This document discusses upcoming changes to process safety management (PSM) regulations and standards. It notes several major industrial accidents in recent decades that prompted reforms. New PSM requirements in California will likely be adopted more widely and require more prescriptive tasks, reporting, and accountability. To ensure future PSM success, the document recommends: making no distinction between internal/external compliance; expanding the definition of mechanical integrity; understanding "double jeopardy"; not replacing investigations with management of change; knowing what the operations team is doing; and clarifying teamwork expectations regarding stop work authorizations.
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.
A real-world introduction to PSM’s 14 Elements360factors
A number of recent incidents in various parts of the world have highlighted the increasing importance of effective Process Safety Management (PSM). This webinar presents a high-level overview of OSHA’s PSM requirements as well as real-world examples of how companies handle compliance.
Objectives
• Describe some of the major catastrophes which led to the formulation of PSM regulations.
• Introduce the 14 Elements of PSM.
• Present examples of various implementation approaches.
Improper management of highly hazardous chemicals, including toxic, reactive or flammable liquids, can cause accidental releases and emergency responses. OSHA’s Process Safety Management of Highly Hazardous Chemicals standard (29 CFR 1910.119) regulates the management of highly hazardous chemicals. Violations can carry fines of up to $126,000. Do you have a PSM program in place?
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.
A real-world introduction to PSM’s 14 Elements360factors
A number of recent incidents in various parts of the world have highlighted the increasing importance of effective Process Safety Management (PSM). This webinar presents a high-level overview of OSHA’s PSM requirements as well as real-world examples of how companies handle compliance.
Objectives
• Describe some of the major catastrophes which led to the formulation of PSM regulations.
• Introduce the 14 Elements of PSM.
• Present examples of various implementation approaches.
Improper management of highly hazardous chemicals, including toxic, reactive or flammable liquids, can cause accidental releases and emergency responses. OSHA’s Process Safety Management of Highly Hazardous Chemicals standard (29 CFR 1910.119) regulates the management of highly hazardous chemicals. Violations can carry fines of up to $126,000. Do you have a PSM program in place?
Nfpa Process Safety Management and osha 6 8 2013John Newquist
Nfpa Process Safety Management and osha 6 8 2013 is a presentation that I gave at the National Fire Protection Association Conference in Chicago in June 2013
Implementation and application of a Process Safety Management System. This presentation will focus on the history, purpose and scope of a Process Safety Management (PSM) system. Topics covered include:
-Distinctions between personnel and process safety
-Framework and elements of PSM
-Importance of Safety Culture in the implementation and application of a PSM system
-Relevance and importance of regular audits and assessments of PSM systems
Enform oil and gas safety: Process safey vs. personal safety Enform
Enform's mission is to get everyone home safely at the end of the day - every day. Both personal and process safety play a role in making this happen. This presentation breaks down what's involved with each and how they work together.
Learning from experience involves monitoring, and acting on,
internal and external sources of information. Despite a company’s best efforts, operations do not always proceed as planned, so organizations must be ready to turn their mistakes – and those of others – into opportunities to improve process safety efforts.
Process Safety Life Cycle Management: Best Practices and ProcessesMd Rahaman
Learn how to transform your current process safety program to deliver intelligent and integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety.
Are you looking for ways to better manage, maintain and streamline your waste management program? Waste streams within the healthcare industry can be misunderstood, underrepresented and sometimes even missed altogether. This presentation offers some tips and tricks for building a Sustainable, Compliant, Cost-Effective, Safe and Simple waste management program.
Safety in your company is a top priority, have you completed a process hazard analysis recently? When you complete a thorough PHA it improves safety, benefits your employees, streamlines the process and boosts your bottom line. In this slideshow, you can learn more about what a Process Hazard Analysis is, how it is completed properly and what to do with that information.
The Problem
Unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals have been reported for many years. Incidents continue to occur in various industries that use highly hazardous chemicals which may be toxic, reactive, flammable, or explosive, or may exhibit a combination of these properties. Regardless of the industry that uses these highly hazardous chemicals, there is a potential for an accidental release any time they are not properly controlled. This, in turn, creates the possibility of disaster.
