Consultivo: Process Safety
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www.consulti vo.in Process Safety lack of awareness could be costlier than you thought Are your process safety risks under control?
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Transcript of Consultivo: Process Safety
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Process Safetylack of awareness could be costlier than you thought
Are your process safety risks under control?
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about the presentationProcess 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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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 OutputProcess
Resources- Equipment- Infrastructure- Human Resource
Controls- Quality / Productivity- Safety
14 Elements of Process SafetySafe
ty
Proc
ess
Man
agem
ent
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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14 ELEMENTS
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:… 2a 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 Analysisidentifying, 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
IncidentAccidentNear MissCorrectionCorrective 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 Audit13
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
14Trade 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 technical 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
RiskManagement
