Introduction to PSM Online Interactive Training

Introduction to Process
Safety Management
Training
JOSEPH SURESH
HAZOP/LOPA Chairman & QRA Specialist -
Process Safety Consultant And HSE Trainer
info@ifluids.com www.ifluids.com

• What is meant by Process Safety Management
• Difference between Occupational safety and Process safety
• Brief History- PSM
• Elements of Process Safety Management (OSHA, CCPS-RBPS, OISD)
• Elements Relevant to Major industries like Refineries
• Brief introduction to each element and How they can be implemented

DEFINING PROCESS SAFETY
Let’s Split the Terms

PROCESS
PROCESS:
Any activity or combination of activities concerning the use,
storage, manufacturing, handling and movement of
hazardous substances

SAFETY
SAFETY:
Safety is a Quality of Mind – Being and Feeling
Safe
You can feel Safe due to the
• Systems present
• Technology
• Equipment
• Procedures
• Practices
• People
• Experience, etc.,

WHAT IS PROCESS SAFETY?
A blend of Engineering, Management and
Operational Skills focused on preventing
catastrophic incidents particularly explosions,
fires and toxic releases associated with the use
of chemicals and petroleum products

How is PSM different from
Occupational Safety ?
Process Safety:
Pro-active and centered on the safety integrity of the process towards
accident prevention.
Occupational safety:
Focuses more on injuries to workers – i.e., very much a Reactive focus.

What is PSM
Process Safety
Management ?
• Proactive Identification, Evaluation & Prevention
of
• Containment ( Material/Energy) loss
in
• A Chemical Process
due to
• Process/Equipment /Components
Failure

WHY PROCESS SAFETY ?

Several catastrophic accidents have occurred, resulting in
loss of life and significant property damage.
Union Carbide: Bhopal, India (Dec 1984)
Chernobyl: Ukraine (April 1986)
Piper Alpha: North Sea (July 1988)
BP: Texas City, TX (Mar 2005)
Deepwater Horizon: TX (April 2010)

PSE – Process Safety Events involving fires,
explosion, or toxic releaseBP Texas Refinery, 2005
https://www.youtube.com/watch?v=QiILbGbk8Qk
https://youtu.be/goSEyGNfiPM
https://youtu.be/3RFDKpwdbEA

INDIFFERENCE
➢Okaaaay !
➢You think that will happen
again? Here?
➢Incidents happen on an off-
chance. They don’t repeat
➢We have better systems.
Don’t we?
➢We run better.

Human
Impacts
• Consumer Injuries
• Community Injuries
• On-site Personnel Injuries
• Unit Personnel Injuries
• Loss of Employment
• Psychological Effects
Environ.
Impacts
• Off-Site Contamination
• Air
• Water
• Soil
• On-Site Contamination
• Air
• Water
• Soil
Economic
Impacts
• Property Damage
• Inventory Loss
• Production Outage
• Poor Product Quality/ Yield
• Lost Market Share
• Legal Liability
• Negative Image
ADVERSE
CONSEQUENCES

Iceberg Safety Theory

PSM Rules -1992
After series of serious accidents ( like Bhopal gas Tragedy & Piper alpha,
North Sea ) that occurred in 1980’s , OSHA developed Process Safety
Management rules in 1992.
These rules made mandatory for Chemicals handling , storing /processing
chemicals above a Threshold quantity.

RULES & LEGISLATIONS
▪ U. S. Occupational Safety & Health Administration (OSHA) PSM RULE 29CFR 1910.119,
1992
▪ COMAH (UK)
▪ U. S. OSHA 3132: Process Safety Management
▪ American Institute of Chemical Engineers (AIChE) Center for Chemical Process Safety
(CCPS): Process Safety Leading & Lagging Metrics, 1998
▪ UK Health Safety Executive (HSE) Guidelines HSEG254: Developing Process Safety
Indicators, 2006
▪ API 754: Process Safety Performance Indicators, 2008
▪ OISD STD-206: Guidelines for Safety Management System in the Petroleum Industry
▪ CCPS Guidelines for Risk Based Process Safety

EFFECT ON BUSINESS
Top
Event
HSE CRITICAL
TASK
THREAT
CONSEQUENCE
Hazard
CONTROL
BARRIERS
RECOVERY
MEASURES
HSE CRITICAL
ACTIVITY
Supervisor Staff
Competency
STANDARDS &
PROCEDURES
INPUTS
OUTPUTS
KPI
REPORTS
Business Activities
Design&
Construction
Operations
Maintenance
Inspection

An effective Process Safety Management Program requires a
systematic approach to evaluating the whole chemical process.