The term Prestartup Safety Review (PSSR) first received prominence in the process industries with the introduction of the Process Safety Management (PSM) regulations.
Nfpa Process Safety Management and osha 6 8 2013John Newquist
Nfpa Process Safety Management and osha 6 8 2013 is a presentation that I gave at the National Fire Protection Association Conference in Chicago in June 2013
Implementation and application of a Process Safety Management System. This presentation will focus on the history, purpose and scope of a Process Safety Management (PSM) system. Topics covered include:
-Distinctions between personnel and process safety
-Framework and elements of PSM
-Importance of Safety Culture in the implementation and application of a PSM system
-Relevance and importance of regular audits and assessments of PSM systems
Enform oil and gas safety: Process safey vs. personal safety Enform
Enform's mission is to get everyone home safely at the end of the day - every day. Both personal and process safety play a role in making this happen. This presentation breaks down what's involved with each and how they work together.
Learning from experience involves monitoring, and acting on,
internal and external sources of information. Despite a company’s best efforts, operations do not always proceed as planned, so organizations must be ready to turn their mistakes – and those of others – into opportunities to improve process safety efforts.
Process Safety Life Cycle Management: Best Practices and ProcessesMd Rahaman
Learn how to transform your current process safety program to deliver intelligent and integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety.
Are you looking for ways to better manage, maintain and streamline your waste management program? Waste streams within the healthcare industry can be misunderstood, underrepresented and sometimes even missed altogether. This presentation offers some tips and tricks for building a Sustainable, Compliant, Cost-Effective, Safe and Simple waste management program.
Safety in your company is a top priority, have you completed a process hazard analysis recently? When you complete a thorough PHA it improves safety, benefits your employees, streamlines the process and boosts your bottom line. In this slideshow, you can learn more about what a Process Hazard Analysis is, how it is completed properly and what to do with that information.
The Problem
Unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals have been reported for many years. Incidents continue to occur in various industries that use highly hazardous chemicals which may be toxic, reactive, flammable, or explosive, or may exhibit a combination of these properties. Regardless of the industry that uses these highly hazardous chemicals, there is a potential for an accidental release any time they are not properly controlled. This, in turn, creates the possibility of disaster.
The term Prestartup Safety Review (PSSR) first received prominence in the process industries with the introduction of the Process Safety Management (PSM) regulations.
Zero Policy = maximize profits; Clients (Refineries and petrochemical Facilit...Vincent Wedelich, PE MBA
Clients (Refineries and petrochemical Facilities) will maximize profits if they develop a zero policy.
Zero-safety incidents
Zero- power failures with fastest power recovery
Zero- flares and process leaks
Zero- process downtime
Introduction to Functional Safety and SIL CertificationISA Boston Section
This overview session will acquaint attendees with the key concepts in the IEC 61508 standard for functional safety of electrical/electronic and programmable electronic systems. An introduction is provided to safety integrity levels (SIL), the safety lifecycle and the requirements needed to achieve a functional safety certificate. Information will be provided on documentation requirements and an introduction to the basic objectives of product design for functional safety.
Program DevelopmentPeer-ReviewedManagementofCExamp.docxbriancrawford30935
Program Development
Peer-Reviewed
Management
ofC
Examples From Practice
By Fred A, Manuele
M
anagement of change (MOC)
is a commonly used technique.
Its purpose is to:
•Identify the potential consequences
of a change.
•Plan ahead so that counter actions
can be taken before a change occurs and
continuously as the change progresses.
With respect to operational risks, the
process ensures that:
•Hazards are identified and analyzed,
and risks are assessed.
•Appropriate avoidance, elimination
or control decisions are made so that
acceptable risk levels are achieved and
maintained throughout the change pro-
cess.
•New hazards are not knowingly in-
troduced by the change.
•The change does not negatively af-
fect previously resolved hazards.
•The change does not increase the
severity potential of an existing hazard.
