Process Safety Management

Soft Skills Programme

Nexus Alliance Ltd

Session Elements

1. Introduction1. Introduction

2. What is Process Safety Management2. What is Process Safety Management

3. Process Safety Elements3. Process Safety Elements

4. What can you do?4. What can you do?

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INTRODUCTIONINTRODUCTIONProcess Safety vs. Personal safetyProcess Safety vs. Personal safety

Process Safety is the safe design, engineering and Process Safety is the safe design, engineering and operation of process units and equipments so that they operation of process units and equipments so that they do not fail and cause catastrophic events such as LOC do not fail and cause catastrophic events such as LOC or fires.or fires.

Personal or occupational safety is the focus on Personal or occupational safety is the focus on preventing injury to personnel as a result of occupational preventing injury to personnel as a result of occupational hazards. hazards.

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INTRODUCTIONINTRODUCTION

Not all hazards are the same or can cause equal Not all hazards are the same or can cause equal consequencesconsequences

Personal or occupational safety hazards such as slips, Personal or occupational safety hazards such as slips, falls, cuts, and vehicle accidents usually affect one falls, cuts, and vehicle accidents usually affect one individual workerindividual worker

Process safety hazards may cause major accidents Process safety hazards may cause major accidents involving release of potentially dangerous materials. Fire involving release of potentially dangerous materials. Fire and explosions or both!and explosions or both!

Process safety incidents can have catastrophic effects Process safety incidents can have catastrophic effects and can result in multiple injuries and fatalities, as well and can result in multiple injuries and fatalities, as well as substantial economic, property and environmental as substantial economic, property and environmental damagedamage

Process Safety Management is the Process Safety Management is the application of management principles and application of management principles and systems to the identification, systems to the identification, understanding, and control of process understanding, and control of process hazards to protect employees, facility hazards to protect employees, facility assets and the environment.assets and the environment.

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What is Process Safety ManagementWhat is Process Safety Management

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Process Safety Elements:Process Safety Elements: Design and Engineering Design and Engineering

of facilitiesof facilities Hazard assessmentsHazard assessments Incident InvestigationIncident Investigation Management of Management of

ChangeChange Employee participationEmployee participation Process Safety Process Safety

InformationInformation

Operating and Operating and maintenance maintenance ProceduresProcedures

Inspection, testing Inspection, testing and maintenance of and maintenance of equipmentequipment

PSSRPSSR Personnel TrainingPersonnel Training Emergency planning Emergency planning

and responseand response

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What is Process Safety ManagementWhat is Process Safety Management

Design and Engineering of Facilities

Requires a documented system for managing Requires a documented system for managing technical codes and standardstechnical codes and standards

Provides procedures for managing exceptions Provides procedures for managing exceptions for projects and modifications to existing for projects and modifications to existing facilities and operationsfacilities and operations

Includes verifications that designs for new Includes verifications that designs for new projects and modifications to existing facilities projects and modifications to existing facilities are consistent with the facility approved are consistent with the facility approved technical codes and standardstechnical codes and standards

Compliance with appropriate technical codes and Compliance with appropriate technical codes and standardsstandards

Hazard Assessments

Process Hazard Analysis (PHA)Process Hazard Analysis (PHA) It’s a comprehensive look at all aspects of It’s a comprehensive look at all aspects of

the process – what has happened, what the process – what has happened, what could happen, and suggestions could happen, and suggestions (recommendations) for preventing disaster (recommendations) for preventing disaster from happening.from happening.

Don’t start until all information has been Don’t start until all information has been gatheredgathered

Hazard Assessments

What-if, checklist, Hazard and Operability What-if, checklist, Hazard and Operability Study (HAZOP), Failure Mode and effects Study (HAZOP), Failure Mode and effects analysis (FMEA), Fault Tree, or an appropriate analysis (FMEA), Fault Tree, or an appropriate equivalent.equivalent.

Information needed: P&IDS, Incidents, Information needed: P&IDS, Incidents, Process drawings.Process drawings.

““Catastrophic release means a major Catastrophic release means a major uncontrolled emission, fire, or explosion uncontrolled emission, fire, or explosion involving one or more highly hazardous involving one or more highly hazardous chemicals, that presents serious danger chemicals, that presents serious danger to employees in the workplace.” - OSHAto employees in the workplace.” - OSHA

Incident Investigation

InvestigateIncidents

&Near-Misses

Begin within48-hours

Teamwith ProcessKnowledge

Report withConclusions &

Recommendatons

Follow-upSystem for

Recommendations

ReatainReports 5-years

IncidentInvestigation

Management of Change

Create formalized system to review all Create formalized system to review all changes to process areas including:changes to process areas including:

Raw material changes / substitutionsRaw material changes / substitutions Personnel changesPersonnel changes Process parametersProcess parameters Facility changes (HVAC / roof / fire Facility changes (HVAC / roof / fire

protection / ……..)protection / ……..)

