PSM Process Safety Management

PSM is the proactive and systematic identification, evaluation and mitigation or prevention of chemical releases that could occur as a result of failures in the process, procedure or equipment.

PSM is the application of management control in a way that process hazard are identified, understood and controlled so that process related injuries and incidents can be eliminated.

It involves an in depth knowledge of the materials in the use, the process operation, equipment specification and facilities.

Why Is PSM Process Safety Management Important

It increase safety level at workplace considering to prevent catastrophic event.

It allows the organization to prioritize the safety and well-being of employees.

We believe human life is the most valuable asset and PSM reduces potential risk of staff, public and environment.

It helps to avoid loss of production, valuable asset and down-time.

Along with that it keep away unwelcoming media attention which affect reputation and business.

There are many process related serious incident happened all over the world causing huge damage, life loss and adverse health issues.

Taking a cause of India a way back in 1984 there was release of a toxic MIC (methyl Iso Cyanate gas from a Union Carbide pesticide plant located at Bhopal.

Resulting 2500 deaths and thousands of causalities because the toxic gas cloud drifted to a densely populated area.

several Safety system installed to prevent such an incident were not functioning at the time of releases.

PSM Process Safety Management Divide in Three Parts

The are divided into following categories technology, facilities and personnel.

Technology	Facilities	Personnel
Process safety information	Work permit	Training and performance
Process hazard analysis	Prestart-up safety review	Employee participation
Operating procedure and safe practices	Mechanical integrity	Incident investigation
Management of change	Quality assurance	Trade secrets
		Contractors management
		Emergency planning & response
		Compliance audit

1. Process Safety Information-PSI

Process safety information provides about hazard of materials, process design basis , equipment information.

Hazard of material

MSDS is the basic document used to know the hazard properties of material used in process.
MSDS provide information about fire hazard, health hazard, reactivity, stability of material, compatibility with metals and non-metals, compatibility with other chemicals.
Permissible exposure limits, toxicity, disposal consideration and transportation information.
Tool box talk on handling material as per MSDS, loose solvent handling permit are the ways of communicating hazard of material to all employees involves in an activity.
PSI package include various studies to know the hazard associated with process like oxygen balance and heat of reaction calculation, criticality call reaction, gad evaluation data, TSU data, ARC data, chemical and thermal hazard summary, negative study report.

Process design basis

Process design documentation describe the basis for safe operation of a process. It defines both the boundaries of the safe operation and testing limits of process variables.
The process designed basis is documented, maintained and communicated to technology transfer team from R&D.
Example of process technology documents are :
- Block Flow Diagram
- Standard Operating Procedure
- Negative Study Reports

Equipment Design Basis

It determines PSM critical equipment and describes key equipment design data. Identifies PSM critical equipment, components or systems that contain hazard materials as identified by process.
Failure of the PSM critical equipment, component or system could lead to the release of hazard material or energy.
Considered during mapping equipment for process :
- GAD drawing
- Material of construction
- Filling capacity
- Design pressure
- Vent sizing
- Heating and cooling load
- Relief system design
- Overfilling protection
- Inertization calculation
The equipment design basis is documented & maintained with site engineering team and controlled P&ID which contains information about equipment design basis is available with plant.

2. Process Hazard Analysis- PHA

PHA is used methodically to identify , evaluate and develop method to control significant hazard in the process.
The completed PHA is used to follow up accepted recommendation and to communicate to affected personnel.

Features

This is an effective tool for identifying evaluating and controlling hazard in the lifecycle of a process.

It include the following steps :

Hazard identification
Consequence analysis
Hazard evaluation
Identification of existing safe guard
minimizing the risk
Hierarchy of risk control

Method Of PHA

Hazop study
- Hazop team member
- Role and responsibility
- Document require for Hazop study
- Consideration for Hazop study
- Acceptable residual risk
The basis of Hazop is a Guide word examination which is a deliberate search for deviation from the design intent.
Step are following for Hazop study :
- CFT meeting with R&D team, Technology transfer team, Production, detailed engineer, site head conducted by PSM Hazop team member to know about process, critical parameter and associated hazard with process, suitability of facility.
- Project manager, Technology transfer & Technology service initiate the Hazop study after receiving controlled P&ID and SOP from DMS system.
- Hazop team defines scope and objectives of the study.
- Hazop team conduct study considering guide words & deviations of process parameter. Safe guard & recommendation are noted to bring the risk to acceptable level.
- After compliance of recommendation, facility manager call PSSR representatives for verification to ensure all the safe guard and recommendation from Hazop study are implemented and to provide the Hazop verification certificate for 100% compliances.

