Framework for Process Safety Management based on Enggg ...psc.tamu.edu/files/symposia/2010/presentations/track4/Shimada_1284083896.pdf--Beyond Regulatory Compliance, Making Safety

Hilton Conference Center, College Station, Texas, USA, October 26Hilton Conference Center, College Station, Texas, USA, October 26‐‐28, 2010 28, 2010 Mary Kay O’Connor Process Safety Center International SymposiumMary Kay O’Connor Process Safety Center International Symposium

--Beyond Regulatory Compliance, Making Safety Second NatureBeyond Regulatory Compliance, Making Safety Second Nature--

Framework for Process Safety Management Framework for Process Safety Management based on Engineering Activity based on Engineering Activity g g yg g y

through Plant Lifecyclethrough Plant Lifecycle

Yukiyasu Shimada Yukiyasu Shimada 1)1), Teiji Kitajima , Teiji Kitajima 2)2), and , and ))Hiroshi Sumida Hiroshi Sumida 3) 3)

1) National Institute of Occupational Safety and Health, Japan1) National Institute of Occupational Safety and Health, Japan2) T k U i i f A i l d T h l J2) T k U i i f A i l d T h l J2) Tokyo University of Agriculture and Technology, Japan2) Tokyo University of Agriculture and Technology, Japan

3) 3) Toyo Engineering Corporation, JapanToyo Engineering Corporation, Japan

1. Introduction1. IntroductionHow the Process Safety Management (PSM) How the Process Safety Management (PSM) should be implementedshould be implemented in chemical processes?in chemical processes?How the Process Safety Management (PSM) How the Process Safety Management (PSM) should be implementedshould be implemented in chemical processes?in chemical processes?

A ti it M d li f PSMA ti it M d li f PSMActivity Modeling for PSMActivity Modeling for PSM

[Goal of this study][Goal of this study]TT th ti l f k f PSMth ti l f k f PSMTo propose To propose the practical framework for PSM the practical framework for PSM for preventing industrial accident.for preventing industrial accident.

2. Discussion on PSM2. Discussion on PSM

What is PSM?What is PSM?What is PSM?What is PSM?

To discuss about To discuss about To discuss about To discuss about -- safetysafety--related engineering related engineering techniquestechniques, , -- schemescheme of plant risk management and of plant risk management and -- safetysafety--related engineering related engineering techniquestechniques, , -- schemescheme of plant risk management and of plant risk management and

effective disaster prevention for outside effective disaster prevention for outside communities, etc. communities, etc. effective disaster prevention for outside effective disaster prevention for outside communities, etc. communities, etc.

What is practical framework for PSM?What is practical framework for PSM?

OSHA (OSHA (Occupational Safety and Health AgencyOccupational Safety and Health Agency)/PSM)/PSMOSHA/PSM, 29 CFR 1910.119OSHA/PSM, 29 CFR 1910.119 (1992)(1992)A A U.S. regulatory standardU.S. regulatory standard that requiresthat requires use of a 14use of a 14--elements management systemelements management system to help prevent or mitigateto help prevent or mitigate

OSHA/PSM, 29 CFR 1910.119OSHA/PSM, 29 CFR 1910.119 (1992)(1992)A A U.S. regulatory standardU.S. regulatory standard that requiresthat requires use of a 14use of a 14--elements management systemelements management system to help prevent or mitigateto help prevent or mitigateelements management systemelements management system to help prevent or mitigate to help prevent or mitigate the effects of catastrophic releases of chemicals or energy the effects of catastrophic releases of chemicals or energy from processes covered by the regulation.from processes covered by the regulation.

elements management systemelements management system to help prevent or mitigate to help prevent or mitigate the effects of catastrophic releases of chemicals or energy the effects of catastrophic releases of chemicals or energy from processes covered by the regulation.from processes covered by the regulation.

14 elements required by OSHA/PSM14 elements required by OSHA/PSM Process Safety InformationProcess Safety Information Employee ParticipationEmployee Participation Process Hazard AnalysisProcess Hazard Analysis Operating ProceduresOperating Procedures Hot Work PermitHot Work Permit Mechanical IntegrityMechanical Integrity Hot Work Permit Hot Work Permit Mechanical Integrity Mechanical Integrity Contractors Contractors Training Training Management of Change Management of Change PrePre--Startup Safety ReviewStartup Safety Review Emergency Planning and Response Emergency Planning and Response Incident Investigation Incident Investigation g y g pg y g p gg Compliance AuditsCompliance Audits Trade SecretsTrade Secrets

Seveso II DirectiveSeveso II DirectiveCouncil Directive 96/82/EC (1996)Council Directive 96/82/EC (1996)Framework of PSM which aims at the prevention Framework of PSM which aims at the prevention Council Directive 96/82/EC (1996)Council Directive 96/82/EC (1996)Framework of PSM which aims at the prevention Framework of PSM which aims at the prevention of major accidents which involve dangerous of major accidents which involve dangerous substances, and the limitation of their substances, and the limitation of their

f d th i t ithf d th i t ith

of major accidents which involve dangerous of major accidents which involve dangerous substances, and the limitation of their substances, and the limitation of their

f d th i t ithf d th i t ithconsequences for man and the environment, with consequences for man and the environment, with a view to ensuring high levels of protection a view to ensuring high levels of protection throughout the community in a consistent andthroughout the community in a consistent and

consequences for man and the environment, with consequences for man and the environment, with a view to ensuring high levels of protection a view to ensuring high levels of protection throughout the community in a consistent andthroughout the community in a consistent andthroughout the community in a consistent and throughout the community in a consistent and effective manner. effective manner. throughout the community in a consistent and throughout the community in a consistent and effective manner. effective manner.