Management of Change

PSIPSI Mechanical IntegrityMechanical Integrity PINDsPINDs Hot WorkHot Work Contractor SafetyContractor Safety Employee TrainingEmployee Training PSSRPSSR Operating ProceduresOperating Procedures

Employee Participation

Employees are required to be an active Employees are required to be an active part of the process and your written part of the process and your written programs need to document what roles programs need to document what roles employees play, their involvement in the employees play, their involvement in the development of the programs, and development of the programs, and continuing participation in the process. continuing participation in the process.

Front line workers – those that live and Front line workers – those that live and breathe the process – are critical to an breathe the process – are critical to an effective program. effective program.

Employee Participation

Consultation / participation with training Consultation / participation with training and supervision to determine the and supervision to determine the frequency and content of initial and frequency and content of initial and refresher training.refresher training.

Consultation / participation to develop Consultation / participation to develop and review operating and maintenance and review operating and maintenance procedures.procedures.

Consultation / participation in incident Consultation / participation in incident investigations regarding the covered investigations regarding the covered process.process.

Process Safety Information

Material Safety Data Sheets (MSDS)Material Safety Data Sheets (MSDS) Piping and instrumentation diagrams Piping and instrumentation diagrams

(P&IDs)(P&IDs) Block flow diagramsBlock flow diagrams Material and energy balance calculationsMaterial and energy balance calculations Relevant consensus standardsRelevant consensus standards Materials of construction Materials of construction

Operating & Mtce Procedures

Standard Operating ProceduresStandard Operating Procedures Do in tandem with Job Hazard Analysis Do in tandem with Job Hazard Analysis

(JHAs)(JHAs) Mesh with training program - OJLMesh with training program - OJL Partner with Quality Team (ISO 9001) to Partner with Quality Team (ISO 9001) to

create training matrix and managed create training matrix and managed documentsdocuments

Inspection, Testing & Mtce

The employer shall develop and maintain a The employer shall develop and maintain a master list of all equipment specifically covered master list of all equipment specifically covered by the standard, and equipment that is important by the standard, and equipment that is important to safety of the process. to safety of the process. Pressure vessels and storage tanks.Pressure vessels and storage tanks. Piping systems including valves and other Piping systems including valves and other

piping components.piping components. Relief and vent systems and devices.Relief and vent systems and devices. Emergency shutdown systems. Emergency shutdown systems. Controls (including monitoring devices and Controls (including monitoring devices and

sensors, alarms, and interlocks).sensors, alarms, and interlocks).

Inspection, Testing & Mtce

Pumps.Pumps. Rotating equipment.Rotating equipment. Heat exchange equipment.Heat exchange equipment. Electrical generation and distribution Electrical generation and distribution

equipment.equipment. Un-interruptable power supplies.Un-interruptable power supplies. Emergency power supply equipment.Emergency power supply equipment. Fire protection equipment.Fire protection equipment.

PSSR

Check, double check, and review any Check, double check, and review any changes, modifications, additions made in changes, modifications, additions made in a PSM covered area – before you flip the a PSM covered area – before you flip the switch.switch.

Personnel Training

The employer shall prepare a record:The employer shall prepare a record: Identity of employee.Identity of employee. Date of training.Date of training. Means to verify that employee understood Means to verify that employee understood

trainingtraining

At a minimum, refresher training shall be At a minimum, refresher training shall be provided at least every three years and provided at least every three years and more often if necessary to each employee more often if necessary to each employee involved in operating a procinvolved in operating a process.

Emergency Planning & Response

Call in all resources and make plan Call in all resources and make plan comprehensive:comprehensive: Information Technology (IT) Disaster Information Technology (IT) Disaster

Recovery PlanRecovery Plan Business Continuity Plan Business Continuity Plan Security Security Communications / Public RelationsCommunications / Public Relations Trained ER personnelTrained ER personnel

What can you do?

Understand specific hazards of the materials in Understand specific hazards of the materials in your facility and your responsibility in the safe your facility and your responsibility in the safe handling of these materialshandling of these materials

Understand the specific hazards of the Understand the specific hazards of the manufacturing, storage, transport, repackaging or manufacturing, storage, transport, repackaging or other process operations conducted at your facilityother process operations conducted at your facility

Understand your role in process safety activities Understand your role in process safety activities including process hazard analysis, management of including process hazard analysis, management of change, incident reporting and investigation, change, incident reporting and investigation, maintenance and testing and following safe work maintenance and testing and following safe work practices and procedures.practices and procedures.

Any Questions?Any Questions?