Process Safety Management

Pertemuan - 4

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 Process Safety Management
Introduction - What is ProcessSafety?
 Process Safety is a disciplined framework for managing the integrity of
operating systems and processes handling hazardous substances by
applying good design principles, engineering, and operatingpractices.

Process safety is everyone’s responsibility

Continuous improvement

A way of thinking and acting

It is aculture

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 Process Safety Management
Introduction - What is ProcessSafety?
 It deals with the prevention and control of incidents that have the
potential to release hazardous materials or energy. Such incidents can
cause toxic effects, fire, or explosion and could ultimately result in
serious injuries, property damage, lost production, and environmental
impact.

 Process safety needs to be considered seperately from occupational

safety.

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 Process Safety Management
Introduction - What is ProcessSafety?
Process Safety is a very common and used topic in the chemical industry.
According to CCPS,an incident is reported as a process safety incident if it
meets all four criteria (process involvement, above minimum reporting
threshold, location and acute release).

Although power plant industry doesn’t handlehazardous chemicals as

much as chemical, petrochemical or refining industry, it has the same
equipments which can be the source of similar accidentssuch as:

Boilers
Tanks
Cooling towers
Reactors
Etc.

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 Process Safety Management
Applicable Standards and Guidelines
 American Occupational Health and Safety Adiministration Process Safety
Management Rule enacted in 1994.
 14 Elements - CSChE- The Canadian Society for Chemical Engineering.
 20 Elements - AIChE CCPS- The American Institute for Chemical Engineers Center
or Chemical Process Safety.
 14 Elements - OSHA 3132 – Process Safety Management
 14 Elements – OSHA 1910.119 – Process Safety Management of Highly Hazardous
Chemicals.
 20 Elements- EU Energy Institute.
 12 Elements - Canadian Societ ChE Eng. Process Safety Management Guide.
 12 Elements - Operational Excellence Expectations CHEVRON.
 14 Elements - Dupont's Process Safety and Risk Management Model DUPONT.

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 Process Safety Management
Applicable Standards and Guidelines
 14 Elements - EXXONMOBIL Operations Integrity* Management System.
 22 Elements - G+System Safety, Health and Environment (SHE) Management
System GALP ENERGIA.
 15 Elements - Health, Safety and Environmental Management System (HSEMS)
ConocoPhillips (previous 2012).
 8 Elements - SHELL HSE MS, SHELL HSSE Management System Manual
(example for Shell Development Australia Pty Ltd).
 8 Elements - OGP Report 210 EP Forum - Guidelines for the Development and
Application of Health, Safety and Environmental.
 13 Elements - Safety & Environmental Management System (SEMS) - Offshore EU
US Bureau of Ocean Energy Management, Regulation and Enforcement's
(BOEMRE) new regulation [30 CFR 250] - API RP 75

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 Process Safety Management
Applicable Standards and Guidelines - Comparison
OSHA ENERGY INSTITUTE AIChE CCPS SEVESO
Employee Staff participation. Staff participation. The organization and staff.
involvement
.
Process hazard Hazards identification Hazards identification and Identification and
analysis. and risk assessment. risk assessment. assessment of major-
accident hazards.

Change Change management Change management. Adaptation of the

managemen and Project modifications.
t. management.

Safety review of Operational availability Operational availability. Exploitation control.

pre-setting up. and start-up processes.

Planning and Emergency Emergency management. Planning of emergency

response against preparednes situations.
emergencies. s.

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 Process Safety Management
OSHA ENERGY INSTITUTE AIChE CCPS SEVESO
Process safety Documentation, records Processes knowledge Exploitation control.
information. and knowledge management.
management.

Contractors. Contractors and Contractors management. The organization and staff.

providers, selection and
management.

Compliance audits. Audit, guarantee, Audits. Monitoring of set

management review and Management review and objectives.
intervention. continuous improvement. Audit and review.
Actions and indicators.

Incidents Incidents investigation Incidents investigation. Monitoring of set

investigation. and investigation. objectives.