HOW?
The OSHA PSM Rule introduced the concept of PSM through Elements.
1. Process Safety Information (PSI)
2. Operating Procedures (OP)
3. Training (TRG)
4. Contractor Safety Management (CSM)
5. Hot Work Permit (HWP)/safe work practices
6. Process Hazard Analysis (PHA)
7. Management of Change (MOC)
8. Pre-Startup Safety Review (PSSR)
9. Mechanical Integrity (MI)
10.Incident Investigation
11.Emergency Planning and Response (ERP)
12.Employee Participation
13.Compliance Audits (CA)
14.Trade secrets

PSM ELEMENTS
OSHA PSM RULE (1910.119)

CCPS-RBPS PSM ELEMENTS
Commit to Process Safety
• Process safety culture
• Compliance with standards
• Process safety competency
• Workforce involvement
• Stakeholder outreach
Understand Hazards and Risks
• Process knowledge management
• Hazard identification and risk analysis (HIRA)
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
• Measurements and metrics
• Auditing
• Management review and continuous
improvement

OISD-GDN-206
1. Safety Organisation
2. Employees Participation
3. Process Safety Information
4. Process Hazard Analysis
5. Operating Procedures
6. Training
7. Contractors
8. Pre-startup Safety Review
9. Mechanical Integrity
10. Work Permit
11. Management of Change
12. Incident Investigation and Analysis
13. Emergency Planning and Response
14. Compliance Audit
15. Occupational Health
16. Off-the job Safety
17. Customers and Products
18. Road Transportation
19. Trade Secrets

PSM elements
1.Safety organization
2.Employee Participation (EP)
3.Process Safety Information (PSI)
4.Process Hazard Analysis (PHA)
5.Operating Procedures (OP)
6.Training & competency
7.Contractor Safety Management (CSM)
8.Pre-Start Up Safety Review (PSSR)
9.Mechanical Integrity (MI)
10.Work Permit System (HW&WPS)
11.Management of Change (MOC)
12.Incident Reporting & Investigation System (IRIS)
13.Emergency Response Planning (ERP)
14.Compliance Audit (CA)
15.Measurement and metrics (Management Review)

PSM Elements Cross
Functional Team
- KICK OFF MEETING
PSM cell NRL

PSM Benefits
• Ensuring Safe Workplace for Workers.
• Reduces Risk to nearby community.
• Reduces Risk to adverse environment impact.
• Increase assets reliability with Reduced downtime &
losses.
• Reduction in Insurance Premium.
• Business management with better controls.

RE-VISIT PSM ELEMENT– Why ?
The protective
barriers are nothing
but PSM Elements
Holes are Gaps in
systems/procedures
execution
When “Holes” aligns, Hazards turns into Accidents.
WEAKNESSES
OR HOLES
PROTECTIVE
BARRIERS
ACCIDENT
Hazards

1. Safety Organization
•Safety Policy
•Safety promotion
•Safety committee
•Enforcement of safety

Safety Culture
35

Keys for Success
36

Management
Commitment
• Managers and supervisors set the tone
for your safety culture. The leadership
team MUST “talk the talk” AND “walk the
walk.”
• The leadership team allocates resources
– people, time, and invests money in their
teammates, demonstrating their
commitment to safety. Leaders know that
safety adds value to the company.
• Fastest way to destroy a safety culture’s
credibility is through a leadership team’s
disregard for the safety rules.
37

Communication
• Build TRUST! Do what you say
• Ensure timely and appropriate responses to
identified hazards.
• Proper safety techniques and procedures training
• Celebrate the successes along the way!
38

Continuous Improvement –
Are we better than we were yesterday?
39
➢ Continuously review your own policies and
procedures, especially after an incident.
➢ Re-train your teammates when
deficiencies have been corrected.

40

41

You just checked into your hotel, round the corner to head towards your
room, and you see a guy standing on a bucket on the top rung of a
ladder.
What do
you do?
42

You see the General Manager of your company walking across
the production floor and he is not wearing all of his PPE.
What do you do?
43

2.Employee
Participation
Provide Input on process
Consult with employees on process
Data available to employee
Training

Employee
Participation
• Standard operating procedures
• Checklist for start/shutdown/critical operations
• Safety observation
• Safety suggestion
• Hazop/LOPA (MOC)
• Permit audit
• Day/shift verification of KPI(process)
• Preparation of Job safety analysis for critical
activities, confined space, hot work
• Confined space identification and document
preparation
• Training
• Process safety information gap analysis (monthly)
• Safety Logbook
• Safety Meeting of each group of Plant

3.PROCESS SAFETY
INFORMATION

4.PSM Element – Process
Hazard Analysis

❑One of the most important elements
❑IDENTIFY and ANALYSE significance of POTENTIAL HAZARDS
associated
❑Analyses potential CAUSES and CONSEQUENCES of Process
Incidents
❑Reduces consequences of accidental releases of hazardous chemicals.
❑Focuses on equipment, instrumentation, utilities, human actions (routine
and non-routine), and external factors that might affect the process.