This process is applied when a site
modifies technology, equipment, fa-
cilities, work practices and procedures,
design specifications, raw materials, or-
ganizational or staffing situations, and
standards or regulations. An MOC pro-
cess must consider:
•safety of employees making the
changes;
•safety of employees in adjacent work
areas;
•safety of employees who will be en-
gaged in operations after changes are
made;
•environmental aspects;
•public safety;
Fred A. Manuele, P.E., CSP, is president of Hazards Limited,
which he formed after retiring from Marsh & McLennan where he
was a managing director and manager of M&M Protection Consul-
tants. His books include Advanced Safety Management: Focusing on
ZIO and Serious Injury Prevention, On the Practice of Safety, Innova-
•product safety and quality;
•fire protection so as to avoid prop-
erty damage and business interruption.
OSHA's (1992) Process Safety Man-
agement Standard (29 CFR 1910.119)
requires that covered operations have
an MOC process in place. No other
OSHA regulation contains similar re-
quirements, although the agency does
address MOC in an information paper
(OSHA, 1994). Also, this subject is a
requirement to achieve desig-
nation in OSHA's Voluntary
Protection Programs.
Establishing the Need
Three studies establish that
having an MOC system as an
element within an operation's
risk management system
would serve well to reduce
serious injury potential. This
author reviewed more than
1,700 incident investigation
reports, mostly for serious in-
juries, that support the need
for and the benefit of an MOC
system. These reports showed
that a significantly large share
of incidents resulting in seri-
ous injury occurs:
•when unusual and non-
routine work is being per-
formed;
•in nonproduction activities;
•in at-plant modification or
construction operations (e.g.,
replacing an 800-lb motor on a platform
15 ft above the fioor);
IN BRIEF
•Studies and statistics indi-
cate that an effective man-
agement of change (MOC)/
prejoh planning compo-
nent within an operations
risk management system
reduces the potential for
serious injuries.
•Specific guidelines from
pr.
Industrial Hygienists and Facility Managers: Potentially Productive PartnersSentry Air Systems, Inc.
Industrial facilities of all types will require evaluation if OSHA's decades-old PELs are revised to standards that offer more protection to workers. Industrial Hygienists and Facility Managers should consider partnering to solve the problems
Safety ManagementSafety Management
O
Management of
Change
A key to safety—not just process safety
By Mark D. Hansen and Gerald W. Gammel
www.asse.org OCTOBER 2008 PROFESSIONAL SAFETY 41
ON NOV. 25, 1998, a fire at the Equilon Enterprises oil
refinery delayed coking unit in Anacortes, WA, caused
six fatalities. A loss of electric power and steam supply
approximately 37 hours before the fire had resulted in
abnormal process conditions (CSB, 2001).
The investigation revealed that personnel had
expected a tarry mass to drain from the drum. [A
drum is a tower or vessel in which materials are
processed, heated or stored. Coke drums can be very
large (e.g., 120 ft tall with a 29 ft diameter) and typi-
cally stand several stories high.] The supervisor had
directed that the drum be opened with a minimum
number of people present. In response to concerns
that the limited flow of steam might not sufficiently
strip all the toxic compounds from the tar inside the
vessel, workers removing the bolts on the drum heads
were required to wear self-contained breathing appa-
ratuses. The top head was unbolted and lifted from
the drum. The bottom head was also unbolted and
held in place by a hydraulic dolly. The operator then
activated a release mechanism to lower the dolly.
Witnesses reported hearing a whooshing sound
and seeing a white cloud of vapor emanate from the
bottom of the drum. The hot petroleum vapor burst
into flames. The process supervisor, an operator and
the four contract personnel assisting were caught in
the fire and died (CSB, 2001). After the incident,
Equilon relocated the controls for the hydraulic
dolly to allow workers to position themselves far-
ther from a drum when opening it (CSB).
Lessons Learned
Why examine this accident? Because it illustrates
the need for management of change (MOC). MOC is
critical to process safety—and it is a concept that if
well implemented could likely prevent incidents in
many other industries as well. Many industries
would benefit from establishing policies to manage
deviations from normal operations. Systematic
methods for managing change are sometimes
applied to physical alterations, such as those that
occur when an interlock is bypassed, new equip-
ment is added or a replacement is “not in kind.”
