PROCESS SAFETY MANAGEMENT(PSM)chemindassociation.com/training/PSM.pdf · Areas :Operation of Ammonia plant, Execution of projects for LPG ... Setting up of an ammonia plant, contract

PROCESS SAFETY MANAGEMENT(PSM)

Process Safety Management

An Introduction

Aug2016

G . R A J A S E K A R A N M . T E C H ( C H E M I C A L ) , T E C H N I C A L

C O N S U L T A N T 1

About the Speaker

Name : G.Rajasekaran

Qualification : M.Tech in Chemical Eng

Experience :35years

Organizations :1. SPIC Ltd, India

Served 2. Caltex Gas India ,Chennai

3.Shriram EPC, Chennai

Functions : Process plant operations

Project Formulation & it’s Execution

HES, Logistics

Contract Bidding

Areas :Operation of Ammonia plant, Execution of projects for LPG storage and Bottling,

Setting up of an ammonia plant, contract bidding for revamping of group gathering

stations of ONGC’s oil field in western on shore assets ,ONGC’s off shore platform modification

jobs, presently director in Oxalis Specialty Chemicals and Services Ltd providing tech consultancy

manpower supply, training in process plant operations






Purpose & Objective

• To impart an awareness level knowledge on PSM

• To enable the employees to realize the importance of safety in chemical process

industries wherein hazardous chemicals are handled

• To make the employees to perform in a responsible manner in their industrial carrier

to achieve an incident free operation




Disastrous Accidents worldwide

• Bhopal India(1984),2000death initially and final tally is 10,000,Isocyanate release

• Pasadena Texas(1989),23 deaths,132 injuries

• Cincinnati Ohio 2 deaths and Explosion

• Sterlington Los Angles(1991)

The above incidents and other major ones woke up the world and made every country to

tighten up their safety standards, PSM by OSHA is an outcome of this awakening




What is meant by Process Safety Management?

• It is the regulations promulgated by Occupational Safety and Health Administration (OSHA) of Labor Dept. ,Federal Govt USA

• PSM Standard was released in 1991 by OSHA

• Applicable to all the industries where certain hazardous chemicals are handled above the prescribed threshold limit

• 137 chemicals are listed and 77 named chemicals are covered in the Standard

• This standard is basically applicable in USA however many countries have adopted these standards after suitably modifying

• It is a structured, systematic and holistic approach to achieve the set target on safety

• Expectations are met through processes and programs put in place by management

• 14 Elements are covered in this standard




PSM protects

• Work Force

• Contractors

• Visitors

• Facility assets

• Surrounding community

• General Public

• Prevents catastrophic incidents like Bhopal tragedy

PROCESS SAFETY MANAGEMENT(PSM



14 Elements covered in PSM

1. Management commitment

2. Employees Participation

3. Process Safety Information

4. Process Hazard Analysis

5. Operating Procedures

6. Training

7. Contractor Safety

8. Pre Start up Safety Review




14 Elements covered in PSM contd

9.Mechanical Integrity

10.Permit to Work

11.Management of Change

12.Incident Investigation

13.Emergency Response Plan

14.Compliance Audit


Applicability of PSM

• Wherever the Threshold Quantity (TQ) of the chemicals

listed in the PSM std exceeds

• For example TQ for Ammonia is 10,000lbs,TQ for Chlorine is

1500lbs (to refer the std for other chemicals)

• Flammable liquid or gas greater than 10,000lbs in one

location





Industries covered in general

• Inorganic and Organic Chemical Industries

• Paints

• Pharmaceutical

• Petrochemical

• Paper Mill

• Food Processing

• Adhesive

• Sealant & Fibers




Facilities excluded

• Industries having less than the prescribed TQ

• Fuels solely for work place

• Retail Facility

• Oil & Gas Well(Off Shore Platform, Oil wells)