❑There are multiple PHA methodologies/ techniques out there, viz.
➢Checklists
➢What-if Analysis
➢Hazard Identification (HAZID)
➢Hazard and Operability Study (HAZOP)
➢Failure Mode and Effects Analysis (FMEA)
➢Event Tree Analysis
➢Fault Tree Analysis
➢Layer of Protection Analysis (LOPA)/SIL
➢Quantitative Risk Analysis (QRA)
Conceptual
Design
• What If Analysis
Preliminary
Design
• What If &/
• Checklist
Final Design
• HAZOP
• FMEA
• Fault-Tree Analysis
Management of
Change
• What If
• HAZOP
Decommissioning
• What If Analysis

5. Operating Procedures

OPERATING PROCEDURES
❑Describes:
• Tasks to be performed,
• Operating conditions to be maintained,
• Safety and health precautions to be taken.
❑Need to be:
• Technically accurate,
• Understandable, and
• Revised periodically to reflect current operations
• It should be readily accessible to employees
❑Should be Reviewed Annually by Plant Operations Team
CSB Video-15 min
https://www.youtube.com/watch?v=rjxBtwl8-Tc&feature=player_embeddedinfo@ifluids.com www.ifluids.com

✓ INITIAL START-UP AND NORMAL START-UP
✓ NORMAL OPERATIONS, EMERGENCY OPERATIONS
✓ NORMAL AND EMERGENCY SHUT-DOWN
✓ TEMPORARY OPERATIONS
✓ OPERATING LIMITS AND CONSEQUENCES OF DEVIATION
✓ HAZARDS PRESENTED BY THE PROCESS
✓ INCLUDE SAFE WORK PRACTICES
✓ LOTO, CONFINED SPACE, CONTROL OVER ENTRANCE TO FACILITY, ETC

6. WORK PERMIT SYSTEM
/SAFE WORK PRACTICES
CSB video-11 Min
https://www.youtube.com/watch?v=PqskpvPejeU

Safe Working Practices (WPS)
➢Safe working practices provides a carefully planned system of
procedure and/or permits involving checking and authorizations
prior to executing non-routine work in progress areas for :
▪ Hot work
▪ Vessel Entry (confined Space)
▪ Heavy lifts & crane operations
▪ Vehicle access
▪ Scaffolding, Excavations etc.

7. Contractor Safety
Management

Contractor Safety Process
▪ Tendering
▪ Pre-Selection & Bidding
▪ Contractor Evaluation – Checklist
▪ Selection – Vendor Presentations including procedures and safety requirements,
Safety Officer evaluation
▪ Field Deployment – Induction Training (to all), Fire Training, Tool-Box Talks, Spot
Training - Skill Development Centre for contractors' supervisors and workers
▪ Performance Evaluation – Checklists, Appreciation, Monthly Performance
Reports, Audits, Violations, Disciplinary Action
▪ Appraisal for extension
▪ Contractor Safety Audits

8.Training &
Competency

▪ Induction Training
▪ Job specific training including safe work practices
▪ Refresher training
▪ Keep training records .

❑Evaluate training programs periodically to see if
necessary skills, knowledge, and routines are
properly understood and implemented.
❑Ensure that employees, including maintenance and
contract employees, receive current and updated
training.
If changes are made to a process, affected employees must
be trained in the changes and understand the effects of the
changes on their job tasks.

Training – PSM Awareness
For knowledge sharing:
❑Safety Moment – Every Meeting
❑CCPS Beacons
❑Key Incident Learnings
❑Process Safety Incident Videos
❑Concept Videos
❑SLIPS (Simple Learnings in Process
Safety)

9.Management of
Change

▪Definition of “Change”
✓Any Change/Modification in Machine, Material and Method.

MANAGEMENT OF CHANGE (MOC)
➢Change includes all modifications to equipment, procedures,
raw materials, and processing conditions other than
"replacement in kind”.
➢Changes in process technology can result from changes in:
➢production rates,
➢new equipment, new product development,
➢change in catalysts, and
➢changes in operating conditions to improve yield or
quality.

➢Equipment changes can be in:
✓materials of construction,
✓equipment specifications,
✓alarms and interlocks.
➢Establish means to detect both technical and mechanical changes.
➢Where the impact of the change is minor and well understood, a check list
reviewed by an authorized person, with proper communication to others
who are affected, may suffice.
➢For a more complex or significant design change, however, a hazard
evaluation procedure with approvals by operations, maintenance, and
safety departments may be appropriate. -> HAZOP/ HAZID based on Risk
Ranking

Changes in documents, as below, should be noted so that
these revisions can be made permanent when the drawings
and procedure manuals are updated.
Copies of process changes must be kept in an accessible
location to ensure that design changes are available to
operating personnel as well as to PHA team members when
a PHA is being prepared or being updated.