For an MOC system to function effectively, field
personnel must know how to recognize which devia-
tions are significant enough to trigger further review.
Thus, operating procedures must include well-de-
fined limits for process variables for all common tasks.
Once on-site personnel are trained on MOC policy
and are knowledgeable about normal limits for
process variables, they can make informed judgments
regarding when to apply the MOC system.
Once a deviation is identified that triggers the
MOC system, management must gather the right
people and resources to review the situation. A mul-
tidisciplinary team may be required to thoroughly
identify potential hazards, develop protective meas-
ures and propos.
Hi @All,
This is a 30 minute introductory presentation of FMEA according to my personal professional view. I have chosen only those references that aligns with what I think best describe this analytical method.
FMEA is a technique developed by military reliability engineers between 1940 2) to 1950 using inductive reasoning (forward logic) single point of systematic failure analysis. FMEA helps to identify potential failure modes based on experience with similar products and processes - or based on common physics of failure logic. Effects Analysis refers to studying the consequences of those failures on different system. FMEA is an examination of all possible failures.
Cheers,
Rufran (091914)
Mike Marshall, PE (mtmarshall.llc@gmail.com) is an Oil & Gas industry consultant who has recently developed an EAM loss prevention and asset optimization software product derived from various spreadsheet-based tools (consisting of business methods, practices, KPIs, scorecards, reports, data maps/views, etc.) which were central to the actual asset performance optimization/management and process safety improvement metrics and methodologies he implemented while working for both Marathon (23 years) and Chevron (10 years).
Similar to Kp bloch psm preparedness final rev (20)
How predictive models help Medicinal Chemists design better drugs_webinarAnn-Marie Roche
All scientific disciplines, including medicinal chemistry, are experiencing a revolution in unprecedented rates of data being generated and the subsequent analysis and exploitation of this data is increasingly fundamental to innovation. Using data to design better compounds is a challenge for Medicinal and Computational chemists.
The design of small-molecule drug candidates, encompassing characteristics such as potency, selectivity and ADMET (absorption, distribution, metabolism, excretion and toxicity) is a key factor in the success of clinical trials and computer-aided drug discovery/design methods have played a major role in the development of therapeutically important small molecules for over three decades. These methods are broadly classified as either structure-based or ligand-based.
In this webinar our expert Dr. Olivier Barberan will discuss ligand-based methods and he will cover the following:
How to use only ligand information to predict activity depending on its similarity/dissimilarity to previously known active ligands.
- Discuss ligand-based pharmacophores, molecular descriptors, and quantitative structure-activity relationships and important tools such as target/ligand databases necessary for successful implementation of various computer-aided drug discovery/design methods in a drug discovery campaign.
Webinar: New RMC - Your lead_optimization Solution June082017Ann-Marie Roche
The drug discovery landscape is rapidly changing and drives the need to generate leads with lower attrition rates.
In this webinar, our expert Dr. Olivier Barberan discussed how NEW Reaxys Medicinal chemistry in NEW Reaxys allows better discovery and exploration of structure activity relationship and also supports a more efficient property-based drug design approach. He covered the following:
• How has RMC being transformed into a more accessible tool for all users, allowing complex searches and workflows to be easily carried out.
• A demonstration of how more than ever RMC is the only lead-optimization solution you will need.
Oil&Gas Thought Leader Webinar - New Plays for Old Ideas - Dr.Gabor TariAnn-Marie Roche
In our April 2017 webinar, three industry experts shared their research and demonstrated the importance of focusing on fundamental geologic and geophysical research approaches that integrate variety of data, information and concepts from disparate sources and related disciplines.
This back-to-fundamentals research can both inspire and accelerate exploration teams’ thinking about petroleum systems and lead to a path to success.