(COMAH* in UK)(COMAH* in UK)* * The Control of Major Accident Hazards Regulations(COMAH* in UK)(COMAH* in UK)* * The Control of Major Accident Hazards Regulations

C. Manage riskC. Manage riskC. Manage riskC. Manage riskAIChE/CCPS Risk Based Process SafetyAIChE/CCPS Risk Based Process Safety

A. Commit to process safetyA. Commit to process safety-- Process safety cultureProcess safety culture-- Compliance with standardsCompliance with standards

A. Commit to process safetyA. Commit to process safety-- Process safety cultureProcess safety culture-- Compliance with standardsCompliance with standards

gg-- Operating proceduresOperating procedures-- Safe work practicesSafe work practices-- Asset integrity and reliabilityAsset integrity and reliability

gg-- Operating proceduresOperating procedures-- Safe work practicesSafe work practices-- Asset integrity and reliabilityAsset integrity and reliabilitypp

-- Process safety competenceProcess safety competence-- Workforce involvementWorkforce involvement-- Stakeholder outreachStakeholder outreach

pp-- Process safety competenceProcess safety competence-- Workforce involvementWorkforce involvement-- Stakeholder outreachStakeholder outreach

g y yg y y-- Contractor managementContractor management-- Training and performance Training and performance

assuranceassurance

g y yg y y-- Contractor managementContractor management-- Training and performance Training and performance

assuranceassurance-- Management of changeManagement of change-- Operational readinessOperational readiness-- Conduct of operationsConduct of operations

-- Management of changeManagement of change-- Operational readinessOperational readiness-- Conduct of operationsConduct of operations

B. Understand hazards and B. Understand hazards and riskrisk

B. Understand hazards and B. Understand hazards and riskrisk Conduct of operationsConduct of operations

-- Emergency managementEmergency managementConduct of operationsConduct of operations

-- Emergency managementEmergency managementriskrisk

-- Process knowledge Process knowledge managementmanagement

-- Hazard identification and riskHazard identification and risk

riskrisk-- Process knowledge Process knowledge

managementmanagement-- Hazard identification and riskHazard identification and risk D. Learn from experienceD. Learn from experienceD. Learn from experienceD. Learn from experienceHazard identification and risk Hazard identification and risk

analysisanalysisHazard identification and risk Hazard identification and risk analysisanalysis

D. Learn from experienceD. Learn from experience-- Incident investigationIncident investigation-- Measurement and metricsMeasurement and metrics-- AuditingAuditing

D. Learn from experienceD. Learn from experience-- Incident investigationIncident investigation-- Measurement and metricsMeasurement and metrics-- AuditingAuditingAuditingAuditing-- Management review and Management review and

continuous improvementcontinuous improvement

AuditingAuditing-- Management review and Management review and

continuous improvementcontinuous improvementRiskRisk--based strategies based strategies Implementation tacticsImplementation tacticsRiskRisk--based strategies based strategies Implementation tacticsImplementation tactics

Subjects on existing PSM systemSubjects on existing PSM system((11)) ExistingExisting PSMPSM systemssystems justjust givegive thethe minimumminimum elementselements

forfor thethe safetysafety managementmanagement,, butbut theythey dodo notnot mentionmentionaboutabout concreteconcrete managementmanagement activityactivity..

((11)) ExistingExisting PSMPSM systemssystems justjust givegive thethe minimumminimum elementselementsforfor thethe safetysafety managementmanagement,, butbut theythey dodo notnot mentionmentionaboutabout concreteconcrete managementmanagement activityactivity..aboutabout concreteconcrete managementmanagement activityactivity..

((22)) ConsistencyConsistency amongamong elementselements isis notnot ensuredensured..((33)) PracticalPractical scopesscopes ofof elementselements areare differentdifferent eacheach otherother..

aboutabout concreteconcrete managementmanagement activityactivity..((22)) ConsistencyConsistency amongamong elementselements isis notnot ensuredensured..((33)) PracticalPractical scopesscopes ofof elementselements areare differentdifferent eacheach otherother..

SubjectsSubjects ononSubjectsSubjects ononjj-- PositionPosition ofof PSMPSM inin thethe engineeringengineering andandproductionproduction activitiesactivities

jj-- PositionPosition ofof PSMPSM inin thethe engineeringengineering andandproductionproduction activitiesactivitiespp

“How“How thethe PSMPSM activityactivity shouldshould bebe executedexecuted withwithroutineroutine activities?”activities?”

pp“How“How thethe PSMPSM activityactivity shouldshould bebe executedexecuted withwithroutineroutine activities?”activities?”

Problem on a legal system in JapanProblem on a legal system in JapanPSM system as tertiary management systemPSM system as tertiary management system(Ref. to ISO9000; QMS and ISO14000; EMS)(Ref. to ISO9000; QMS and ISO14000; EMS)PSM system as tertiary management systemPSM system as tertiary management system(Ref. to ISO9000; QMS and ISO14000; EMS)(Ref. to ISO9000; QMS and ISO14000; EMS)

-- 4 major laws4 major laws concerning safety of chemical process concerning safety of chemical process industry; managed under different ministry or agency industry; managed under different ministry or agency

-- 4 major laws4 major laws concerning safety of chemical process concerning safety of chemical process industry; managed under different ministry or agency industry; managed under different ministry or agency

-- Companies are preoccupied with responses to make Companies are preoccupied with responses to make enormous documents for each audit.enormous documents for each audit.

N f kN f k di h l ldi h l l

-- Companies are preoccupied with responses to make Companies are preoccupied with responses to make enormous documents for each audit.enormous documents for each audit.

N f kN f k di h l ldi h l l-- No frameworkNo framework to audit whole process plant to audit whole process plant comprehensivelycomprehensively

-- No frameworkNo framework to audit whole process plant to audit whole process plant comprehensivelycomprehensively

Difficult to establish the standardization Difficult to establish the standardization for safety management activity!for safety management activity!

Points of agendaPoints of agendaActivityActivity modelmodel forfor PSMPSM ToTo makemake precondition,precondition, constraintconstraint condition,condition, resources,resources, etcetc

toto performperform PSMPSM activitiesactivities withinwithin PLCEPLCE clearclear

ActivityActivity modelmodel forfor PSMPSM ToTo makemake precondition,precondition, constraintconstraint condition,condition, resources,resources, etcetc

toto performperform PSMPSM activitiesactivities withinwithin PLCEPLCE clearcleartoto performperform PSMPSM activitiesactivities withinwithin PLCEPLCE clearclear.. ToTo specifyspecify what,what, how,how, andand whywhy toto dodo forfor activityactivity ofof eacheach

PSMPSM elementelement.. TT ii ll blbl dd lili ff i li l kk ff

toto performperform PSMPSM activitiesactivities withinwithin PLCEPLCE clearclear.. ToTo specifyspecify what,what, how,how, andand whywhy toto dodo forfor activityactivity ofof eacheach

PSMPSM elementelement.. TT ii ll blbl dd lili ff i li l kk ff ToTo summarizesummarize glossaryglossary tabletable andand listlist ofof typicaltypical taskstasks ofof