Hazard Identification

Hazard are characteristics of material and chemistry used.
Example : Flammability, Toxicity, Reactivity etc.
Like the way the chemistry works in the process example : Pressure, Temperature, concentration etc.
Reactive hazard identification includes desktops scanning, thermal stability study like TSU study, RC study, Powder safety study.

Consequence analysis

List types of event that might occur from the hazard.
Example : Fire, Explosion, Toxic release, Environmental impact, health hazard and impact on community.

Hazard Evaluation

Hazard evaluation is done by risk matrix adapted and bring the risk at acceptable level.

Strategies to address the hazard and reduce the process risk are (IPAP)

Inherent : Eliminate the hazard by using non-hazardous materials and process conditions.

Passive : Reduce risk by process and equipment design features that frequency or severity without the active functioning of any device such as robust vessel design, containment and drainage, blast resistant construction, ATEX.

Active : Use control, instrumented protective system and other devices such as safety relief valves for responding to abnormal situations or lessen the loss event impacts.

Procedural : Use operating procedures, checks, emergency response and other management approaches to prevent or minimize the effect of an accident. example: hot work permit, emergency plan.

Documentation And Communication

Prepared Hazop report consist detailed about :

P&ID
Raw material & their quantity
Nodes considered during Hazop study as per SOP
Engineering calculation
References safety data
Key engineering control

Hazop report shared with all team member fro production, detailed engineering, R&D and site head for further action.

3. Operating Procedure

Operating procedure provide a clear understanding of steps and parameter for safe operation of those who are performing activity.
Safe practices provide a carefully planned system of procedures and permits involving checks and authorization prior to doing work in process. For routine activities, SOP’s And Log sheet.
All routing activities are governed through permit system or JSA Or Checklist. All activities routine and non-routine are carried in close supervision of employee.
Example of work permit are :
- Height work permit
- Hot work permit
- Loose solvent handling permit
- Confined space permit
Operating procedures provide the foundation of operator training. The procedure and training go hand in hand, supporting one another, For an operating procedure to be effective, it must always be updated.
Once an operating procedure is firmly established as the path to safe operation, complete with personnel trained to the point that the procedure and the field practice are consistent with each other, then no change in technology, facilities or procedures can be permitted until the operating procedure is properly updated and authorized and until personnel have been trained in the proposed change.

4. Management Of Change -MOC

All the changes related to process, equipment, process parameter, change in batch etc, are implemented through CIGMA system with site head approval after doing risk assessment of change.
All process related changes like in batch size, process parameter, change in process are carried out through process upgradation. Lab trials are required to any change under process upgradation.
All engineering related change like change in equipment, change in MOC of equipment & piping are carried out under modification work order for existing product.
For new molecule /product required changes are implemented through capex & change request form.
Change in interlock, like level indicator interlock with receiving line XV are under interlock change request form.
- Purpose for change
- Technical purpose for change
- Safety, health, environment purpose for change
- Interlock change
- Process related change
- Purpose for Modification change
- Process related change

5. Mechanical integrity

New equipment purchase is in accordance with the design specification from the vendor, through specification data sheet by DE team for capex project and by engineering team for site specific project.

Only factory acceptances tested equipment are installed.

Equipment facility map is specified by asset planning department considering suitability of process and raw material.

Engineering team is responsible for assembled and installation of equipment properly.

Preventive maintenance of equipment is as per schedule by maintenance department.

PSM critical equipment list is available with maintenance department and it is a part of preventive maintenance schedule.

Equipment specification data sheet is finalized by DE team and site local engineering team and plant manager & maintenance team.

Mechanical personnel are trained in an overview of the process specific safety and hazard applicable to their job.

Equipment critical to process safety include but is not limited to :

Pressure vessels and tanks
Piping system and valves
Relief and vent systems
Emergency shut down systems
Control, alarms and interlocks

6. Prestart-up safety review (PSSR)

After Hazop study, PPSR representative with production team member ensure all the recommendation of HAZOP study are implemented and updated in P&ID and sop.

Control P&ID and SOP which are uploaded in DMS system used for PSSR.

PSSR representative issue compliances certificate after compliance of all recommendation from HAZOP sheet.

In case of an recommendation requires time for compliance, deviation is raised by production plant manager and approved by site head. Then PSSR PSM representative issues compliances certificate with deviation.

All pending HAZOP recommendation are tracked by PPSR representative till their compliances and track report is shared with the concern team.

7.Training

Properly trained and performing personnel are a requirement for keeping process equipment and machinery safely.

Employees must also be physically able, mentally alert and capable of using good judgement to properly follow prescribed practices.