Dr Gabor Tari is currently the Group Chief Geologist at OMV. He has over 20 years’ experience working in upstream oil & gas and has worked for Amoco, BP, and Vanco, before joining OMV in 2007. Gabor has worked on exploration projects in basins around the globe, including Romania, Angola, North Africa, and the Middle East. He has authored over 50 scientific publications, presented papers at dozens of conferences, and most recently co-authored the book Permo-Triassic Salt Provinces of Europe, North Africa and the Atlantic Margins, with Dr Joan Flinch (Repsol) and Juan Soto, Professor of Geodynamics in the Granada University and in the Instituto Andaluz de Ciencias de la Tierra, Spain, which is currently available from Elsevier for pre-order online.
Gabor discussed and shared some examples of how new plays can be built on a solid foundation of petroleum system development and research, and how new ideas can be garnered from building on published research of oil & gas companies, academia, service providers and consultants.
Oil&Gas Thought-Leader Webinar - New Plays for Old Ideas - Dr. Rob ForknerAnn-Marie Roche
In our April 2017 webinar, three industry experts shared their research and demonstrated the importance of focusing on fundamental geologic and geophysical research approaches that integrate variety of data, information and concepts from disparate sources and related disciplines. This back-to-fundamentals research can both inspire and accelerate exploration teams’ thinking about petroleum systems and lead to a path to success.
Dr Rob Forkner is a carbonate geologist at Statoil, working in the carbonate plays and reservoirs research group in Austin, Texas, focusing on carbonate play prediction in Atlantic margin systems. Prior to Statoil, Rob worked at Maersk and Shell in onshore and offshore in well planning, geosteering, high-resolution sequence stratigraphy and facies prediction, carbonate sedimentology in unconventional assets, evaporite classification and prediction, rock typing, and more recently, carbonate system suppression and recovery during Oceanic Anoxic Events.
Oil&Gas Thought-Leader Webinar - New Plays for Old Ideas - Dr. Sander HoubenAnn-Marie Roche
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This back-to-fundamentals research can both inspire and accelerate exploration teams’ thinking about petroleum systems and lead to a path to success.
Dr. Sander Houben is a biostratrapher and researcher within the Basin Analysis team at TNO, Netherlands Organisation for Applied Scientific Research, and the leading research institute for applied sciences in the Netherlands. As part of the Basin Analysis Team, Sander provides scientific and technical expertise regarding stratigraphic and paleo-environmental constraints for multidisciplinary projects. In addition to conducting research, he leads TNO’s biostratigraphic consultancy research programs.
Embase for pharmacovigilance: Search and validation March 22 2017Ann-Marie Roche
Scientific literature plays a critical role in Pharmacovigilance and Drug Safety workflows. Monitoring literature for mentions of adverse drug reactions (ADRs) is mandated by regulatory bodies, and marketing authorization holders (MAHs) that do not properly report ADRs can be subject to heavy fines. With an increasing volume of unstructured content to cover, along with rising labor costs, MAHs are looking for ways to make their literature monitoring more effective and efficient.
Abstract and indexing (A&I) databases play an important role in Literature Monitoring – due to the vast amount of scientific literature published daily – in order for MAH’s to locate specific articles or conference presentations that may be relevant for their products (for both benefit/risk analysis and ADR detection). Rather than reading all the literature, MAH’s create search strategies that identify the relevant records in A&I databases and execute the searches regularly. GVP module VI mandates that searches are done at least weekly, but many companies maintain a daily monitoring and review cycle.
In this webinar, Senior Product Development Manager Embase, Dr. Ivan Krstic discussed best practices for saving time, staying current, validating search strategies and mitigating risk in the face of these increasingly complex processes in literature monitoring
Literature Management for Pharmacovigilance: Outsource or in-house solution? ...Ann-Marie Roche
Pharmaceutical companies are required to screen scientific literature on a regular basis and this comes with many challenges, such as handling large amounts of data, building search strings and integrating EMA MLM results. Out-sourcing literature screening to service providers reduces the workload for the PV-team, but how does it impact the literature management process overall? Maybe it results in decreased oversight and additional activities like audits and reconciliation? And what about building the search strategy?
During this webinar our PV expert, Dr. Joyce De Langen spoke about the following:
• The importance of literature management in Pharmacovigilance and the challenges.