PSMPSM activitiesactivities ToTo summarizesummarize glossaryglossary tabletable andand listlist ofof typicaltypical taskstasks ofof

PSMPSM activitiesactivities

P i lP i l f kf k ff llll i ii i ff PSMPSMP i lP i l f kf k ff llll i ii i ff PSMPSMPracticalPractical frameworkframework ofof overalloverall activityactivity ofof PSMPSM PerformancePerformance inin thethe formform ofof PDCAPDCA (Plan(Plan--DoDo--CheckCheck--Act)Act)

cyclecycle

PracticalPractical frameworkframework ofof overalloverall activityactivity ofof PSMPSM PerformancePerformance inin thethe formform ofof PDCAPDCA (Plan(Plan--DoDo--CheckCheck--Act)Act)

cyclecyclecyclecycle ResourceResource provisionprovision

cyclecycle ResourceResource provisionprovision

PositionPosition ofof OSHA/PSMOSHA/PSM elementselementsPositionPosition ofof OSHA/PSMOSHA/PSM elementselementsPositionPosition ofof OSHA/PSMOSHA/PSM elementselements ActivitiesActivities ofof thethe PLCEPLCE RelationRelation amongamong eacheach PSMPSM elementelement

PositionPosition ofof OSHA/PSMOSHA/PSM elementselements ActivitiesActivities ofof thethe PLCEPLCE RelationRelation amongamong eacheach PSMPSM elementelement

Purpose of PSM from PLCE perspectivePurpose of PSM from PLCE perspective

3. Activity model for PSM3. Activity model for PSMIDEF0 IDEF0 (Integrated DEfinition for Functional model)(Integrated DEfinition for Functional model)-- Box: Box: Activity means what to do Activity means what to do (Verb)(Verb)..-- Arrow:Arrow: Object (information) used by activityObject (information) used by activity (Noun).(Noun).Arrow Arrow Object (information) used by activityObject (information) used by activity (Noun).(Noun).

Controls(constraints on an activity, e.g., procedures, budgets, etc.)

Controls(constraints on an activity, e.g., procedures, budgets, etc.)

Inputs Function orActivity

Outputs(what is required

Inputs Function orActivity

Outputs(what is required (what is produced by an

activity, e.g., reports, products, etc.)

ct v ty(Verb Phase)

(what is required before an activity can occur, e.g., purchase order, supervisor’s signature, etc.)

(what is produced by an activity, e.g., reports, products, etc.)

ct v ty(Verb Phase)

(what is required before an activity can occur, e.g., purchase order, supervisor’s signature, etc.)

Mechanisms(what enables an activity, e.g., equipment, personnel assignments, etc.)

Mechanisms(what enables an activity, e.g., equipment, personnel assignments, etc.)

ActivityActivity transfers transfers InputInput to to OutputOutputby using by using MechanismMechanism under under ControlControl..

IDEF0 activity model IDEF0 activity model -- Hieratical structureHieratical structure

Activity

Control

OutputInput

Mechanism

Control

Sub-Activity

Input

Sub-Activity Output

Sub-Activity

Mechanism

Why using IDEF0 formatWhy using IDEF0 formatTo develop To develop reference model for PSMreference model for PSM which can be which can be used used for various companies commonlyfor various companies commonly

FunctionFunction--basedbased discussiondiscussion forfor activityactivity modelingmodelingvsvs Di iDi i b db d hh i tii ti f kf k

FunctionFunction--basedbased discussiondiscussion forfor activityactivity modelingmodelingvsvs Di iDi i b db d hh i tii ti f kf kvsvs.. DiscussionDiscussion basedbased onon eacheach organizationorganization frameworkframework

WhatWhat isis neededneeded asas functionfunction oror activity?activity?vsvs.. DiscussionDiscussion basedbased onon eacheach organizationorganization frameworkframework

WhatWhat isis neededneeded asas functionfunction oror activity?activity?

-- What kind of PSM activities should be implemented?What kind of PSM activities should be implemented?-- What kind of PSM activities should be implemented?What kind of PSM activities should be implemented?pp-- What kind of information, tools or methods is needed for What kind of information, tools or methods is needed for supporting the PSM activities effectively?supporting the PSM activities effectively?

pp-- What kind of information, tools or methods is needed for What kind of information, tools or methods is needed for supporting the PSM activities effectively?supporting the PSM activities effectively?

What to do for PSM?What to do for PSM?What to do for PSM?What to do for PSM?

Template for activity modelingTemplate for activity modelingEngineering

t d dDirective Requirement

(f th ti ) Requirement to Request to

Manage (Action)

Directive to perform execution plan(incl. requirement from other section)

standard(from upper

plane)

(from upper plane)

(from other section) Requirement to provide resources

Requirement of change

qmake or change standard

Managea) a) Performance and resultsPerformance and results for the for the directive and the plandirective and the plan

T1(Action)

T2

Plan

Result of performance for execution plan

(incl. requirement of change)

Output(Approved)

Engineering standard

for performingPlan

(Act) b) b) Compliance with ESCompliance with ESc) c) Sufficient provision Sufficient provision of resourcesof resourcesd) d) Validity of ESValidity of ES itselfitself

T3

Do

Check

Directive to make Execution plan

(incl. requirement from other section)

Result of evaluation

for performingeach activity

Do

CheckT4

T5

Provide Resources Output

(part of)

Check

ProvideResourcesa) a) Educated and trained peopleEducated and trained people and and organizationsorganizations

Resource (Info.)(f l )Resource (human facility etc )Info. to perform PDC activity, Info. for progress management

(incl result of evaluation)

ggb) b) FacilitiesFacilities and equipmentand equipment, , toolstools and and methodsmethods forfor

supporting activitiessupporting activitiesc) c) InformationInformation to perform PDC activitiesto perform PDC activitiesd)d) Information for progress managementInformation for progress management (from upper plane)Resource (human, facility, etc.)p y,

(operation log, etc.)(incl. result of evaluation)d) d) Information for progress managementInformation for progress managemente) e) Engineering standardsEngineering standards for controlling each for controlling each activity which are distributed from upper levelactivity which are distributed from upper level

