Process Saf Mgt

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Topic 3

Process Safety

Management

1



Industrial Safety

2



Process Safety Management

PSM is a performance (not specification) standard prevent or

minimize the consequences of catastrophic releases of chemicals

that are:

•

Toxic

•

Reactive

•

Flammable

•

explosive



Process Safety Management (PSM)

PSM is the proactive identification,

evaluation and mitigation or

prevention of chemical releasesthat could occur as a result of

failures in processes, procedures,

or equipment.



PSM Standard

1. Process SafetyInformation

2.

Process HazardAnalysis

3. Operating Procedures

4. Training

5.

Contractors

6. Pre-startup Safety

Review

7. Mechanical Integrity

8. Hot-work Permits

9.

Management of Change

10. Incident Investigations

11. Emergency Planning &

Response

12.

Compliance Safety

Audits

•

29 CFR 1910.119 - OSHA’s Process Safety

Management Standard



Application

Highly Hazardous Chemical processing where – Toxic or reactive chemical(s) are present in

processes at or above a listed threshold quantity(Appendix A Material)

–

Flammable liquids or gases are present inprocesses in quantities 10,000 pounds and above

– Explosives or pyrotechnics are manufactured

6



Chemical Name CAS # TQ (lbs)

Ammonia, Anhydrous 7664-41-710000 10,000

Chlorine 7782-50-51500 1500

Hydrogen Sulfide 7783-06-4 1500

NOTE: 1500 lbs. of Hydrogen Sulfide = 16,760 ft 3 at NTP

NTP – Normal Temperature and Pressure - is defined as air at

20oC (68°F) and 1 atm (14.7 psia, 0 psig, 30 in Hg, 760 torr)

STP – Standard Temperature and Pressure - is defined as air at

0oC ( 32oF) and 1 atm (14.7 psia, 0 psig, 30 in Hg, 760 torr)

Appendix A Examples



Exclusion

An employer is exempted from the requirements of PSMwhen:

–

HC fuels used only for workplace consumption and if not a

part of a covered hazardous process

• (e.g., propane used for comfort heating, gasoline for vehicle refueling

–

Flammable liquids stored in atmospheric tank or transferredbelow NBP w/o chilling or refrigeration

–

Retail facilities

–

Oil, gas well drilling or servicing operations

–

Normally unmanned remote facilities



1. Process Safety Information

• Chemicals

–

Toxicity, PEL, Physical Data, Reactivity and Corosivity,Thermal and Chemical Stability, Effects of Mixing Chemicals

• Process

–

Block flow or process flow diagram, Process chemistry,Maximum intended inventory, Safe upper/lower limits for

such items as temperatures, pressures, flows or

compositions, Consequences of deviations, e.g. runaway

reaction potential

• Equipment –

Materials of construction, P&IDs, Electrical Classification,Relief system design & design basis, Ventilation systemdesign, Design codes and standards, Material & energybalances, Safety systems



2. Process Hazard Analysis

•

Systematic effort to identify and analyze the significance of

potential hazards associated with the processing or handling of highly hazardous chemicals

– PHA METHODS: What If?, Checklist, What If?/Checklist, HAZOP,FMEA, FTA etc

•

PHA focuses on Equipment, Instrumentation, Utilities, Human

Actions, External Factors•

PHA Must address Hazards of the process

– Engineering & administrative controls

–

Consequences of failure of controls

– Facility siting, Human factors

–

Evaluate potential effects to on-site personnel from failure ofcontrols

– Identification of previous incidents



3. Operating Procedures

•

Provide clear instructions for safely conducting activities

involved in each covered process consistent with the processsafety information

• Address at least the listed elements

•

Operating procedures readily accessible

•

Reviewed as necessary to reflect current procedures and

changes

• Certified annually as current & accurate

•

Develop & implement safe work practices to provide for thecontrol of hazards during operations, e.g. lockout/tag out/confined space entry, opening equipment & pipes, facility entry

•

Apply to employees & contractor employees

•

Steps for each operating phase (start up, operation, shutdown)

•

Operating limits

•

Safety and health considerations



4. Training

•

Process overview

•

Process hazards

• Operating procedures

• Emergency procedures

• Refresher training at least every 3 yrs

• Documentation



5. Contractors

•

Employer’s Responsibility

–

Evaluate contractor’s safety performance & programs

– Inform contractor of potential hazards: fire, explosion, toxic

release, applicable plant safety rules

– Develop/Implement safe work practices

– Evaluate contractor performance

•

Contractor Responsibilities

– Advise employer of any unique work hazards of contracted work

– Each employee follow all applicable work practices & safety rulesof the facility

