Solving the Puzzle · For some adults, past experiences with education were unpleasant and not helpful. Adults learn best when they feel comfortable. By making the learning environment

Process SafetyMANAGEMENT

Facilitator Guide

Solvingthe

Puzzle

What’s Inside

Facilitator’s Guidelinesa Overview

b Getting Started

d Presentation Guidelines

f Lesson Plan

h Frequently Asked Questions

1 IntroductionFollow the 14 elements of Process Safety Management to preventincidents.

2 Employee ParticipationYour commitment to Process Safety Management is important.

3 Process Safety InformationKnow the three types of process safety information.

4 Process Hazard AnalysisThe four steps to proactively prevent incidents.

5 Management of ChangeWritten procedures are required when a change occurs.

7 Pre-Startup Safety ReviewSteps to ensure safe operation of the process for new and modified facilities

8 Operating ProceduresWritten operating procedures describe duties to be performedand operating conditions for each part of the process.

9 Hot Work PermitsRequired for any hot work job on or near covered processes.

10 Employee TrainingWho needs to be trained and how often?

11 Incident InvestigationThe objective and duties of an incident investigation team.

13 Mechanical IntegrityKnow the components of a mechanical integrity program.

14 Emergency Planning & ResponseKnow what to do to prepare for an incident.

15 Contractor SafetyThe contractor’s responsibilities for process safety.

16 AuditsWhat is an audit and when it is conducted.

17 Trade SecretsWhen confidentiality is required.

18 Process Safety Management QuizReview what you learned.

© 2003 Summit Training Source® Inc. All rights reserved. No part of this book may be reproduced in any form or by any means without written permission from Summit Training Source® Inc. If you wish to purchase additional copies please call our office at 1-800-842-0466.

a © Summit Training Source, Inc.

Overview

The following sections provide detailed information, discussiontopics and review questions for each of the 14 elements of ProcessSafety Management, or PSM. The roles, job functions and respon-sibilities of the group being trained will determine the depth andscope of information covered for each element.

The objective of PSM is to prevent catastrophic incidents caused bythe uncontrolled release of highly hazardous chemicals. ProcessSafety Management can accomplish this goal through a systematicapproach that includes identifying, analyzing and controlling thechemicals in the process.

To be effective, Process Safety Management requires theparticipation of all personnel at your facility. This includes the plantmanager, supervisors, engineers, operators, mechanics and evencontractors. Each person needs to contribute his or her specificexpertise, whether it is experience, technology or processknowledge.

b© Summit Training Source, Inc.

Getting Started

Training Materials

Collect all of the necessary materials and supplies before train-ing begins. Here are some suggested materials and supplies:

• A training location that is free of distractions, has goodlighting, and a comfortable temperature.

• Desks and chairs arranged so that everyone will be able tosee the viewing screen, the facilitator, and each other.

• The video, a VCR, and a TV with a remote. Make sure thevideo is rewound.

• An employee handbook and pen/pencil for each trainee.Each handbook includes a quiz at the back, which can beused to test comprehension and document training.

• Other supplies and equipment you may need are:blackboard chalk, paper, handouts, transparencies,overhead projector, markers, notepads, etc.

• Additional information, such as a copy of the regulation orother reference tools.

c © Summit Training Source, Inc.

Getting Started continued

Preparation

A successful presentation requires preparation and planning.Give yourself several days before the training session to getorganized.

• Locate and schedule the training site as soon as possible.

• Notify trainees of the training date and time, the trainingschedule, and proper dress.

• Obtain all necessary equipment and supplies.

• Make sure you know how to operate the TV, VCR, and otherequipment. Check to ensure that it is working properly.Replace or repair any damaged equipment.

• Review all training materials, including the Facilitator’sGuide, handouts, and any other reference materials.

• Prepare your presentation, including a lesson plan oroutline of the training. Include the training goals andobjectives. Some presentation guidelines are included onthe next page. A sample lesson plan has been included onpage f of this Facilitator’s Guide.

• A day or so before conducting the training session, you maywant to have participants take the quiz as a pre-test. Theresults of this test can help you to determine weak areas tofocus on during the training session.

