Process Safety- Lack of awareness could be costlier

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Process Safety
lack of awareness could
be costlier than you
thought
Are your process safety risks under control?

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about the presentation
Process Safety Management (PSM) is a concern
in any of the industries who store, handle and
process hazardous chemicals & gases. The risks
related to process safety are often managed in
an isolated way.
This presentation will help organisations to
manage process safety risks in a more structured
fashion.

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Process Safety
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Now on the subject:
Process
Safety

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What is Process Safety Management System?
The Process Safety Management System is a
comprehensive management system that proactively
avoids incidents in the hazardous industries like
chemical plants, oil and gas installations, fertilizer,
pharmaceutical, explosives and that handle, store or
process toxic or flammable chemicals.

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Process Safety Management
System integrates different aspects
of risks in a facility and puts them
under the control of a management
system.
By establishing a risk based
awareness of the safety impacts of
technology, personnel and the
management, the system provides
a dynamic environment for
continual improvement.

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Process Safety Management System
Input Output
Process
Resources
- Equipment
- Infrastructure
- Human Resource
Controls
- Quality / Productivity
- Safety
14 Elements of Process Safety
Safety
Process
Management
Plan
Do
Check
Act
• Process Industries like
O&G, Fertilizer, Pesticides,
Chemical, Pharmaceutical,
Explosives etc.
• Processes in any other
industry
ApplicabilityStorage Handling Emissions / Waste Utilities

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14ELEMENTS
of Process Safety
Element 1: Employee participation
Element 2: Process Safety Information
Element 3: Process Hazard Analysis
Element 4: Operating Procedures
Element 5: Safe work practices
Element 61: Contractor control
Element 7: Training
Element 8: Pre-Start up Safety Review
Element 9: Mechanical integrity
Element 10: Management of Change
Element 11: Emergency response planning
Element 12: Trade secrets
Element 13: Incident Investigation
Element 14: Compliance audits

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These 14 elements follow a
simple management system
framework

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Hazard
Information
from
Employees
Process
Safety
Information
• Hazard
Identification
• Risk
Assessment
• Prioritization
Hierarchy of
Controls:
• Elimination
• Substitution
• Engineering
Control
• Admin Control
• PPE
• Operating procedures
• Safe work practices
• Contractor control
• Training
• Pre-Start up safety
Review
• Mechanical integrity
• Management of change
• Emergency response
planning
• Trade secrets
Element # 1
Element # 2
Element # 3 Element # 4 - 12
Set ControlsProcess
Hazard
Analysis
Compliance
Audits
Element # 13
Incident
Investigation
Element # 14
Plan Do Check & Act

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Action Points
Develop a written plan of action to
implement the employee participation
required by PSM.
Consult – provide platforms to share their
views, advices, suggestions, alerts
Involve people in hazard identification and
analysis process
Provide access to safety information
…1
Employee
Participation

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Process Safety Information:… 2
a compilation of written process safety information that helps to identify and
understand the hazards posed by those processes involving highly hazardous
chemicals.

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Process safety information
must include :
Hazards of the highly hazardous chemicals in the
process shall consist of at least the following:
• Toxicity
• Permissible exposure limits
• Physical data
• Reactivity data
• Corrosivity data, and
• Thermal and chemical stability data, and
hazardous effects of inadvertent mixing of
different materials

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• A block flow diagram or simplified process
flow diagram,
• Process chemistry
• Maximum intended inventory
• Safe upper and lower limits for such items as
temperatures, pressures, flows or
compositions, and
• An evaluation of the consequences of
deviations, including those affecting the safety
and health of employees
Information on the technology of the process
must include at least the following:

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Methods
• What-if
• Checklist
• What-if/checklist
• Hazard and operability study
(HAZOP)
• Failure mode and effects analysis
(FMEA)
• Fault tree analysis
• An appropriate equivalent
methodology
Process Hazard Analysis
identifying, evaluating, and controlling the hazards of
processes involving highly hazardous chemicals.
…3

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Tasks and procedures related to the
covered process must be appropriate,
clear, consistent, and most importantly,
well communicated to employees.
Steps for each operating phase:
• Initial start up
• Normal operations
• Temporary operations
• Emergency shutdown,
• Emergency operations
• Normal shutdown and
• Start up following a turnaround or
after an emergency shut-down
4Operating Procedure