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 Process Safety Management
OSHA ENERGY INSTITUTE AIChE CCPS SEVESO
Work permit Work control, work Safe working practices. Explotation control.
(non-routine work permit and risk Planning of emergency
authorizations). management of tasks. situations.

Operating Operating manuals and Operating procedures. Explotation control.

procedures. procedures.

Mechanical Inspection and Mechanical integrity and Explotation control.

integrity. maintenance. reliability.

Employee training. Recruitment, hiring and Training and assurance The organization and staff.
skills and health and performance. Planning of emergency
safety assurance. Competence in process situations.
safety. Monitoring of set
objectives.

- Leadership, commitment Process safety culture. The organization and staff.

and responsibility.

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 Process Safety Management
OSHA ENERGY INSTITUTE AIChE CCPS SEVESO
Trade secrets. - - -

- Identification and Compliance with Explotation control.

compliance with laws standards. Monitoring of set
and regulations. objectives.

- Communication with Communication with The organization and

interested parties. interested parties. staff.

Operating Monitoring of Monitoring of the

procedures. operational variables operation. Explotation control.
Operating and relays.
instructions.

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 Process Safety Management
OSHA ENERGY INSTITUTE AIChE CCPS SEVESO
- Operational - -
interfaces tracking.

- Regulations and - -
practices.

- Management of - -
critical elements for
safety.

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 Process Safety Management
Components of Process Safety Management

Process Safety Information Pre-Start up SafetyReview

Mechanical Integrity
Process HazardAnalysis
Hot-work Permit
Operating Procedures
Management of Change
Employee Participation
Incident Investigation
Training Emergency Planning and
Response
Contractors ComplianceAudits

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 Components of ProcessSafety
Process Safety Information
Tobe assesed in process hazard analysis and management of change,following
information should be considerd:

• Process and instrumentation diagrams (P&I).

• Block or simplified diagrams of the process, flowdiagrams.
• Diagrams of electrical installations.
• A list of critical components.
• Mass and energy balances.
• Acceptable upper and lower limits for variables and any deviationsfrom
variables.
• A safety data sheet of the substances
• The classification of electrical areas.
• Design and layout relief and ventilation systems.
• Specifications for pipes and equipment.
• A description of the interlock and shutdownsystems.

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 Components of ProcessSafety
Hazard Analysis
Hazard identification and evaluation is contemplated at
every stage of the plant’s operations, from the initial
project to the day it is decommissioned. This includes
identifying the potential dangers associatedwith
 Operating conditions
 Start-ups, stops, maintenance and special
situations
 Previous incidents
 Process Hazards

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 Components of ProcessSafety
Hazard Analysis
 Potential accidents and their consequences caused
by;
 Failure of monitoring, controls, alarms,
interlocks, ESD
 Human factors
 External events
 Failure of safety management system

In every 5 years a process hazard analysis should be

developed.

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 Components of ProcessSafety
Operating Procedures
The operating instructions must cover all possible operativestages:

 Start-up
 All phases of normal operations, including testing, maintenanceand
inspection
 Detection ofand response to, departures from normal operating conditions.
 Temporary or special operations
 Operation under maintenance conditions.
 Normal shutdown
 Emergency operations including shutdown.
 Decommissioning

Most of the accidents occur during non-routine operations.

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 Components of ProcessSafety
Operating Procedures
Operating limits:
 Consequences of deviation, and
 Steps required to correct or avoiddeviation.

Safety and health considerations:

 Properties of, and hazards presented by, the chemicals used in theprocess;
 Precautions necessary to prevent exposure, including engineeringcontrols,
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 ofhazardous 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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 Components of ProcessSafety
Employee Participation
Consult with employees and their representatives on the development and
conduct of hazard assessments and the development of chemical accident
prevention plans and provide access to these and other records requiredunder
the standard.

 Develop a written participation plan

 Consult with employees on PHAand PSMdevelopment
 Provide to employees access to PSMinformation

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 Components of ProcessSafety
Training
Ensure contractors and contract employees are
provided with appropriate information and
training.
 Identify the training needs ofemployees
 Identify the trainingperods
 Training plans
 Evaluation of eEffectiveness of training

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 Components of ProcessSafety
Training
Ininital training: PSM requires that each employee
presently involved in operating a process or a
newly assigned process must be trained in an
overview of the process and in its operating
procedures.
Refesher Training: Refresher training must be
provided at least every three years, or more often
if necessary, to each employee involved in
operating a process to ensure that the employee
understands and adheres to the current operating
procedures of the process.