Hierarchical structure of PSM activityHierarchical structure of PSM activity

Enterprise-level

Perform PLCE-PSM

Announce corporate philosophy and

management policy

Make basic plan for PLCE-PSM

Evaluate result of PLCE-PSM

Provide resources for PLCE-PSM

E1 E2 E3 E4 E5

Plant-site level

Evaluate performance pf

PLCE-PSM

Provide H&O for performing PLCE-

PSM

Provide resources for performing

PLCE-PSM

Manage PLCE-PSM execution

Make execution plan for PLCE-PSM activities

Perform PLCE-PSM activities at

plant development

Perform PLCE-PSM activities at plant operation

A1 A2 A3 A4 A5 A6 A7

PLCE-PSM

Manage Plan Perform PSM Perform Perform PSM Check P R Manage Plan

Perform PSM Perform PSM Check P R

PSM PLCE-PSMPSM activities stage stage

A31 A32 A33 A34 A35 A36 A37 A41 A42 A43 A44 A45 A46

Manage Plan Perform PSM activities at R/D stage

PSM activities at design stage

PSM activities at construction

stage

Check P.R. Manage Plan PSM activities at production

stage

activities at maintenance

stage

Check P.R.

Typical tasks

Typicaltasks

Typicaltasks

Typicaltasks

Typicaltasks

� PDCA-PR� � PDCA-PR� � PDCA-PR� � PDCA-PR� � PDCA-PR�

Top activity model for PSM related with PlantTop activity model for PSM related with Plant--LCELCEC4C1 C2C3

Engineering standard (ES) for PLCE-PSMEnforcement of policy for improving safety culture on PLCE-PSM

Practical action plan for PLCE-PSM

PSM system

O1

O2O4

O5

O3

I1 Manage PLCE-PSM execution

A1

Pumped resources

Requirement of resources for performing PLCE-PSM

Requirement of H&O for performing PLCE-PSM

PLCE-PSM execution policy

Requirement of change for performing PLCE-PSM

CSR report

Result of PLCE-PSM

Opinion from participation of employee

Safety management policy

ES for making execution plan of PLCE-PSM

Practical action plan for PLCE-PSM

ES for PSM execution management

Perform PLCE-PSM at plant development phase

A3

Make execution plan of PLCE-PSM

A2

Requirement of change for performing PSM at plant development

Result of PSM at plant development

Plant

Requirement of change for making plan of PLCE-PSM

PSM execution plan

ES for PSM at plant developmentResources for making execution plan of PLCE-PSM

H&O for making execution plan of PLCE-PSM

Manage(Act)

Plan

Do: Plant-LCE-PSM

Evaluate performance

Perform PLCE-PSM at plant operation phase

A4

A3

Requirement of change for PLCE-PSM perofrmance

Result of process safety audit

Requirement of change for performing PSM at plant operation

Result of PSM at plant operation

ES for performance evaluation of PLCE-PSM

ES for PSM at plant operation

Resource for PSM execution at plant operationH&O for performing PSM at plant operation

Resource for PSM at plant developmentH&O for PSM at plant development

Plan

Check Provide Resource-Human resource& Organization

Provide human resources and organization (H&O) for performing PLCE-PSMA6

erformance of PLCE-PSM

A5

Measure and policy of enhancement of PS culture

Info. on H&O for performing PLCE-PSM

H&O for performing PLCE-PSM

Result of process safety audit

Result of performance evaluation for PLCE-PSM

ES for providing H&O for PLCE-PSMResource for performance evaluation of PLCE-PSM

H&O for performance evaluation of PLCE-PSM

gfor Plant-LCE-PSM-- Human resources and organizationHuman resources and organization

(Employee participant, Contractor M Ed i d i i )

Provide resources for performing PLCE-PSM

A7

Info. for management of PLCE-PSM

ES for performing PSM (site level)

Resources for performing PLCE-PSM

Resources for providing H&O for performing PLC-PSMManagement, Education and training)

-- Information on result of activity execution and Information on result of activity execution and requirement of changerequirement of change

M1Stored safety info. and knowledge and inccident info.

-- Information on result of performance evaluationInformation on result of performance evaluation-- Tools and methodsTools and methods-- Engineering standardEngineering standard

Activity model for performing PSM activity Activity model for performing PSM activity at plant development stageat plant development stagep p gp p g

O1O2

C2C1

Manage PSMRequirement of change for performing PSM at plant development

Result of PSM at plant development

ES for PSM at plant developmentPSM execution plan

ES for management of PSM at plant development

O2

Make execution plan for PSM at plant development phase

A32

Manage PSM at planning phase

A31

Requirement of change for making plan of PSM at plant development

Plan for PSM at plant development

Requirement of resources needed for PSM at plant developmentDirection of PSM at plant development

Plan for PSM at process development

ES for PSM at process development

ES for making execution plan for PSM at plant development

Resource for making execution plan of PSM at plant development

Perform PSM at process design phase

Perform PSM at process development phase

A33

Requirement of change for performing PSM at process design

Result of PSM at process design

Requirement of change for performing PSM at process development

Result of PSM at process development

Plan for PSM at process designES for PSM at process design

Plan for PSM at process development

H&O for PSM at process development

Resource for PSM at process development

H&O for making execution plan of PSM at plant development

Resource for making execution plan of PSM at plant development

O3

Evaluate performance

f PSM t

Perform PSM at plant construction phase

A35

phase A34

Requirement of change for PSM performance at plant development

Requirement of change for performing PSM at plant construction

Result of PSM at plant construction

Plant

ES for performance evaluation of PSM at plant development

Plan for PSM at plant constructionES for PSM at plant construction

H&O for PSM at plant constructionResource for PSM at plant construction

H&O for PSM activity at process designResource for PSM at process design

Provide resources for PSM at plant development phase

of PSM at plant development phase

A36

Info. for management of PSM at plant development

Engineering standard for performing PSM at plant development

H&O for executing PSM at plant development

Result of performance evaluation of PSM at plant development

H&O for PSM performance evaluation at plant development

Resource for PSM performance evaluation at plant development

M1M2

A37Resources for executing PSM at plant development

Resource for PSM at plant developmentH&O for PSM at plant development

Activity model for performing PSM activity Activity model for performing PSM activity at plant operation stageat plant operation stagep p gp p g

O1

C2C1

Manage PSMactivity a

Requirement of change for performing PSM at plant operationResult of PSM at plant operation