Change of Personnel
(OISD-GDN-178)
❑ Introduction of new personnel may introduce new hazards.
❑ Each employee shall be trained in an overview of the process and in
the operating procedures BEFORE field deployment
❑ Training shall emphasize on specific safety and health hazards,
emergency operations including shutdown, safe work practices
applicable to employees' job task.
❑ The employer shall ensure that each employee involved in operating
a process has received and understood the required training. -
COMPETENCY
❑ A record shall be prepared containing the identity of the employee,
date of training and the means used to verify that the employee
understood the training.

10. Pre-Start up Safety Review

Pre - Startup Safety Review
▪ PSSR facilitates the safe transfer of projects from the construction stage to
operation stage.
▪ A PSSR must be performed for new facilities and for modified facilities.
▪ PSSR must confirm that :
• Construction and equipments are in accordance with design specifications;
• Safety, operating, maintenance, and emergency procedures/system are in
place and are adequate.

➢Follow-up PHA Reviews/ HAZOP Recommendations
➢Field Rounds – Technical HSE Site Reviews
➢Document Reviews
➢Specific Equipment/ Loop – detailed Checklists
➢Punch Points
➢Cat. A = “HOLD”. Complete before commissioning
➢Cat. B = complete parallel to commissioning;
➢Cat. C = complete after commissioning as per agreed upon
action plan
➢Resolution of Punch Lists - Monitoring & Tracking Implementation

11. Mechanical Integrity

❑Is a “Breakdown” Philosophy used?
❑Requires that a Mechanical Integrity Program be in place to ensure the continued integrity of process
equipment.
❑Elements of a mechanical integrity program include:
➢ Identifying And Categorizing Equipment And Instrumentation,
➢ Inspections And Tests And Their Frequency;
➢ Maintenance Procedures;
➢ Training Of Maintenance Personnel;
➢ Criteria For Acceptable Test Results;
➢ Documentation Of Test And Inspection Results; And
➢ Documentation Of Manufacturer Recommendations For Equipment And Instrumentation.

12.Incident Reporting &
Investigation System

▪ Each credible incident must be investigated
Incident Reporting and Investigation System

➢ Incident Reporting & Investigation System (IRIS)
➢ Online Reporting
➢ Incident categorization based on consequence matrix
➢ Investigation Team & Reporting times dictated based on Incident Levels
➢ Identification of Intermediate & Root Causes
➢ Event Sequencing/ Timeline study
➢ Root Cause Analysis (RCA) by Fault Tree Analysis done; 5-Whys trained personnel
available
➢ Area Manager authority for approval and formation of Investigation Teams
➢ Investigation Completion Time restraints
Incident Reporting and Investigation System
5-WHYS TECHNIQUE

➢ The incident report must be made available to all employees as well as
contractors.
➢An incident investigation team must thoroughly investigate and analyze the
incident.
➢ Key leanings to be communicated to all.

13.Emergency Response Planning
https://www.youtube.com/watch?v=R2Ez7lkjg1Y

▪ An Emergency Action Plan (EAP) must be developed to ensure the safe
evacuation of employees.
▪ Plan must address all foreseeable emergency situations (e.g., fire, weather,
chemical releases, etc.)
▪ Plan must address the means and methods necessary to protect employees
responding to an uncontrolled release of a process chemical

14.Compliance Audit

15.Measurements
& Metrics- KPI

Performance Indicators (Leading Indicators)
• Number of observation received and target no (%)
• No of work permit audit conducted Vs target
• No of safety suggestions received and target no (%)
• Percentage of process safety training completed vs. plan
• Number of unplanned safety system activations for valid reasons
• % of deviations in key operating parameters recorded and corrected
• % of planned maintenance activities of critical instruments completed
on time
• % of planned maintenance activities of critical equipments completed
on time
• % of planned PSV testing completed on time

Performance Indicators (Lagging)
• Percentage of near misses and incidents identified as being caused by
unsafe acts or shortcuts
• Number of critical instruments/alarms that fail to operate as designed,
either in use or during testing
• Number of unexpected loss of containment incidents
• Number of times, plant operations (Start‐up / Shutdown) does not
proceed as planned due to human errors
• Number of incidents involving plant breakdown, loss of containment of
hazardous material where deficiency in plant maintenance
• No of work permits with serious deficiencies observed during audit

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Introduction to PSM Online Interactive Training

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