety Management (PSM)

of Highly Hazardous Chemicalsof Highly Hazardous Chemicals

Major IncidentsMajor Incidents

• 1984 - Mexico City1984 - Mexico City

• 1984 - Union Carbide Corp, Bhopal 1984 - Union Carbide Corp, Bhopal IndiaIndia

• 1989 - Phillips Petroleum, 1989 - Phillips Petroleum, Pasadena TexasPasadena Texas

• 1990 - ARCO Petroleum, 1990 - ARCO Petroleum, Channelview TexasChannelview Texas

• 1991 - IMC, Sterlington Louisiana 1991 - IMC, Sterlington Louisiana

14 Elements to PSM14 Elements to PSM

•Employee ParticipationEmployee Participation Process Safety InformationProcess Safety Information Process Hazard AnalysisProcess Hazard Analysis Operating ProceduresOperating Procedures TrainingTraining ContractorsContractors Hot WorkHot Work Mechanical IntegrityMechanical Integrity Management of ChangeManagement of Change Pre-Startup Safety ReviewPre-Startup Safety Review Incident InvestigationIncident Investigation Emergency Planning and Emergency Planning and

ResponseResponse Compliance AuditsCompliance Audits Trade SecretsTrade Secrets

The 14 ElementsThe 14 Elements

•Employee Participation

•Trade Secrets

•Emergency Planning and Response

•Incident Investigation

•Process Safety Information

•Process Hazard Analysis•Hot Work•Mechanical Integrity

•Training•Operating Procedures•Contractors

•Management of Change

•Pre-Startup Safety Review

•Compliance Audits

System Wide Prevention

Reaction Control

Employee Participation Employee Participation Everyone plays a partEveryone plays a part

You Make the DifferenceYou Make the Difference

Your Participatio

n is a critical part

of PSM

Nothing happens unless we pull together

Process Safety Process Safety InformationInformation

Provides the foundation for understanding the chemical, technical, and equipment hazards

associated with the processesRetains basic research and development

information to guide future efforts

Process Hazard Process Hazard AnalysisAnalysis

PHAs are the cornerstone of an effective hazard management

program and are aimed at reducing risk

RISK = SEVERITY + LIKELIHOOD

Operating Procedures

Ensures that all individuals are doing their job, the same way

and in the safest manner possible

Training

Awareness causes Action

ContractorsContractors

Contractors need to be informed of the

potential hazards related to the Process

Chemical 1 (ABC)

Chemical 2 (123)

Review (Hazards)

Hot Work

This element establishes the criteria to ensure any

work that may cause a source of ignition is done safely. This includes open

flame, running combustible engines, running

electronics and test equipment that is not

intrinsically safe, grinding, drilling, or any other

possiblesource of ignition.

A Hot Work Permit is Required.

Mechanical IntegrityMechanical Integrity

Critical equipment is identified, designed,

installed, and properly

maintainedEmployees maintaining

equipment are trained to do so Defects are

resolved before continued use of

equipment

Management of Change

Ensures changes are

not made without due

consideration

Improves communications among facility

employees affected by the change

Pre-Startup Safety Pre-Startup Safety ReviewReview

The final "thought stop" to make

sure a new or changed facility doesn't contain any surprises

Incident InvestigationIncident Investigation

Spotlights the chain of events leading to an incident, to

avoid a future occurrence

Near-misses also require an

investigation. They are not minor

incidents, they are free spins on the

wheel

Emergency Planning and Emergency Planning and ResponseResponse

Small problems can become major if not

handled properly

Written plans allow everyone to know what to do in the event of

an emergency

Compliance AuditsCompliance Audits

Audits can verify if programs are in place and measure

their effectiveness

ases the awareness of process

safety throughout a facility, by reviewing

documentation, inspecting facilities and interviewing employees

Incre

Trade SecretsTrade SecretsPssst!Pssst!

Any information needed to comply with PSM must be available

"Sensitive" material may require the signing of a confidentiality

agreement before it is provided

Top

Secret

Benefits of PSMBenefits of PSM

For the Employee reduces chances of being injured by catastrophic releases

For the Environmentreduces chances of loss of containment of Highly Hazardous Chemicals

For the CommunityCreates a sense of security

For the Facility and Equipment...

Increases reliability and reduces unscheduled

downtimeFor the Customer...

Provides a reliable, steady flow of product from a responsible supplier

For the Industry...Contributes to overall

reduction in catastrophic incidents