• Preview the videotape. Note any key points you want toexpand upon in your training.

d© Summit Training Source, Inc.

Presentation Guidelines

How you present the training course can have a greatimpact on learning. By following these simple presentationguidelines and keeping your objectives in mind, you caneffectively and efficiently get the most out of your trainingsession.

Organize Training Time Efficiently

In today’s busy work climate it can be difficult to find the timeneeded for training, so it is important to be organized andwell-prepared when you do schedule training sessions.Whether you use Summit’s suggested lesson plan or not, it isimportant to have a lesson plan prepared that you can imple-ment comfortably. This ensures that time spent in training isproductive and beneficial for everyone.

Stress the Purpose and Goals of Training

Training needs to be goal-oriented. State the purpose oftraining in a clear, specific manner - whether it’s to reduceinjuries, increase production, improve quality, improve work-ing conditions, etc. Review the goals and objectives of thetraining so trainees know what is expected of them.

Capture Their Attention

Training needs to be interesting and compelling to holdtrainees’ attention. To help motivate learners, give them spe-cific evidence that their effort makes a difference and providefeedback on their progress. Also, remember that the firstexperience with a new subject usually forms a lasting impres-sion on the learner. By making that experience a positiveone, you can help ensure your audience retains the informa-tion learned.

e © Summit Training Source, Inc.

Make New Learning Experiences Pleasant

For some adults, past experiences with education wereunpleasant and not helpful. Adults learn best when they feelcomfortable. By making the learning environment open andfriendly, you can help adults to feel secure in their new learn-ing experience. Offer support and feedback as often as possi-ble, and be ready to provide extra attention to those who mayrequire it.

Ask If There Are Any Questions

When most adults learn new information that conflicts withwhat they already know, they are less likely to integrate thosenew ideas. It is very important to make sure participants fullyunderstand the training and do not have any unresolved ques-tions. Provide for a question and answer period so partici-pants can resolve those questions and/or answer questionsthroughout the training session.

Presentation Guidelines continued

f© Summit Training Source, Inc.

Lesson Plan

As a qualified trainer, your job is to effectively communicatea great deal of information in a well-organized manner. Bypreparing a lesson plan, you can ensure that each minute ofthe training session is productive. Summit has provided asuggested lesson plan for your use.

1. Program Objective

This guide reviews Process Safety Management. In it, we will cover:

• Employee Participation • Employee Training

• Process Safety Information • Incident Investigation

• Process Hazard Analysis • Mechanical Integrity

• Management of Change • Emergency Planning & Response

• Pre-Startup Safety Review • Contractor Safety

• Operating Procedures • Audits

• Hot Work Permits • Trade Secrets

2. Show the Video: “Process Safety Management”

3. Discussion and Demonstration

To help relate the training to your site, you may wish to incor-porate your own discussion topics and exercises. Key issuesyou might consider include:

• Discuss your facility’s procedures for conducting the variouselements of Process Safety Management

• Employee training required

• Safe work procedures

g © Summit Training Source, Inc.

Lesson Plan continued

4. Use Handbooks to Reinforce Training

The handbooks increase comprehension and reinforce theinformation learned in the video program by explaining themain points and expanding on the original material. Forincreased employee information retention, go over one sec-tion at a time and stop to answer questions. The quiz at theback of the Facilitator’s Guide is provided to documentemployee training. Answers to the quiz are in bold.

5. Questions and Answers

Provide for a Q&A session to answer any questions. It maybe necessary to review some of the material when providinganswers. The employee handbook, equipment manuals, andother reference tools may be helpful.

h© Summit Training Source, Inc.

Frequently Asked Questions

Is there a procedure that must be followed when there is a changein the process?

All changes, including those that are temporary, are required to bedocumented. These written procedures must include authorizationrequirements for the proposed change, the technical basis for thechange, health and safety considerations, changes required for oper-ation and maintenance procedures and the time period for thechange. A Pre-Startup Safety Review must be performed if thechange is significant enough to require a modification in the ProcessSafety Information. This should be done after the change andbefore hazardous chemicals are introduced into the process.