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About the speaker:
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The All-New 2016 Engineering Academic Challenge - developed by students for students
The Engineering Academic Challenge (formerly as the Knovel Academic Challenge) is an immersive, 5-week interactive problem-set competition, featuring weekly thematic engineering challenges built around five transdisciplinary themes inspired by the National Academy of Engineering Grand Challenges.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
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Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
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Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
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Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
1. Process Safety Management
(PSM) Preparedness
changes to expect and how they
affect you
Kenneth P. Bloch
processreliability@gmail.com
Sr. HES Professional in Process Safety
Houston, Texas USA
2. Personal Background
• Kenneth Bloch
– BS Lamar University 1988
– 30 years experience investigating industrial
incidents and process / mechanical failures
• Specialty & commodity chemical processes
• Downstream oil & gas / petrochemical
– Reliability & maintenance, process safety, &
operations roles in 2 major petroleum refineries
– Lessons learned & hazard mitigation speaker
(API, AFPM, AIChE/CCPS)
– Author of Rethinking Bhopal (Elsevier, June
2016) ISBN 978-0128037782
3. Topic Overview
• The push for PSM reform
– Industry performance review
– The call for action
– Change overview
• Significant developments in PSM’s growth
– The Bhopal disaster (1984)
– The PSM standard (1992)
– Event order reversal analysis (2016)
• PSM’s future success
– What does it require of you?
– Application summary
– Questions & answers
4. What you will learn
• How to prevent future disasters and
minor precursor incidents.
• Why reputable organizations are more
likely to incur a catastrophic event.
• What must be done to maintain
effective PSM performance when
regulatory requirements change.
• How to achieve satisfactory PSM
performance before new regulations go
into effect.
6. March 23, 2015
A. The 20-year anniversary of industry’s
cooperative effort to eliminate
catastrophic process incidents?
B. A devastating fire and explosion
occurred at a major USA refinery?
11. BP Deepwater Horizon
Summary
• Catastrophic loss of primary containment
(LOPC)
• Crude oil spill over 4 million barrels into the
Gulf of Mexico
• 11 fatalities, 17 injuries, and serious
environmental damage
• Economic damage to multiple adjunct
industries
• Mechanical integrity, human error, and
organizational culture issues
• Presidential-appointed committee report
• CSB Report
15. West Fertilizer Company
Summary
• Fire and explosion
• Detonation of 40 to 60 tons of ammonium
nitrate
• 15 fatalities & more than 260 injuries
• Property damage to more than 150 offsite
buildings
• Loss of operating license (the company
went out of business)
• Hazard awareness, emergency response
and planning, and facility siting defects
• CSB Report
17. DuPont Mercaptan Release
Summary
• Catastrophic loss of primary
containment (LOPC)
• 24,000 pounds of toxic gas released
• 4 fatalities due to asphyxia and acute
exposure to toxic chemicals
• Process shut down permanently [1]
• Mechanical integrity, operating
procedures, and safety equipment
defects (CSB)
• Human error (DuPont Report) [1]
19. Pemex Petrochemical, Veracruz
Summary
• Catastrophic loss of primary
containment (LOPC)
• Vinyl chloride (plastic) plant
• 32 fatalities & 160+ injuries
• More information expected in the future.
20. Performance Summary
• PSM events are a global concern
– Domestic (USA) and international incidents
– Major event frequency of 1.77 years in
manufacturing industry’s last 40 years [2]
• Major incidents have damaged the
reputation of companies once recognized
for PSM superiority (BP, DuPont [1]).
• Mechanical integrity (including
maintenance), facility siting, and cultural
defects are found in most tragic industrial
incidents.
• A bad enough incident can drive a
manufacturing enterprise out of business.
24. Significant Changes Underway
(Cal/OSHA) [3]
• Process Hazard Analysis (PHA) / Safeguard
Protection Analysis (SPA)
– SPA is a new element used to gauge the
independence and effectiveness of safeguards
against failure scenarios evaluated during a PHA.
• Management of Change (MOC)
– New requirement to apply a Hazard Control Analysis
(HCA) prior to implementing a major change.
