Introduction to Process Safety Management (PSM) of Highly Hazardous Chemicals.
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Transcript of Introduction to Process Safety Management (PSM) of Highly Hazardous Chemicals.
Introduction toIntroduction toProcess Safety Management (PSM)Process Safety Management (PSM)
of Highly Hazardous Chemicalsof Highly Hazardous Chemicals
Major IncidentsMajor Incidents
• 1984 - Mexico City1984 - Mexico City
• 1984 - Union Carbide Corp, Bhopal 1984 - Union Carbide Corp, Bhopal IndiaIndia
• 1989 - Phillips Petroleum, 1989 - Phillips Petroleum, Pasadena TexasPasadena Texas
• 1990 - ARCO Petroleum, 1990 - ARCO Petroleum, Channelview TexasChannelview Texas
• 1991 - IMC, Sterlington Louisiana 1991 - IMC, Sterlington Louisiana
14 Elements to PSM14 Elements to PSM
•Employee ParticipationEmployee Participation Process Safety InformationProcess Safety Information Process Hazard AnalysisProcess Hazard Analysis Operating ProceduresOperating Procedures TrainingTraining ContractorsContractors Hot WorkHot Work Mechanical IntegrityMechanical Integrity Management of ChangeManagement of Change Pre-Startup Safety ReviewPre-Startup Safety Review Incident InvestigationIncident Investigation Emergency Planning and Emergency Planning and
ResponseResponse Compliance AuditsCompliance Audits Trade SecretsTrade Secrets
The 14 ElementsThe 14 Elements
•Employee Participation
•Trade Secrets
•Emergency Planning and Response
•Incident Investigation
•Process Safety Information
•Process Hazard Analysis•Hot Work•Mechanical Integrity
•Training•Operating Procedures•Contractors
•Management of Change
•Pre-Startup Safety Review
•Compliance Audits
System Wide Prevention
Reaction Control
Employee Participation Employee Participation Everyone plays a partEveryone plays a part
You Make the DifferenceYou Make the Difference
Your Participatio
n is a critical part
of PSM
Nothing happens unless we pull together
Process Safety Process Safety InformationInformation
Provides the foundation for understanding the chemical, technical, and equipment hazards
associated with the processesRetains basic research and development
information to guide future efforts
Process Hazard Process Hazard AnalysisAnalysis
PHAs are the cornerstone of an effective hazard management
program and are aimed at reducing risk
RISK = SEVERITY + LIKELIHOOD
Operating Procedures
Ensures that all individuals are doing their job, the same way
and in the safest manner possible
Training
Awareness causes Action
ContractorsContractors
Contractors need to be informed of the
potential hazards related to the Process
Chemical 1 (ABC)
Chemical 2 (123)
Review (Hazards)
Hot Work
This element establishes the criteria to ensure any
work that may cause a source of ignition is done safely. This includes open
flame, running combustible engines, running
electronics and test equipment that is not
intrinsically safe, grinding, drilling, or any other
possiblesource of ignition.
A Hot Work Permit is Required.
Mechanical IntegrityMechanical Integrity
Critical equipment is identified, designed,
installed, and properly
maintainedEmployees maintaining
equipment are trained to do so Defects are
resolved before continued use of
equipment
Management of Change
Ensures changes are
not made without due
consideration
Improves communications among facility
employees affected by the change
Pre-Startup Safety Pre-Startup Safety ReviewReview
The final "thought stop" to make
sure a new or changed facility doesn't contain any surprises
Incident InvestigationIncident Investigation
Spotlights the chain of events leading to an incident, to
avoid a future occurrence
Near-misses also require an
investigation. They are not minor
incidents, they are free spins on the
wheel
Emergency Planning and Emergency Planning and ResponseResponse
Small problems can become major if not
handled properly
Written plans allow everyone to know what to do in the event of
an emergency
Compliance AuditsCompliance Audits
Audits can verify if programs are in place and measure
their effectiveness
ases the awareness of process
safety throughout a facility, by reviewing
documentation, inspecting facilities and interviewing employees
Incre
Trade SecretsTrade SecretsPssst!Pssst!
Any information needed to comply with PSM must be available
"Sensitive" material may require the signing of a confidentiality
agreement before it is provided
Top
Secret
Benefits of PSMBenefits of PSM
For the Employee reduces chances of being injured by catastrophic releases
For the Environmentreduces chances of loss of containment of Highly Hazardous Chemicals
For the CommunityCreates a sense of security
For the Facility and Equipment...
Increases reliability and reduces unscheduled
downtimeFor the Customer...
Provides a reliable, steady flow of product from a responsible supplier
For the Industry...Contributes to overall
reduction in catastrophic incidents