• Unoccupied remote facilities




Management Commitment

• It is the single largest factor the success of PSM implementation

• Management should set a clear vision and objective on safety

• Management should direct to implement all the processes put in place under

PSM

• Leadership should send message by their actions to drive home the fact that

safety is the priority among all the performance indicators

• Management should ensure that required resources are made available and

roles, responsibilities and accountabilities are fully aligned through the

organizations




10 things a leader can do to build safety culture

1. Engage in dialogue with members of workforce(employees and contractors)

inquire about their work and working conditions, Understand individual’s

contribution to incident free operations

2. Positively reinforce safe behavior on the spot

3. Never ignore a suggestion to improve operations

4. Devote required resources including your time

5. Sponsor and participate in the critical PSM element process formations

6. Set clear, specific, measurable objectives

7. Always follow safety instructions without fail and set an example

8. Conduct field visits ask questions about safety

9. Hold yourself and others accountable for achieving set target on safety

10. Set high, specific standards for continues improvement


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Employee Participation

• Next to management commitment, employee participation is the most

important factor, without their active involvement it is not possible to achieve the

goals of PSM,employees include contract employees also

• Form a team comprising of

Process Engineer

Operators

Safety Engineers

Maintenance

Management

Consultant

Remember you can not do it alone


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Process and Programs required for each element

• Process and Programs are to be developed for each element and established

• These process and programs should be working effectively

• Well designed and effectively implemented processes are required to achieve the desired results

• Processes should be documented and it shall have the following component

Purpose,Scope,Objective

Necessary step by step procedure

Resources, Roles and Responsibilities

Measurement and verification

Continual improvements


C O N S U L T A N T

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Process Safety Information

• What are all the chemicals in your process

• Chemical’s Process chemistry

• Quantity of Chemicals in lb. and comparison with it’s TQ

• Obtain Toxicity information from MSDS (Material Safety Data sheet) NIOSH (National Institute of occupational safety and health) pocket guide,ACGIH TLV

• Process Flow Diagram

• Maximum inventory, it's upper and lower limits

• Consequences of deviations

• Process and Instrumentation Diagram P&ID

• Materials of Construction of various equipment's

• Electrical Classification

• Relief System design


C O N S U L T A N T

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Process Safety Information continued

• Ventilation System

• Design code

• Material & Energy Balance

• Each piece of equipment is to be identified with a no

• Must be able to track each no through entire PSM


C O N S U L T A N T

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Mechanical Integrity

• To develop procedures to ensure that equipment's used to process ,store, handle

hazardous chemicals are designed,constructed,installed and maintained properly

to avoid any release of these chemicals

• A process is in place to identify critical ,structures,equipments and work

processes for a possible failure modes and take steps to prevent or mitigate

• A process is in place for condition monitoring(or time based inspection and

testing) to monitor and ensure mechanical integrity of all critical structures,

equipment and protection devices

• A process is in place to plan and schedule maintenance


C O N S U L T A N T

18


Process Hazard Analysis

• Most difficult part of the standard

• It is dynamic and subjected to revision

• Must be done by a team

• Analysis is to be done on each element

• PFD,P&ID is required

• Takes significant time and effort


C O N S U L T A N T

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Management of Change

• A process should be in place to manage changes to facilities,operations,products or organization

• It shall address

Both permanent and temporary changes

Authority for approving changes

Technical basis for change

Modification required in operating procedure

Time period for change

Evaluation of health and ,safety hazards, environmental impacts and mitigation

Communication of the change

Training


C O N S U L T A N T

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Operating Procedure

It shall contain the following

• Initial start up

• Normal Operation

• Temporary Operation

• Emergency Shut down

• Normal Shut down

• Start up

• Consequences of deviations

• Steps to avoid or correct the deviations

It shall cover

• Process Chemicals

• Technology and equipment's

• Facilities


C O N S U L T A N T

21


Operating Procedure Contd

• A process should be in place to develop and maintain operating and maintenance procedures, process safety information