• Process Safety Management Program (PSMP)
– An entirely new PSM element directed at stop work
authorization and criteria for rejecting
recommendations.
25. Significant Changes Underway
(Cal/OSHA) cont’d [3]
• Mechanical Integrity (MI) / Damage
Mechanism Review (DMR)
– DMR is a new element that utilizes a broad team to
identify any deficiencies associated with damage
mechanisms that could degrade equipment or
material performance.
• Inherently Safer Technology (IST), Hierarchy
of Hazard Control Analysis (HCA), and Safer
Technology and Alternatives Analysis (STAA)
– New processes for prioritizing hazard mitigation with
the preferred practice of eliminating or minimizing
the hazard before resorting to less effective, more
human-dependent measures.
26. Significant Changes Underway
(Cal/OSHA) cont’d [3]
• Process Safety Culture Assessment
(PSCA)
– A new PSM element related to assessing
cultural safety practices at a production site.
• Human Factors (HF)
– A new PSM element that requires assessing
how the complexity of tasks, employee training
and skills requirement, human-machine
interface design, physical process demands,
and the impact of shift work will affect human
performance.
27. Changes also apply to . . . [3]
• Process safety information (PSI)
• Training
• Contractors
• Pre-startup safety review (PSSR)
• Hot work
• Employee participation
• Operating procedures
• Incident investigation – root cause analysis
• Emergency planning & response
• Management of organizational change
(MOOC)
29. What to Expect
• Mandatory PSM/RMP changes (USA)
based on changes in progress (Cal/OSHA)
• Indoctrination of similar practices by EU
and APAC, due to networking of best
practices by NGOs (CCPS, IChemE, API,
AFPM, etc.)
• Additional regulatory requirements without
de-emphasizing standing requirements.
• More complex Safety Management
Systems (SMS)
– Prescriptive tasks
– Reporting commitments
– Industrial accountability
30. Balancing
compliance with complexity
“. . . a complex SMS Regulatory
Environment can create implementation
challenges for not only industry, but also
for regulators providing oversight. It is an
important objective for regulators to
always minimize unnecessary complexity,
because unnecessary complexity can
erode some of the safety benefits desired
from the promulgation of Modernized
PSM/RMP regulations.” [3]
31. Regulatory Growth
Relevant questions
• How can I prevent
counterproductive
results from the
impending
regulatory
changes?
• What must I do to
reduce the potential
for a process
release where I
work?
[4]
33. The PSM Movement’s
Development
• Catastrophic loss of primary containment (LOPC)
• 28 tons of toxic gas emitted into the atmosphere
• > 3000 fatalities; > 200,000 injuries
• Residual mortality and environmental impact
• Mechanical integrity, hazard awareness, emergency
response and planning, and facility siting defects
• Organizational culture defects
• Destruction of a successful manufacturing
enterprise
34. Event order reversal analysis
December 1984 – Catastrophic LOPC incident, Union Carbide India Limited
February 1992 – 29 CFR 1910.119 (PSM Standard USA)
What should we
be doing?
36. 1. Make no distinction between
internal and external compliance
REGULATORY, VISIBLE TO ALL
• MOC, deviation process, waivers & exceptions, deferrals
• Specifications
• Standards
• Procedures
• Policies
• Asset reliability
• Action items
• Operating limits
• Site auditing
• Disciplinary program
• Management systems
• Administrative controls
?
External Compliance
(Mandatory)
Internal Compliance
(Discretionary)
37. 2. Expand your definition of
mechanical integrity
• Establish and insist on meeting asset
performance targets
– Reliability limits (pressure, temperature, flow, level,
composition, etc.)
– Failure performance (MTBF & life expectancy)
– Investigate deviations
• Understand the concept behind “Inherently
Safer Technology.”
– “Safety is built into the process or product, not
added on. Hazards are eliminated or significantly
reduced, not controlled, and the way they are
eliminated or reduced is fundamental to the design
that it cannot be changed or defeated without
changing the process. In many cases this will result
in simpler and cheaper plants.” [5]
38. 3. Understand what “double
jeopardy” means
• Most failure scenarios are much less
rare than you think.
