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14 Tips for Process Safety Management


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Process 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.

Published in: Engineering, Business, Technology

14 Tips for Process Safety Management

  1. 1. Process Safety lack of awareness could be costlier than you thought Are your process safety risks under control?
  2. 2. Inspiring Excellence about the presentation Process 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.
  3. 3. Inspiring Excellence Download your free e-book on Process Safety Click Here You should download your e-book here.. Its free!
  4. 4. Inspiring Excellence Now on the subject: Process Safety
  5. 5. Inspiring Excellence 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.
  6. 6. Inspiring Excellence 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.
  7. 7. Process Safety Management System Input Output Process Resources - Equipment - Infrastructure - Human Resource Controls - Quality / Productivity - Safety 14 Elements of Process Safety Safety Process Management 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
  8. 8. 14ELEMENTS 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
  9. 9. Inspiring Excellence These 14 elements follow a simple management system framework
  10. 10. Inspiring Excellence 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
  11. 11. Inspiring Excellence 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
  12. 12. Inspiring Excellence Process Safety Information:… 2 a compilation of written process safety information that helps to identify and understand the hazards posed by those processes involving highly hazardous chemicals.
  13. 13. Inspiring Excellence 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
  14. 14. Inspiring Excellence • 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:
  15. 15. Inspiring Excellence 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 Analysis identifying, evaluating, and controlling the hazards of processes involving highly hazardous chemicals. …3
  16. 16. Inspiring Excellence 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
  17. 17. Inspiring Excellence 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
  18. 18. Inspiring Excellence 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
  19. 19. Inspiring Excellence 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.
  20. 20. Inspiring Excellence Training: • Initial Training • Refresher Training Training Documentation is important 7
  21. 21. Inspiring Excellence 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
  22. 22. Inspiring Excellence 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
  23. 23. Inspiring Excellence 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
  24. 24. Inspiring Excellence Use of a ‘Problem Solving Technique’ Incident Investigation Incident Accident Near Miss Correction Corrective Action Preventive Action 11
  25. 25. Inspiring Excellence Emergency Planning & Response 12 • Identification of possible emergency situations • Emergency preparedness plan • Training of people • Practice
  26. 26. Inspiring Excellence Compliance Audit 13 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
  27. 27. Inspiring Excellence No requirement to enter into confidentiality agreements to not disclose the information 14 Trade Secret
  28. 28. Inspiring Excellence • 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
  29. 29. Inspiring This is a knowledge initiative About the author: Saikat Is the CEO and Chief Mentor of Verde Ventures, it provides consulting and advisory services in the field of business management. He is heading the company’s technical team. He is a mechanical engineer by profession and worked in manufacturing industries, service industries and engineering infrastructural projects. Saikat has expertise in areas like Sustainability (Occupational Health & Safety, Environment Protection Corporate Social Responsibility) and Business Excellence (Management Systems, , Training and Human Capital Development). Saikat is a trainer, speaker and assessor with 23 years of rich experience in capacity development, training, assessment and certification of more than 800 organisations worldwide. He has worked with 200+ organisations globally on Occupational Health & Safety, Process Safety, Behaviour Based Safety, OHS Management System development, OHS Risk Management and training. Saikat is Lead Tutor for OHSAS 18001 and participated in 300+ safety audits across industries. Saikat can be reached at
  30. 30. Inspiring Excellence What Verde does? Verde 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 techni cal standards and fulfils relevant requirements. Verde 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 Safety, Health & Environment People ExcellenceFood Safety Social Compliance Quality & Business Excellence Information Security Sustainability Risk Management