• The process shall ensure

Procedure is well written and covers all the aspects,

Documentation and proper record keeping

Procedure is updated periodically and current

Easily accessible to operation, maintenance and other persons concerned

Document control procedure including confidentiality and retention

• It should be certified annually


C O N S U L T A N T

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Safe Work Practices

It may be of following nature

• Permit to Work

• Hot Work

• Confined space entry

• Equipment isolation(lockout/tag out)

• Opening an equipment

• Earth Excavation

• Working at Height

• Electrical work

• By passing critical protections

• Lifting and rigging


C O N S U L T A N T

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Training

• Training in PSM itself

• Standard Operating Procedure

• Safety and Health Hazards

• Safe work practices

• Refresher training is required for every 3 years or as prescribed in PSM

• Contract employees also should be given training on the topics relevant to them

• Training records must be maintained for company as well as contract employees


C O N S U L T A N T

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Training

• Training in PSM itself

• Standard Operating Procedure

• Safety and Health Hazards


• Refresher training is required for every 3 years or as prescribed in PSM

• Contract employees also should be given training on the topics relevant to them

• Training records must be maintained for company as well as contract employees


C O N S U L T A N T

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Contractor Safety

Contract employees also play a key role in

• Maintenance and Repair

• Plant Turn around jobs

• Major Renovation

• Initial Project Construction stage

• Other jobs

They should be trained in


• Permitting system

• PPEs


C O N S U L T A N T

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Emergency Response Plan

• Every facility should have well documented Emergency Response Plan considering the credible emergencies

• Company and Contract employees should be trained in ERP

• Must have provision for small release of HHCs

• Early warning system should be incorporated

• Training on the meaning of various alarms should be given

• Emergency evacuation procedures and evacuation maps should be in-corporated

• Roles and Responsibilities of employees should be clearly defined and mock drill should be conducted at scheduled intervals

• Organization chart during emergencies should be displayed at strategic locations in the plant

• What to do during emergencies is also to be intimated to visitors and contract employees through written instructions


C O N S U L T A N T

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Incident Investigation and Reporting

• A process should be in place to report, record, investigate incidents and near misses

• Root cause analysis should be done to find out the root cause

• Solution and recommendations should find a place in the report(improvements in system, processes, practices and procedures are to be recommended)

• Timeline should be specified for implementing the solutions

• Management roles and responsibilities should be specified

• Emergency evacuation procedures and evacuation maps should be in-corportaed

• Sharing of the lessons learned


C O N S U L T A N T

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Incident Investigation and Reporting contd

• Investigation must be initiated ASAP but within 48hrs

• An investigation team should be formed

• Solution and recommendations should find a place in the report(improvements in

system, processes, practices and procedures are to be recommended)

• Timeline should be specified for implementing the solutions

• Management roles and responsibilities should be specified

• Emergency evacuation procedures and evacuation maps should be in-corporated

• Sharing of the lessons learned


C O N S U L T A N T

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Incident Investigation and Reporting contd

• Team must include persons knowledgeable in the process

• Include contractor if work of the contractor is involved

• Include other person with appropriate knowledge of the covered process

• To cover the following

Date of incident

Date of start of investigation

Description of the incident

Factors contributing

Resolution and corrective action must be documented


C O N S U L T A N T

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Compliance Audit

• To ensure that PSM is effective and employer must certify every 3 years

• Must be completed by one who is knowledgeable in the process

• Audit report must be developed and documented

• Last two audit compliance audits must be kept on file. Implementation of the

action items specified in the earlier reports should be completed


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Some References

• https://www.osha.gov

• En.wikipedia.org/wiki/Process Safety Management

• www.epa.gov/region

• www.siemens.com/Process-safety


C O N S U L T A N T

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Thank You


C O N S U L T A N T

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Documents

PROCESS SAFETY MANAGEMENT(PSM)chemindassociation.com/training/PSM.pdf · Areas :Operation of Ammonia plant, Execution of projects for LPG ... Setting up of an ammonia plant, contract