All other element of PSM can be in place but without properly trained and performing personnel the chances of safe process operation are greatly diminished.

Many serious incidents cause due to lack of adequate training.

Considering importance of manpower empowering on field and class room training conducted on various process safety topic like PSI information, PSM induction training conducted by PSM team regularly.

8.Contractors

All tasks must be completed safely and performed in accordance with established procedure and safe work practices, consistent with principle of good PSM whether the task completed by site personnel or contract personnel.

The use of contractor in industry has increased over the past decade.

The safety and training of contractor employees have at times been below standard and have resulted in accident and injuries.

Injuries to contractor employees have involves the site owner in costly litigation and in some cases substantial settlements.

Contractor employees about hazard associated with activities and fire & explosion hazard through training and mock drills.

Contractor induction training & its evaluation method during the joining of contractor employee to increase his knowledge and understanding of hazard and safe work practices.

Tool box talk and shop floor training are conducted on regular basis to inform contractor of safety rules, procedures and practices.

9.Incident Investigation

Serious and serious potential incidents are likely to recur unless key factor are identified and corrected.

Aggressive and persistent investigation of all serious potential incident is necessary to continuously improve safety performance.

When incident investigation are handled as a search for fact, the entire organization is more likely work together.

A climate of openness is achieve the success.

Fact finding phase is :

Take samples of spills. vapors, residues and other relevant materials.
Preserve accurate depiction of scene (photograph, video , sketches).
Obtain on the spot information from the eyewitness interviews.
Examine key mechanical equipment as it is disassembled.
Conduct metallurgical tests.
Develop detailed chronology of event that occurred before during and after the incident.

To determine key factor which contributed to incident man, machine, material, method, measurement, environment principle during accident investigation.

To find appropriate root cause of failure, victim/ first response person is a part of the incident investigation process.

After investigation report finalize & approved by site leadership team, recommended preventive and corrective actions are implemented by responsible person within targeted date and safety team tracks it till its compliance.

10. Emergency planning and response

In depth planning is required for potential emergency so that an effective response by the site the local community can mitigate the impact on people, environment and facilities.

A written emergency response plan for the entire site is available for mitigation of the potential consequences arising of the emergency situation.

Emergency plan features :

Nature of business &hazard associated with it.
Name of product and chemical storage information at site.
Role and responsibility of site controller, emergency response team member, incident controller, ERT leader, adviser to incident controller, member of environment monitoring team, medical assistance, media communicator.
Emergency response plan updated every 2 year or as per requirement.
Quarterly mock drill training are conducted at site to increase awareness and identify the gaps.
Monthly siren testing is conducted to ensure healthiness of emergency siren system.
Fire hydrant system and fire extinguisher testing is done by fire department on monthly basis.
Fire tender facility is checked quarterly & maintenance is done by third party persons annually.
Local nearby hospital are tied up to handle the emergency cases.
ERT team is available on site for handling of any emergency.
Training on emergency response plan is a part of induction training.

11. Audit

Auditing provides a measurement of compliance with the established PSM program. Field observations yield data for determining performance against established standards.

An audit is an examination and verification that the PSM system is indeed carried out as stipulated in corporate department, plant and government directives.

It is not enough to establish a PSM program and then assume it will function as implemented.

All element of PSM audited by site and corporate management once in year and responsible care audit in which element are audited by respective authority every three years.

Positive feedback is included on significant strengths as well as corrective feedback on areas requiring improvement.

Line of action prepared and implemented against the corrective feedback to strengthen the PSM implementation at site.

Conclusion

PSM process safety management is the application of management controls to identify, understand and eliminate process hazard related injuries and incident.

The 14 key element of PSM when implemented satisfactory achieve process control through hazard identification, risk analysis and assessment and risk mitigation.

The PSI package generally consist of three parts like process chemicals, process technology and process equipment.

PHA is used to identify, evaluate and develop method of parameter significant hazard in the process.

Operating procedure provide a clear understanding of parameter for safe operation.

Internal SOP for Hazop study provides information about Hazop team members are their roles and responsibilities, documents required and risk matrix consideration for Hazop and acceptable residual risk.

Once the Hazop study for a new or modified facility has been completed a prestart-up safety review is to be conducted by the PSSR representative along with the production team member to ensure all the recommendation of Hazop study are implemented and updated in P&ID and SOP.

Controlled P&ID and SOP are updated in DMS system used for PSSR.

A comprehensive mechanical integrity program ensure the system integrity to contain hazardous materials and should be maintained from initial installation to the life of the facility.

PSM greatly enhances safe operation with properly trained and performing personnel.