ES for PSM at plant operationPSM execution plan

ES for management of PSM activity at plant operation

O2

Make execution plan for PSM at plant operation phaseA42

activity at production phase

A41

Requirement of change for making plan of PSM at plant operation

Execution plan for PSM at plant operation

Requirement of resources needed for PSM at plant operationDirection of PSM at plant operation

Result of PSM at plant operation

ES for making plan for PSM at plant operation

Perform PSM at plant

Perform PSM at production phase

A43

A42

Requirement of change for performing PSM at plant maintenance

Requirement of change for performing PSM at productionResult of PSM at productionOperating data (information)Deteriorated plant

Plan for PSM at plant maintenance

ES for PSM at plant maintenance

Plan for PSM at productionStandard for PSM at production

Resource for PSM at productionH&O for PSM at production

Resource for making plan of PSM at plant operation

H&O for making plan of PSM at plant operation

Evaluate performance of PSM at plant oper

ti h

M at plant maintenance phase

A44

Requirement of change for PSM perofrmance at plant operation

Result of performance evaluation of PSM at plant operation

Integrity info. on equipment and facility

Result of PSM at plant maintenance

ES for performance evaluation of PSM at plant operationResource for PSM at plant maintenance

H&O for PSM at plant maintenance

Provide resources for PSM at plant operation phase

A46

ation phaseA45

Info. for management of PSM at plant operation

ES for performing PSM at plant operation

Resources for executing PSM at plant operation

H&O for executing PSM at plant operation

Resource for performance evaluation of PSM at plant operationH&O for performance evaluation of PSM at plant operation

M2M3M1

A46

Resource for PSM execution at plant operationH&O for performing PSM at plant operationPlant

4. Glossaries and typical tasks of PSM Activities4. Glossaries and typical tasks of PSM Activities

Activity model for PSMActivity model for PSM::-- position of activities in the form of PDCA cycleposition of activities in the form of PDCA cycleActivity model for PSMActivity model for PSM::-- position of activities in the form of PDCA cycleposition of activities in the form of PDCA cycle-- flow of related information and resourcesflow of related information and resources

Explanations of each activity box and arrow are written inExplanations of each activity box and arrow are written in

-- flow of related information and resourcesflow of related information and resources

Explanations of each activity box and arrow are written inExplanations of each activity box and arrow are written inExplanations of each activity box and arrow are written in Explanations of each activity box and arrow are written in fixed phrase, fixed phrase, User may not understand User may not understand the meanings of developed the meanings of developed

Explanations of each activity box and arrow are written in Explanations of each activity box and arrow are written in fixed phrase, fixed phrase, User may not understand User may not understand the meanings of developed the meanings of developed yy g pg pactivity modelactivity model and and the concrete tasks of activitiesthe concrete tasks of activities. .

yy g pg pactivity modelactivity model and and the concrete tasks of activitiesthe concrete tasks of activities. .

For the easyFor the easy toto understand explanation of the activityunderstand explanation of the activityFor the easyFor the easy toto understand explanation of the activityunderstand explanation of the activityFor the easyFor the easy--toto--understand explanation of the activity understand explanation of the activity model for PSMmodel for PSM, , -- Glossaries of each activityGlossaries of each activity are summarized.are summarized.

For the easyFor the easy--toto--understand explanation of the activity understand explanation of the activity model for PSMmodel for PSM, , -- Glossaries of each activityGlossaries of each activity are summarized.are summarized.Glossaries of each activityGlossaries of each activity are summarized.are summarized.-- Typical tasks of each PSM activityTypical tasks of each PSM activity are listed.are listed.Glossaries of each activityGlossaries of each activity are summarized.are summarized.

-- Typical tasks of each PSM activityTypical tasks of each PSM activity are listed.are listed.

List of typical tasks of PSM activityList of typical tasks of PSM activity

Enterprise-level

Perform PLCE-PSM

Announce corporate philosophy and

management policy

Make basic plan for PLCE-PSM

Evaluate result of PLCE-PSM

Provide resources for PLCE-PSM

E1 E2 E3 E4 E5

Plant-site level

Evaluate performance pf

PLCE PSM

g p y

Provide H&O for performing PLCE-

PSM

Provide resources for performing

PLCE PSM

Manage PLCE-PSM execution

Make execution plan for PLCE-PSM ti iti

Perform PLCE-PSM activities at

plant development

Perform PLCE-PSM activities at plant operation

A1 A2 A3 A4 A5 A6 A7

PLCE-PSM

M Pl Perform PSM Perform Perform PSM Ch k P R M Pl

Perform PSM Perform PSM Ch k P R

PSM PLCE-PSMPSM execution PSM activities plant development stage

plant operation stage

A31 A32 A33 A34 A35 A36 A37 A41 A42 A43 A44 A45 A46

Manage Plan Perform PSM activities at R/D stage

PSM activities at design stage

PSM activities at construction

stage

Check P.R. Manage Plan PSM activities at production

stage

activities at maintenance

stage

Check P.R.

Typical tasks

Typicaltasks

Typicaltasks

Typicaltasks

Typicaltasks

� PDCA-PR� � PDCA-PR� � PDCA-PR� � PDCA-PR� � PDCA-PR�

Typical tasks of PSM activities (format)Typical tasks of PSM activities (format)Typical tasksGlossaryActivityNo Typical tasksGlossaryActivityNo

Revision and/or improvement---

Create basis principle and purpose for PSM activity at production stage---Request to provide resources needed for performing PSM at production stage---

Explanation of activity for ‘manage’ and ‘act’

Manage for PSM activity at ---

A---1

Revision and/or improvement---

Create basis principle and purpose for PSM activity at production stage---Request to provide resources needed for performing PSM at production stage---

Explanation of activity for ‘manage’ and ‘act’

Manage for PSM activity at ---

A---1

Surveillance and compliance with relevant law and regulationExplanation

Make execution plan for PSM at production---

Explanation of activity for ‘plan’

Make execution plan for PSM activity at ---

A---2

Surveillance and compliance with relevant law and regulationExplanation

Make execution plan for PSM at production---

Explanation of activity for ‘plan’

Make execution plan for PSM activity at ---

A---2

Ch k i i f ESA l i f i ( b l it ti ) (tE l ti

p g---Risk analysis at production stage---Risk reduction strategy for production safety---

pof activity for ‘do’Perform PSM

activity at ---A---3

Ch k i i f ESA l i f i ( b l it ti ) (tE l ti

p g---Risk analysis at production stage---Risk reduction strategy for production safety---

pof activity for ‘do’Perform PSM

activity at ---A---3

Check provision of ESs---Check provision of resources (info.)---Check provision of HRS and organization---