What is an Incident Investigation Team and what is its purpose?

The job of the Incident Investigation team is to investigate incidentsthat resulted or could have resulted in a catastrophic incident.Members of this team include personnel who must be proficient ininvestigative, fact finding and reporting skills and the processinvolved. At the end of the investigation, they must compile a reportcontaining the description of the incident and the date it occurred,the date the investigation began, a description of the investigationand findings of the factors that contributed to the incident.

1 © Summit Training Source, Inc.

Objective

The objective of Process SafetyManagement, or PSM, is to pre-vent any incidents which couldlead to property damage, majorinjuries or even death. Thisoverview of PSM will help you

see how your job fits together with the other elements of PSM.By following procedures forPSM and respecting the poten-tial hazards, you can preventincidents in your facility.

Introduction

Processes that use highly hazardous chemicals could cause dangerto you and damage to the facility and the surrounding communityif an explosion, spill or fire happened in the work place.

This has been demonstrated with recent explosions that have beenhighlighted in the news in the past few years.

There are 14 elements in Process Safety Management:

• Employee Participation• Process Safety

Information• Process Hazard Analysis• Management of Change• Pre-Startup Safety

Review• Operating Procedures• Hot Work Permits

• Employee Training• Incident Investigation• Mechanical Integrity• Emergency Planning &

Response• Contractor Safety• Audits• Trade Secrets

2© Summit Training Source, Inc.

A written plan of action is needed which details employeeparticipation in the process.

Employee Participation

Your participation in the differ-ent elements of PSM is impor-tant. Whether it is your knowl-

edge, work experience, trainingor education, your participationis a valuable part of its success.


Process ChemicalInformation

Process Chemical Informationincludes toxicity, permissibleexposure limits (PELs), physicaldata, reactivity, corrosion anderosion effects, thermal andchemical stability and thepotential effects of accidentalmixing of different chemicals.

Process TechnologyInformation

This information includes ablock flow diagram or simpli-fied process flow diagramshowing the flow of the mater-ial and process chemistry.Process Technology Informationalso includes an evaluation ofthe results of a change, the

inventory of chemicals used,and safe upper and lower limitsfor variables such as tempera-ture, pressures, flow and com-position.

Process EquipmentInformation

Process Equipment Informationincludes the materials of con-struction, piping instrument dia-grams, electrical classification,design codes and standardsused, safety systems, and reliefand ventilation system designs.Newer processes will alsoinclude material and energybalances. Documentation willverify equipment follows gener-ally accepted good engineeringpractices.

Process Safety Information

Written Process Safety Information is needed.

There are three kinds of Process Safety Information:• Information on the process chemicals• Information on the process technology• Information on the process equipment


Process Hazard Analysis (PHA) isa way of thinking of all the pos-sible things that could gowrong in the process thatwould result in a catastrophicincident. If you conduct a PHA,there are four main steps youneed to follow:

1. Identify possible problems in the process

2. Identify possible causes and results

3. Develop prevention techniques

4. Evaluate the current system and operations

Process Hazard Analysis isconducted by plant personnelwho are knowledgeable inengineering, the process beinganalyzed and/or the methodol-ogy being used.

Process Hazard Analysis

An investigation team will perform an initial Process HazardAnalysis.


Written procedures are needed to manage changes to processchemicals, technology, equipment, procedures, and also to facilitiesthat affect a covered process. Even temporary changes are subjectto management of change.

Changes in process technology include changes in the flow route.Changes may also happen in production rates, operating conditionsto improve yield and quality, and to equipment.

Management of Change

"Replacement in kind" is notconsidered change. For exam-ple, if you replace a valve in theprocess with one that has the

same design, it would not beconsidered a change in the process.


Written procedures shouldaccompany all changes. Thisshould include:

• Time period for the change

• Technical basis for the change

• Health and safety considerations

• Authorization for the proposed change

• Changes required for operation and maintenance procedures

Follow-up should be performedto see if the change requiresany changes to the process safe-ty information and/or processhazard analysis.

Follow-up to see if thechange requires anychanges to the processsafety informationand/or process hazardanalysis.