• All simultaneous failures must be
revealed for double jeopardy to apply.
• Common-cause failures tend to be
hidden and make double jeopardy
scenarios highly probable.
39. 4. Do not replace an incident
investigation with an MOC
• Reject workaround solutions.
• Generate recommendations that
preserve the process’ original design
basis.
• Investigate production constraints as
process safety defects.
• Avoid using consequence thresholds as
investigation triggers.
40. 5. Know what your line
organization is doing.
• How is the work getting done?
• Is tribal knowledge creating the false
impression of a reliable process?
• Does “employee participation” focus
around hazard awareness & control or
employee relations?
41. What is wrong with this picture?
How many people did it take
for this to happen?
42. 6. Clarify Teamwork
Expectations
Stop Work Authorization (card, policy, etc.)
?Internal
(Hidden)
• Line organization’s
courage and PSM
commitment
• Supervision’s visibility
& consistency
External
(Visible)
Teamwork requires going
against the team.
43. Get the Book
(ISBN 9780128037782)
• Discuss its contents with the line
organization.
• How do they respond under similar
circumstances?
• What they say might surprise you.
• Your success depends on what you know.
• Take steps now to stabilize PSM.
• On sale now for preorder at Elsevier
bookstore and Amazon.
• Expected release date June 6, 2016.
• All royalties go to the “Process Safety
Heritage Trust” science and engineering
scholarship
44. Application Summary
Action Step: 1 2 3 4 5 6
Process Hazard Analysis (PHA) / Safeguard Protection Analysis (SPA) X X
Management of Change (MOC) X X X X X
Process Safety Management Program (PSMP) X X X X
Mechanical Integrity (MI) / Damage Mechanism Review (DMR) X X X X X
Inherently Safer Technology (IST), Hierarchy of Hazard Control Analysis
(HCA), and Safer Technology and Alternatives Analysis (STAA)
X X X
Process Safety Culture Assessment (PSCA) X X X X X
Human Factors (HF) X X X X X X
45. For More Information
1. Kenneth Bloch, Rethinking Bhopal: a definitive guide to investigating,
preventing, and learning from industrial disasters, 2016.
2. Steven Maher, Aleksandar Metulev, PSM/RMP Modernization
Programs in California (New Developments and Correlation to
Evolution at the Federal Level), 2016 Spring Meeting and 12th Global
Congress on Process Safety, Houston, Texas (USA), April 10-14,
2016. http://www.rmpcorp.com/sms_regulatory_updates/
3. J. Wayne Chastain, Stanley Urbanik, Robert Johnson, John Murphy,
New CCPS Guideline Book: Guidelines for Enabling Conditions and
Conditional Modifiers in LOPA, 2013 Spring Meeting and 9th Global
Congress on Process Safety, San Antonio, TX, April 28 – May 1, 2013.
4. Dennis Hendershot, Inherently Safer Design: The Fundamentals,
Chemical Engineering Progress, 108 (1), 40, 2012.
5. Trish Kerin, Improving learning through interactive case studies, 2016
Spring Meeting and 12th Global Congress on Process Safety,
Houston, Texas (USA), April 10-14, 2016.
46. References
Mark Collette, DuPont's La Porte plant, site of worker
deaths, won't reopen, Houston Chronicle, March 31, 2016.
Chason Coelho, Addressing Human Factors in Process
Safety – Corporate and Plant Practices, 2016 Spring
Meeting and 12th Global Congress on Process Safety,
Houston, Texas (USA), April 10-14, 2016.
Steven Maher, Aleksandar Metulev, PSM/RMP
Modernization Programs in California (New Developments
and Correlation to Evolution at the Federal Level), 2016
Spring Meeting and 12th Global Congress on Process
Safety, Houston, Texas (USA), April 10-14, 2016.
Daniel Crowl, Joseph Louvar, Chemical Process Safety:
Fundamentals with Applications, Second Edition, 69,
2002.
Dennis Hendershot, Inherently Safer Design: The
Fundamentals, Chemical Engineering Progress, 108 (1),
40, 2012.
[1]
[2]
[3]
[4]
[5]