–

Ensure each employee is trained in necessary work practices

–

Ensure each employee is instructed in known fire, explosion, ortoxic release problems related to his/her job

– Document that understanding of training has been evaluated,

verified



6. Pre-startup Safety Review

•

Done when: –

New processes

–

Modified process

•

Pre-startup Review Verifies

–

Construction: conforms to design –

Procedures: adequate, in place

–

PHA recommendations resolved or implemented

– Management of change requirements met

–

All affected workers trained



7. PSM Mechanical Integrity

• Pressure vessels, storage tanks, Pumps, Piping

systems & components, Relief & vent systems,devices, Emergency shutdown systems

• Controls: monitoring devices, sensors, alarms,interlocks

•

Written procedures• Training: process hazards, job tasks

• Inspections

• Testing

•

Corrective action

• Records



8. Hot Work Permits

•

Welding, cutting, brazing• Control of ignition sources

• Verify safe conditions

• Authorization



9. Management of Change

• Establish written procedures

•

Develop management support

•

Evaluate safety of any changes to:

– process chemicals facility

–

technology equipment

•

MOC Procedures Must Address

–

Everything except “replacement in kind”

–

Temporary as well as permanent changes

–

Technical basis for change

–

Safety & health effects –

Modified operation procedures

–

Time necessary for change

–

Authorization for change

–

Ways to inform & train workers before change



10. Incident Investigation Goals

• Goals

–

Identify incident causes and implement steps to prevent

reccurrence

• Implementation

–

Every incident

–

Prompt investigation –

Knowledgeable team

–

Documentation & report

– Recommendations & findings

–

Resolutions & corrective actions



11. Emergency Planning Response

• Develop Emergency Action Plans

• Pre-plan for catastrophe

• Train & equip workers

• Drills



12. Compliance Safety Audits

•

Certify all elements of standard• Knowledgeable audit team

• Report & recommendations

• Address all finding & recommendations

•

Conduct every three years



Appendices

A: List of chemicals

B: Sample block & flow diagrams

C: Compliance guidelines

D: References

Each of the 20 elements of Risk Based Process Safety is fullydescribed in the CCPS Guidelines book: Guidelines for Risk Based

Process Safety, Wiley, 2007, ISBN 978-0-470-16569-0.



22

C o m m

i t m e n t t o P S M

U n d e r s t a n d H a z a r d s

a n d R i s k

M a n a g e R i s k

L e a r n

f r o m E x p e r i e n c e

PSM Structure



23

Commit to Process Safety

•

Process Safety Culture• Compliance with Standards• Process Safety Competency• Workforce Involvement• Stakeholder Outreach

Understand Hazards and Risk

•

Process Safety Information•

Hazard Identification and Risk Analysis

Manage Risk

•

Operating Procedures•

Safe Work Practices•

Asset Integrity and Reliability•

Contractor Management•

Training and Performance

Assurance• Management of Change• Operational Readiness• Conduct of Operations• Emergency Management

Learn from Experience

• Incident Investigation• Measurement and Metrics• Auditing• Management Review and

Continuous Improvement

Risk Based PSM Framework



24

PSM Structure

•

Each of the 20 elements of Risk BasedProcess Safety is fully described in the CCPS

Guidelines book: Guidelines for Risk BasedProcess Safety, Wiley, 2007, ISBN

978-0-470-16569-0.

•

A better understanding of process safety may

be acquired through a participative workshop

with other professionals.



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Engineering Discipline Involvement

CHEMICAL

Process selection

Operating

conditionsSafe operating

envelope

Process design

Process control

Safeguards

Monitoring

CIVIL

Site layout

Elevated

structuresGrading

Drainage

Buildings

Facility siting

Infrastructure

MECH

Pressure

envelope

design

Rotating

equipment

Codes

Monitoring

ELECTRICAL

Reliable power

Arc flash

protectionArea

classification

Grounding

bonding

GFIs



Summary

PSM is proactive and systematic identification,

evaluation, and mitigation or prevention of

chemical releases that could occur as a result

of failures in process, procedures, orequipment.

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END OF

SECTION 1.3

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Process Saf Mgt

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