KEY POINT


A pre-startup safety review is afinal check to make sure allsteps have been taken to ensuresafe operation of the process.

Before hazardous chemicals areput into the process, the pre-startup safety review will makesure that the following havebeen done:

• All construction and equipment meet design requirements.

• For new facilities, a process hazard analysis has been performed and any recommendations have been resolved or carried out before start-up.

• Safety, operating, maintenance and emergency procedure meet all requirements and are in place.

• Training of each employee involved in operating a process has been complet-ed.

Pre-Startup Safety Review

A pre-startup safety review needs to be performed for new andmodified facilities when the modification requires a change in theprocess safety information.


Written operating procedures are needed to provide clearinstructions for safely conducting all activities in theprocess.

Operating Procedures

The operating proceduresdescribe in detail the duties tobe performed and operatingconditions kept for each part ofthe process.

This includes steps for startup,operating procedures for nor-mal, temporary and emergencysituations, and emergency andnormal shutdown procedures.

The procedures spell out oper-ating limits for each part of the

process, results of deviation andhow they can be avoided andcorrected if they do happen.

Operating procedures alsoinclude health and safety provi-sions, data that needs to berecorded, the built-in safety sys-tems in the process, safe workpractices for procedures thataffect the process such a lock-out and tagout, and what con-stitutes upset conditions.


Hot work includes any spark-producing activities, devices andopen flames such as welding,soldering or grinding. The per-mit provides the following information:

• Identity of the object that the hot work is being done on.

• Dates the work is authorized for.

• Fire prevention and protection requirements.

All affected personnel, such asoperators, should be notified ofthe hot work. The permit mustbe kept on file until the hotwork is done.

Hot Work Permits

A hot work permit is required for hot work jobs carried outon or near a covered process.


If you are involved with theprocess, directly or indirectly, itis important that you under-stand the safety and health haz-

ards of the chemicals and theprocess. This includes operators,maintenance and support per-sonnel, and outside contractors.

Employee Training

Employees involved in the process will be trained on anoverview of the process and their specific job function as it relates to the process.

Refresher training and documentation is necessary at leastevery three years.


Incident Investigation

Any incident or near miss that ended in or could have result-ed in a dangerous release of a highly hazardous chemical inthe work place should be investigated within 48 hours of the event.

ObjectiveThe objective of the incidentinvestigation is to find possiblecauses of all incidents or “nearmisses” and solutions to preventthem from happening again.

The Investigation TeamThe investigation team shouldbe skilled in investigating, factfinding and reporting skills, and the process involved.

If the incident involved a con-tract employee, then the teammust have a contractor repre-sentative.

The team’s job is to analyze allpossible causes of the incident,gather a list of the sequence ofevents, and determine the causeof incident.


Finally, the investigation teamputs together a report that isshared with all personnelinvolved in or affected by theincident.

The report must have the following information:

• A description of the incident and the date it happened

• The date the investiga-tion began

• A step-by-step descrip-tion of the investigation

• The investigation team's findings of the factors that led to the incident

• Recommendations to eliminate chances of a similar incident occurring in the future.

The team’s findingsand recommendationsare detailed in a writ-ten report.

KEY POINT


Maintaining mechanical integri-ty means making sure thatprocess equipment operates theway it is designed to withoutany problems. A mechanicalintegrity program includes thefollowing:

• Develop and use written maintenance procedures

• Train maintenance personnel

• Set up and document testing and inspection procedures

• Correct equipment defects

• Assure quality of new equipment, materials and parts

A quality assurance system isalso a part of the PSM programbecause it helps to keep theintegrity of the process bymaking sure proper materialsare used and the right codes,standards and procedures arefollowed.

Mechanical Integrity

The Mechanical Integrity of process equipment must be maintained.


An Emergency Action Plan for the whole plant should include pro-cedures for handling small releases.

Emergency Planning & Response

An Emergency Action Planshould include arrangementsfor warning and clearing allpersonnel from the facility if amajor accidental release ofhighly hazardous chemicalshappens.

Plans and procedures are alsoneeded for the handling ofsmall spills.