Analysis of issue (abnormal situation) (to clear up the problem)---Check result for execution plan (directive)---Check compliance with ESs

Explanation of activity for ‘check’Evaluate

performance of PSM activity at ---

A---4

Check provision of ESs---Check provision of resources (info.)---Check provision of HRS and organization---

Analysis of issue (abnormal situation) (to clear up the problem)---Check result for execution plan (directive)---Check compliance with ESs

Explanation of activity for ‘check’Evaluate

performance of PSM activity at ---

A---4

[HRs (education and ) ]

[Info.][ESs (created within the ]

[Facility and ]

[HRs (education and training) and organization]---

[Info.]---

[ESs (given from activity of upper plane]---

[Facility and equipment]---

Explanation of activity for ‘provide resources’Provide

resources for

---

[HRs (education and ) ]

[Info.][ESs (created within the ]

[Facility and ]

[HRs (education and training) and organization]---

[Info.]---

[ESs (given from activity of upper plane]---

[Facility and equipment]---

Explanation of activity for ‘provide resources’Provide

resources for

---

[Info. for progress management for PSM activity at production stage (to transfer to ‘act’ activity)]---

training) and organization]---

---plane]---

equipment]---

performing PSM activity at ---

A---5

[Info. for progress management for PSM activity at production stage (to transfer to ‘act’ activity)]---

training) and organization]---

---plane]---

equipment]---

performing PSM activity at ---

A---5

5. Framework for Overall PSM5. Framework for Overall PSMPSM activity should be PSM activity should be -- performed under company’s management policy and performed under company’s management policy and execution strategyexecution strategy

PSM activity should be PSM activity should be -- performed under company’s management policy and performed under company’s management policy and execution strategyexecution strategyexecution strategyexecution strategy-- integrated with engineering activityintegrated with engineering activity to ensure safety and to ensure safety and stable production through the plant lifecycle. stable production through the plant lifecycle.

execution strategyexecution strategy-- integrated with engineering activityintegrated with engineering activity to ensure safety and to ensure safety and stable production through the plant lifecycle. stable production through the plant lifecycle. p g p yp g p yp g p yp g p y

A framework for overall PSMA framework for overall PSM is developed as is developed as a a summary of activity model for PSMsummary of activity model for PSM. . A framework for overall PSMA framework for overall PSM is developed as is developed as a a summary of activity model for PSMsummary of activity model for PSM. . y yy y

Integration of Integration of flow of things and information on flow of things and information on production and human and material resourcesproduction and human and material resources

y yy y

Integration of Integration of flow of things and information on flow of things and information on production and human and material resourcesproduction and human and material resourcesproduction and human and material resourcesproduction and human and material resourceslinked with linked with business management activitybusiness management activity. . production and human and material resourcesproduction and human and material resourceslinked with linked with business management activitybusiness management activity. .

Framework for PSM at enterprise levelFramework for PSM at enterprise levelSocial DemandSocial Demand Law/RegulationLaw/Regulation

CSR CSR Re o tRe o t

ManageManage(Act)(Act)

PSM at Enterprise LevelPSM at Enterprise Level

PhilosophyPhilosophy

Enterprise LevelEnterprise Level

PlanPlan

ReportReport

Request for Request for Modification/Modification/ImprovementImprovement

PSM PrinciplePSM Principle

DoDopp

PSM ResultsPSM Results(PSM at Plant Site Level (PSM at Plant Site Level

th h Pl t Lif l )th h Pl t Lif l ) PSM ResultsPSM Results

EvaluationEvaluation

through Plant Lifecycle)through Plant Lifecycle)

CheckCheck

EmployeeEmployee

Evaluation Evaluation of PSMof PSM

Resources Resources for PSMfor PSM

StandardsStandards

Management/ Management/ Improvement Improvement

P.R. ESFacility

Resources for PSMResources for PSM

Employee Employee ParticipationParticipation

p ove ep ove eStrategyStrategy H/OInfo.

Framework for PSM at plant site levelFramework for PSM at plant site levelPSM PrincipalPSM Principal StandardsStandards

DoDo PSM at Plant Site LevelPSM at Plant Site Level

M

Request for Request for Modification/Modification/ImprovementImprovementPSMPSMResultsResults


PlanPlan

ImprovementImprovement

PlanPlanDirection of Direction of Pl iPl i

DoDoResultResult

Request for Request for ModModificationification//ImprovementImprovement

PlanningPlanning

P.R.P.R.

CheckCheck

ESESF ilitF ilit

EvaluationEvaluation ES for ES for PSMPSM

P.R.P.R.

H/OH/OInfo.Info.

ESESFacilityFacilityRequirement for Requirement for Modification/Modification/ImprovementImprovement

PSM activitiesPSM activitiesEEmmployee ployee ParticipationParticipation


PSM activities PSM activities through the through the

plant lifecycleplant lifecycle

Framework for overall PSMFramework for overall PSMSocial DemandSocial Demand Law/RegulationLaw/Regulation

経営レベル経営レベル

CSR CSR RR





PlanPlan

ReportReport


PSM PrincipPSM Principlele

DoDoDoDoDoDo PSM at Plant Site LevelPSM at Plant Site Level

MM ImprovementImprovement

PSM R ltPSM R lt

（（PSMPSM at Plant Site Level at Plant Site Level through Plant Lifecyclethrough Plant Lifecycle））


PlanPlan

DoDoResultResult


PlanPlanDirection of Direction of PlanningPlanning

PSM ResultsPSM Results

E l tiEvaluation

through Plant Lifecyclethrough Plant Lifecycle））

P.R.P.R.

CheckCheck

H/OH/OInfoInfo

ESESFacilityFacility


Requirement for Requirement for Modification/Modification/

CheckCheck

EmployeeEmployee



StandardsStandards

Management/ Management/ ImprovementImprovement

P.R. ESFacility

H/OH/OInfo.Info.ImprovementImprovement


Employee Employee ParticipationParticipation

Improvement Improvement StrategyStrategy H/OInfo.