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 Components of ProcessSafety
Contractors
 When selecting a contractor, obtain and evaluate
information regarding the contract employer’s safety
performance and programs. Inform contract employers of
the known potential fire, explosion, or toxic release
hazards related to the contractor’s work and theprocess
 Explain to contract employers the applicable provisions of
the emergency action plan
 Develop and implement safe work practices to control the
presence, entrance, and exit of contract employers and
contract employees in covered process areas
 Evaluate periodically the performance of contract
employers in fulfilling their obligations; and maintain a
contract employee injury and illness log related to the
contractor’s work in the processareas

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 Components of ProcessSafety
Mechanical Integrity
 Written procedures to maintain ongoing integrity of process equipment.
 Establish a quality assurance program to ensure that initial process-related
equipment, maintenance materials, and spare parts are fabricated and
installed consistent with designspecifications

Controls,
Relief and Emergency
Piping sensors,
vent shutdown Pumps
systems alarms and
systems systems
interlocks

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 Components of ProcessSafety
Mechanical Integrity

Elements of a mechanical integrityprogram

Identify & categorizeequipments
Inspections & tests frequency
Maintenance procedures
Training of maintenance personnel
Criteria for acceptable test results
Documentation of manufacturer
recommendations

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 Components of ProcessSafety
Pre-Start Up Safety Review
Prior to start-up or implementation of a significant change, followings should be
checked:

 Any documents which may be affected by the change must have been modified
(procedures, instructions, etc.).
 The staff affected by the change must have been adequately informed/trained.
 The modified procedures must have been made available to the staff affected.
 In the event of changes to the conditions of the activity, the relevant authorisations
must have been issued and the staff affected informed.
 There must be compliance with applicable laws and all the relevant authorisations
and licenses must have been obtained.
 That, where appropriate, findings from completed hazard assessments must be taken
into consideration.
 That all safety systems must be fully operational

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 Components of ProcessSafety
Management of Change
Management of change is key to safe design and maintaining the safe
operations.

Followings are considered as«change»:

Process
Eployees Installations Processes
variables

Materials Equipments Procedures Software

External
Design
conditions

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 Components of ProcessSafety
Management of Change
Written procedures addressing;
 The technical basis for the proposedchange,
 Impact of the change onemployee safety and health,
 Modifications to operatingprocedures,
 Necessary time period for thechange, and
 Authorization requirements for the proposedchange.

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 Components of ProcessSafety
Work Permit
 Non-routine operations
 Sub-contractor activities
 Hot-Work
Risk assessment prior to the work

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 Components of ProcessSafety
Incident Investigation
Investigate every incident that results in or could have
resulted in a major accident in the workplace, with any
findings to be reviewed by operating personnel and
modifications made, if appropriate.
An investigation report must be prepared includingat
least:
 Date of incident,
 Date investigation began,
 Description of the incident,
 Factors that contributed tothe incident, and
 Recommendations resulting from the investigation.

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 Components of ProcessSafety
Emergency Planning and Response
Develop and implement an emergency action plan for
the entire plant. Train and educate employees and
contractors in emergency response procedures.
 Identify the emergencies
 Measures to prevent their negativeconsequences
 Identify the emergency responseteams
 Specific tactical procedures defining how to response
against the different kind ofaccidents
 Evacuation procedures
 Emergency drills
 Review emergency plans

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 Components of ProcessSafety
Compliance Audits
 To be certain process safety management is effective,
employers must certify that they have evaluated
compliance with the provisions of PSM at least every three
years.
 This will verify that the procedures and practices
developed under the standard are adequate and are being
followed.
 The compliance audit must be conducted by at least one
person knowledgeable in the process and a report of the
findings of the audit must be developed and documented
noting deficiencies that have beencorrected.
 The two most recent compliance audit reports must be
kept on file.

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Thank you…

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