Additional training for cleanupteams will be provided. Thisshould include safe work prac-tices and steps for cleanup anddisposal of hazardous chemi-cals.


The safety record and trainingprogram of a contractor mustbe verified BEFORE the job isawarded. This includes anymaintenance, repairs, turn-around jobs, major renovationsor specialty work.

BEFORE the contractor beginswork in the process area, allcontract employees should betold about the possible hazards,safe work practices, and theEmergency Action Plan.

The contractor must train his orher employees on safe workpractices and document thattraining was given and under-stood. The contractor is respon-sible for making sure his or heremployees follow all safety rulesand for telling the facility aboutany safety hazards that the con-tract work might cause or thathis employees identify.

The safety record of a contractor should be checked. The contractorwill need to train his employees on the safe work practices and safe-ty rules of the facility, the potential hazards involved, and theEmergency Action Plan.

Contractor Safety


An audit is a way of checking tomake sure that all elements ofPSM are being followed andmeeting their goals.

It is done by at least one person who is knowledge-able in the process.

The audit is usually done with achecklist and includes a reviewof logs, records and visualobservations and inspections.

The most important part of theaudit is a follow-up on all rec-ommended actions to improvePSM at your facility.

To make sure that evaluations of the Process Safety Managementsystem are carried out and proper procedures are being followed,an audit will be completed at least every three years.

Audits


All information needed forgathering process safety infor-mation, developing processhazard analysis and operatingprocedures, conducting inci-dent investigations, emergencyresponse and planning, andaudits should be made available

to the proper personnel.

If this information is madeavailable to you, you may berequired to enter a confidential-ity agreement if it involves tradesecrets.

Your employer will make available to proper personnel any infor-mation needed to comply with the standard.

Trade Secrets

© Summit Training Source, Inc.

Test Yourself With This ProcessSafety Management Quiz

Your Name Date

______________________________________________________

1. Process safety information includes information on which of the following?A. Audits B. Employee trainingC. Process technology D. None of the above

2. The four main steps in process hazard analysis are identifying potential problems, identifying probable causes and consequences, prevention techniques and evaluation of current system and operations.A. True B. False

3. A methodology used to conduct a process hazard analysis is:A. Family tree diagram B. What-if/checklistC. Fault tree analysis D. Both B and C

4. Management of change occurs when there are changes in process chemicals, technology, equipment, procedures or facilities.A. True B. False

5. Which of the following information should be documented when a change in the process takes place?A. Technical basis for B. Changes required for

the change operation & maintenance procedures

C. Health & safety D. All of the aboveconsiderations

6. A pre-startup safety review should be performed after hazardous chemicals have been introduced into the process.A. True B. False

18


7. What operating guidelines do the operating procedures spell out?A. Temperature ranges B. Hazard limitsC. Flow rates D. Both A and C

8. Hot work permits do not always need to identify the object on which the hot work is being performed.A. True B. False

9. Refresher training for employees must be provided how often?A. Every year B. At least every three

yearsC. Once a month D. Never

10. Incident investigations should begin within 48 hours of the incident.A. True B. False

11. Maintaining mechanical integrity means that equipment is kept in good operating conditions and proper procedures are followed.A. True B. False

12. The standard requires employers to establish and implement written operating procedures that must address steps for each operating phase.A. True B. False

13. The contractor does not have to train employees on:A. Rescue procedures B. Safe work practicesC. Potential hazards D. Provisions of the emer-

gency action plan

14. The employer must conduct evaluations of the process safety management system at least every three years.A. True B. False

15. The employer must make available to the proper personnel all necessary information to comply with the standard without regard to possible trade secret status of the information.A. True B. False


Notes


Quiz Answers

1. C Process technology2. A True3. D Both B and C4. A True5. D All of the above6. B False7. D Both A and C8. B False9. B At least every three years

10. A True11. A True12. A True13. A Rescue procedures14. A True15. A True


Notes

Notes


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Documents

Solving the Puzzle · For some adults, past experiences with education were unpleasant and not helpful. Adults learn best when they feel comfortable. By making the learning environment