6. Mapping of OSHA/PSM Elements on6. Mapping of OSHA/PSM Elements onProposed PSM FrameworkProposed PSM FrameworkIn order to make In order to make the role of proposed PSM the role of proposed PSM In order to make In order to make the role of proposed PSM the role of proposed PSM

Proposed PSM FrameworkProposed PSM Framework

framework for existing PSM systemframework for existing PSM system clear, clear, OSHA/PSM 14OSHA/PSM 14--elements have been mapped on it.elements have been mapped on it.framework for existing PSM systemframework for existing PSM system clear, clear, OSHA/PSM 14OSHA/PSM 14--elements have been mapped on it.elements have been mapped on it.

(a) Applications (a) Applications (b) Definitions(b) Definitions(c) Employee Participation(c) Employee Participation(d) Process Safety Information(d) Process Safety Information(e) Process Hazard Analysis(e) Process Hazard Analysis

(j) Mechanical Integrity(j) Mechanical Integrity(k) Hot Work Permit (k) Hot Work Permit (l) Management of Change (l) Management of Change

(f) Operating Procedures(f) Operating Procedures(g) Training(g) Training(h) Contractors(h) Contractors(i) P(i) P St t S f t R iSt t S f t R i

(m) Incident Investigation(m) Incident Investigation(n) Emergency Planning and Response(n) Emergency Planning and Response(o) Compliance Audits(o) Compliance Audits( ) T d S t( ) T d S t(i) Pre(i) Pre--Startup Safety ReviewStartup Safety Review (p) Trade Secrets(p) Trade Secrets

Mapping OSHA/PSM elements on the proposed frameworkMapping OSHA/PSM elements on the proposed framework

経営ベ経営レベル

Social DemandSocial Demand

PSM t E t i L lPSM t E t i L lE t i L lE t i L l

Law/RegulationLaw/Regulation


CSR CSR ReportReport





PlanPlan

ReportReport




ManageManage( )

(e) Process hazard (e) Process hazard l il i



(Act)(Act)

PlanPlan

DoDoResultResult


PlanPlanDirection of Direction of PlanningPlanning

analysisanalysis(o) Compliance (o) Compliance

auditsaudits(Site)(Site)

(o) Compliance audits(o) Compliance audits(S t )(S t )

Evaluation Evaluation

P.R.P.R.

CheckCheck

H/OH/OInfo.Info.



Requirement for Requirement for Modification/Modification/ImprovementImprovement

(l) Management (l) Management of Changeof Change

(Site)(Site)

(Site)(Site) (System)(System)

CheckCheck

Employee Employee P ti i tiP ti i ti

of PSMof PSM


StandardsStandards

Management/ Management/ Improvement Improvement St tSt t

P.R.H/OI f

ESFacility

(Site)(Site)

(l) Management (l) Management of Changeof Change(S te )(S te )

(g)(g)(d) Process Safety (d) Process Safety Info ationInfo ation

(g) Training(g) Training


ParticipationParticipationStrategyStrategy H/OInfo.(System)(System) InformationInformation

Mapping of OSHA/PSM elements on proposed PSM frameworkMapping of OSHA/PSM elements on proposed PSM frameworkSocial DemandSocial Demand Law/RegulationLaw/Regulation


CSR CSR R tReport





PlanPlan

ReportReport




ManageManage p




PlanPlan

DoDoResultResult


PlanPlanDirection of Direction of PlanningPlanning (e)(e)

(i)(i)

(f)(f)

(o)(o) PSM ResultsPSM Results

EvaluationEvaluation

g yg y ）

P.R.P.R.

CheckCheck

H/OH/OInfo.Info.



Requirement for Requirement for Modification/Modification/ImprovementImprovement

（（hh））

( )( )

(k)(k)

(m)(m)(Site)(Site)

(j)(j)(l)(l)

（（SiteSite））

(l)(l)（（SystemSystem））

(d)(d)(n)(n)

(o)( )(Site)(Site)

(o)(o)(System)(System)

CheckCheck

EmployeeEmployee



StandardsStandards

Management/ Management/ Improvement Improvement

P.R. ESFacility

ImprovementImprovement（（SystemSystem））

(c)(c)

( )(g)

(m)(m)(System)(System)

( )(g)

((pp))


Employee p oyeeParticipationParticipation

p ove e tpStrategyStrategy H/OInfo.

(g)(g)(g)(g)

7. Discussion and Conclusion7. Discussion and Conclusion(1)(1) Useful for various chemical process companiesUseful for various chemical process companies

(2)(2) E if bl h i th ltE if bl h i th lt

(1)(1) Useful for various chemical process companiesUseful for various chemical process companies

(2)(2) E if bl h i th ltE if bl h i th lt(2) (2) Even if some problems happen in the result Even if some problems happen in the result and performance of PSM activity, they will be and performance of PSM activity, they will be corrected by ‘Check’ and ‘Act’ activitiescorrected by ‘Check’ and ‘Act’ activities

(2) (2) Even if some problems happen in the result Even if some problems happen in the result and performance of PSM activity, they will be and performance of PSM activity, they will be corrected by ‘Check’ and ‘Act’ activitiescorrected by ‘Check’ and ‘Act’ activitiescorrected by Check and Act activities.corrected by Check and Act activities.

(3)(3) Resources required for performing the PSM Resources required for performing the PSM

corrected by Check and Act activities.corrected by Check and Act activities.

(3)(3) Resources required for performing the PSM Resources required for performing the PSM q p gq p gactivities activities can be clearly specified as an activity.can be clearly specified as an activity.1) 1) Human resources and organizationHuman resources and organization Ed ti d t i i t t t tEd ti d t i i t t t t

q p gq p gactivities activities can be clearly specified as an activity.can be clearly specified as an activity.1) 1) Human resources and organizationHuman resources and organization Ed ti d t i i t t t tEd ti d t i i t t t t Education and training, contractor management, etc. Education and training, contractor management, etc.

2) 2) Information, facilities, tools, methodsInformation, facilities, tools, methods Structure of PSM info. sharing through the PLCStructure of PSM info. sharing through the PLC

Education and training, contractor management, etc. Education and training, contractor management, etc. 2) 2) Information, facilities, tools, methodsInformation, facilities, tools, methods Structure of PSM info. sharing through the PLCStructure of PSM info. sharing through the PLCSt uctu e o S o. s a g t oug t e CSt uctu e o S o. s a g t oug t e CSt uctu e o S o. s a g t oug t e CSt uctu e o S o. s a g t oug t e C

Discussion and conclusion Discussion and conclusion (cont.)(cont.)