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Operating limits:
• Consequences of deviation, and steps required correcting or
avoiding deviation. Safety and health considerations
• Properties of, and hazards presented by, the chemicals used in the
process
• Precautions necessary to prevent exposure, including engineering
controls, administrative controls, and personal protective equipment
• Control measures to be taken if physical contact or airborne
exposure occurs
• Quality control for raw materials and control of hazardous chemical
inventory levels; and
• Any special or unique hazards
• Safety systems (e.g., interlocks, detection or suppression systems)
and their functions

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The employer must develop and implement safe
work practices to provide for the control of hazards
during work activities such as
• Lockout / tagout
• Confined space entry
• Opening process equipment or piping; and
• Access control over entrance into a facility by
maintenance, contractor, laboratory, or other
support personnel
These safe work practices must equally apply both
to employees and to contractor employees.
5 Safe work practice

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Contractor Control 6
PSM includes special provisions for contractors and their employees
to emphasize the importance of everyone taking care that they do
nothing to endanger those working nearby who may work for
another employer.

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Training:
• Initial Training
• Refresher Training
Training Documentation is important
7

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Prior to the introduction of a highly hazardous chemical to a
process, the pre-start-up safety review must confirm that the
following:
• The constructions and equipments are in accordance
with design specifications
• Safety, operating, maintenance, and emergency
procedures are in place and are adequate
• A process hazard analysis has been performed for new
facilities and recommendations have been resolved or
implemented before start up, and modified facilities
meet the management of change requirements; and
• Training of each employee involved in operating a
process has been completed
8Pre Start up Safety Review

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Mechanical Integrity:
• Pressure vessels and storage tanks
• Piping systems (including piping
components such as valves)
• Relief and vent systems and devices
• Emergency shutdown systems
• Controls (including monitoring
devices and sensors, alarms and
interlocks); and
• Pumps
9

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Management of change
These written procedures must ensure
• The technical basis for the proposed change
• Impact of the change on employee safety and
health
• Modifications to operating procedures
• Necessary time period for the change, and
• Authorization requirements for the proposed
change
10

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Use of a
‘Problem Solving
Technique’
Incident
Investigation
Incident
Accident
Near Miss
Correction
Corrective Action
Preventive Action
11

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Emergency Planning & Response 12
• Identification of possible
emergency situations
• Emergency preparedness
plan
• Training of people
• Practice

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Compliance Audit
13
Establish a process of evaluated
compliance with the provisions of PSM
Planned & conducted at regular
intervals
Conducted by Trained and competent
auditors knowledgeable in the process
Documented process
Management attention and actions on
findings

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No requirement to enter
into confidentiality
agreements to not disclose
the information
14
Trade Secret

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• Proactive management system
• Safer workplace for employees
• Reduced risk
• Compliance with industry codes, standards
and practices
• Reduces downtime and losses
• Reduces risk to nearby communities
• Continual improvement

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What Consultivo does?
Consultivo is an international advisory firm involved in the field of Responsible
Business, Business Excellence and Risk Management.
1
Assessment
Identifying the
gaps in a
system against
standard(s) and
requirement. to
meet
compliance and
facilitate
improvement.
2
Consulting
Supporting &
handholding
organisations
to solve their
problems and
to meet the
gaps identified
during the
assessment or
any other audit.
3
Training
Empowering
people to
perform their
duties
effectively and
efficiently.
4
Assurance
&
Certification
Ensuring that a
process,
product, or
service meets
relevant techni
cal standards
and fulfils
relevant
requirements.
Consultivo services in
Occupational
Health & Safety
• Safety Audit
• Safety Management System
• Ergonomic
• Electrical Safety
• Accidental Investigation
• Safety Legal
• Fire Risk Assessment
• OHS Due Diligence
• Behavior bases safety
• Safety Management System
Maturity Assessment
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Safety,
Health &
Environment
People
ExcellenceFood Safety
Social
Compliance
Quality &
Business
Excellence
Information
Security
Sustainability
Risk
Management