Process Safety Management Soft Skills Programme Nexus Alliance Ltd
Session Elements 1. Introduction 2. What is Process Safety Management 3. Process Safety Elements 4. What can you do?
INTRODUCTION Process Safety vs. Personal safety • Process Safety is the safe design, engineering and operation of process units and equipments so that they do not fail and cause catastrophic events such as LOC or fires. • Personal or occupational safety is the focus on preventing injury to personnel as a result of occupational hazards.
INTRODUCTION • Not all hazards are the same or can cause equal consequences • Personal or occupational safety hazards such as slips, falls, cuts, and vehicle accidents usually affect one individual worker • Process safety hazards may cause major accidents involving release of potentially dangerous materials. Fire and explosions or both! • Process safety incidents can have catastrophic effects and can result in multiple injuries and fatalities, as well as substantial economic, property and environmental damage
What is Process Safety Management • Process Safety Management is the application of management principles and systems to the identification, understanding, and control of process hazards to protect employees, facility assets and the environment.
Process Safety Elements: What is Process Safety Management • Design and Engineering of facilities • Hazard assessments • Incident Investigation • Management of Change • Employee participation • Process Safety Information • Operating and maintenance Procedures • Inspection, testing and maintenance of equipment • PSSR • Personnel Training • Emergency planning and response
Design and Engineering of Facilities • Requires a documented system for managing technical codes and standards • Provides procedures for managing exceptions for projects and modifications to existing facilities and operations • Includes verifications that designs for new projects and modifications to existing facilities are consistent with the facility approved technical codes and standards Compliance with appropriate technical codes and standards
Hazard Assessments • Process Hazard Analysis (PHA) • It’s a comprehensive look at all aspects of the process – what has happened, what could happen, and suggestions (recommendations) for preventing disaster from happening. • Don’t start until all information has been gathered
Hazard Assessments • What-if, checklist, Hazard and Operability Study (HAZOP), Failure Mode and effects analysis (FMEA), Fault Tree, or an appropriate equivalent. • Information needed: P&IDS, Incidents, Process drawings. • “Catastrophic release means a major uncontrolled emission, fire, or explosion involving one or more highly hazardous chemicals, that presents serious danger to employees in the workplace.” - OSHA
Management of Change • Create formalized system to review all changes to process areas including: • Raw material changes / substitutions • Personnel changes • Process parameters • Facility changes (HVAC / roof / fire protection / ……..)
Management of Change • PSI • Mechanical Integrity • PINDs • Hot Work • Contractor Safety • Employee Training • PSSR • Operating Procedures
Employee Participation • Employees are required to be an active part of the process and your written programs need to document what roles employees play, their involvement in the development of the programs, and continuing participation in the process. • Front line workers – those that live and breathe the process – are critical to an effective program.
Employee Participation • Consultation / participation with training and supervision to determine the frequency and content of initial and refresher training. • Consultation / participation to develop and review operating and maintenance procedures. • Consultation / participation in incident investigations regarding the covered process.
Process Safety Information • Material Safety Data Sheets (MSDS) • Piping and instrumentation diagrams (P&IDs) • Block flow diagrams • Material and energy balance calculations • Relevant consensus standards • Materials of construction
Operating & Mtce Procedures • Standard Operating Procedures • Do in tandem with Job Hazard Analysis (JHAs) • Mesh with training program - OJL • Partner with Quality Team (ISO 9001) to create training matrix and managed documents
Inspection, Testing & Mtce • The employer shall develop and maintain a master list of all equipment specifically covered by the standard, and equipment that is important to safety of the process. • Pressure vessels and storage tanks. • Piping systems including valves and other piping components. • Relief and vent systems and devices. • Emergency shutdown systems. • Controls (including monitoring devices and sensors, alarms, and interlocks).
Inspection, Testing & Mtce • Pumps. • Rotating equipment. • Heat exchange equipment. • Electrical generation and distribution equipment. • Un-interruptable power supplies. • Emergency power supply equipment. • Fire protection equipment.
PSSR • Check, double check, and review any changes, modifications, additions made in a PSM covered area – before you flip the switch.
Personnel Training • The employer shall prepare a record: • Identity of employee. • Date of training. • Means to verify that employee understood training • At a minimum, refresher training shall be provided at least every three years and more often if necessary to each employee involved in operating a process.
Emergency Planning & Response • Call in all resources and make plan comprehensive: • Information Technology (IT) Disaster Recovery Plan • Business Continuity Plan • Security • Communications / Public Relations • Trained ER personnel
What can you do? • Understand specific hazards of the materials in your facility and your responsibility in the safe handling of these materials • Understand the specific hazards of the manufacturing, storage, transport, repackaging or other process operations conducted at your facility • Understand your role in process safety activities including process hazard analysis, management of change, incident reporting and investigation, maintenance and testing and following safe work practices and procedures.