(4)(4) GlossaryGlossary and and list of typical taskslist of typical tasks of PSM of PSM activitiesactivities

(4)(4) GlossaryGlossary and and list of typical taskslist of typical tasks of PSM of PSM activitiesactivities

(5)(5) Purposes of each activity at each stage of plant Purposes of each activity at each stage of plant lifecyclelifecycle

(5)(5) Purposes of each activity at each stage of plant Purposes of each activity at each stage of plant lifecyclelifecyclelifecyclelifecycle

(6)(6) Proposed PSM framework Proposed PSM framework is not entirelyis not entirely--new new

lifecyclelifecycle

(6)(6) Proposed PSM framework Proposed PSM framework is not entirelyis not entirely--new new pp yysystemsystem but comprises of existing PSM systemsbut comprises of existing PSM systems

(7)(7) P d PSM f k i b ild bP d PSM f k i b ild b

pp yysystemsystem but comprises of existing PSM systemsbut comprises of existing PSM systems

(7)(7) P d PSM f k i b ild bP d PSM f k i b ild b(7)(7) Proposed PSM framework is build up by Proposed PSM framework is build up by process safety cultureprocess safety culture as underlying as underlying fundamentalfundamental

(7)(7) Proposed PSM framework is build up by Proposed PSM framework is build up by process safety cultureprocess safety culture as underlying as underlying fundamentalfundamentalfundamental.fundamental.fundamental.fundamental.

Discussion and conclusion Discussion and conclusion (cont.)(cont.)

(8)(8) Organization of engineering standardsrganization of engineering standards as an as an important activity of PSMimportant activity of PSM

(8)(8) Organization of engineering standardsrganization of engineering standards as an as an important activity of PSMimportant activity of PSM

(9)(9) Integration of PSM activity and routine Integration of PSM activity and routine production activitiesproduction activities

(9)(9) Integration of PSM activity and routine Integration of PSM activity and routine production activitiesproduction activitiesproduction activitiesproduction activities

(10)(10) Improvement of company’s PSM systemImprovement of company’s PSM system by by

production activitiesproduction activities

(10)(10) Improvement of company’s PSM systemImprovement of company’s PSM system by by p p y yp p y y yycomparison to the proposed PSM frameworkcomparison to the proposed PSM framework

p p y yp p y y yycomparison to the proposed PSM frameworkcomparison to the proposed PSM framework

AcknowledgementAcknowledgement –– WG Members of safety division of SCEJWG Members of safety division of SCEJ

These works have been discussed at the safety division in These works have been discussed at the safety division in Society of Chemical Engineer Japan and supported by Society of Chemical Engineer Japan and supported by JSPS, KAKENHI (21310112).JSPS, KAKENHI (21310112).

These works have been discussed at the safety division in These works have been discussed at the safety division in Society of Chemical Engineer Japan and supported by Society of Chemical Engineer Japan and supported by JSPS, KAKENHI (21310112).JSPS, KAKENHI (21310112).JSPS, KAKENHI (21310112). JSPS, KAKENHI (21310112).

The authors are grateful to the following process safety The authors are grateful to the following process safety experts for their cooperation in discussion;experts for their cooperation in discussion;

JSPS, KAKENHI (21310112). JSPS, KAKENHI (21310112).

The authors are grateful to the following process safety The authors are grateful to the following process safety experts for their cooperation in discussion;experts for their cooperation in discussion;experts for their cooperation in discussion; experts for their cooperation in discussion;

Dr. Hideo Saito (Saito MOT Labo.)Dr. Hideo Saito (Saito MOT Labo.)Mr. Hiroshi Sumida (Toyo Engineering Corporation)Mr. Hiroshi Sumida (Toyo Engineering Corporation)Mr Toshinori Kawabata (Life Science Technology Spread Center)Mr Toshinori Kawabata (Life Science Technology Spread Center)

experts for their cooperation in discussion; experts for their cooperation in discussion; Dr. Hideo Saito (Saito MOT Labo.)Dr. Hideo Saito (Saito MOT Labo.)Mr. Hiroshi Sumida (Toyo Engineering Corporation)Mr. Hiroshi Sumida (Toyo Engineering Corporation)Mr Toshinori Kawabata (Life Science Technology Spread Center)Mr Toshinori Kawabata (Life Science Technology Spread Center)Mr. Toshinori Kawabata (Life Science Technology Spread Center)Mr. Toshinori Kawabata (Life Science Technology Spread Center)Mr. Hitoshi Motoyama (Daikin Industries)Mr. Hitoshi Motoyama (Daikin Industries)Mr. Kiyotaka Bito (Kaneka Corporation)Mr. Kiyotaka Bito (Kaneka Corporation)Mr. Noboru Yamamuro (Zeon Corporation)Mr. Noboru Yamamuro (Zeon Corporation)

Mr. Toshinori Kawabata (Life Science Technology Spread Center)Mr. Toshinori Kawabata (Life Science Technology Spread Center)Mr. Hitoshi Motoyama (Daikin Industries)Mr. Hitoshi Motoyama (Daikin Industries)Mr. Kiyotaka Bito (Kaneka Corporation)Mr. Kiyotaka Bito (Kaneka Corporation)Mr. Noboru Yamamuro (Zeon Corporation)Mr. Noboru Yamamuro (Zeon Corporation)Mr. Noboru Yamamuro (Zeon Corporation)Mr. Noboru Yamamuro (Zeon Corporation)Dr. Yasunori Kikuchi (University of Tokyo)Dr. Yasunori Kikuchi (University of Tokyo)Dr. Kazuhiro Takeda (Shizuoka Univ.)Dr. Kazuhiro Takeda (Shizuoka Univ.)

Mr. Noboru Yamamuro (Zeon Corporation)Mr. Noboru Yamamuro (Zeon Corporation)Dr. Yasunori Kikuchi (University of Tokyo)Dr. Yasunori Kikuchi (University of Tokyo)Dr. Kazuhiro Takeda (Shizuoka Univ.)Dr. Kazuhiro Takeda (Shizuoka Univ.)

Thank you for you attention!Thank you for you attention!

Documents

Framework for Process Safety Management based on Enggg ...psc.tamu.edu/files/symposia/2010/presentations/track4/Shimada_1284083896.pdf--Beyond Regulatory Compliance, Making Safety