3. Philosophy
EPCL believes that Process Safety
Information package is necessary to:
Provide a description of the chemical process
or operation.
Foundation for identifying and understand the
hazard involved, which is the first step in the
PSRM effort.
4. Process Safety Information
It is the First Step in the Process Safety Management effort
and consists of three parts:
Hazards of Materials
Process Design Basis
Equipment Design Basis, including Safety Critical
Equipment
PSI Package shall be prepared for each process unit.
Documents of PSI package will be maintained up-to-date – for
the life of each process unit.
Where the original technical information no longer exists,
information shall be developed
5. Hazards of Materials
Material Safety Data Sheets (MSDS) are primary
source. The hazard information must contain:
Permissible Exposure Limits, TLV (NH3 = 25 ppm)
Physical Data, such as:
Boiling point, Freezing point, Vapor pressure, Flammability
limits, Combustion range,
Reactivity Data
Shall contain Environmental Impact due to
Inadvertent Leakage or Spillage
Hazard information communicated to and readily
available to all relevant employees
6. Process Design Basis - Requirements
Process Flow Diagram – Flow Path, Major Equipment and
Material / Energy balances.
Process Description including:
Purpose of the Process / Major Equipment
How the Process Works & Process chemistry
Any Side / Runaway Reactions
Standard Operating Conditions, Understanding and
Consequences
Maximum Intended Inventories – Inherently Safer Design
Alarm and Interlock Summary
Data History, Change History and References for Operating
Conditions / Alarms, Equipment, Inspections, etc.
7. Equipment Design Basis –
Requirements
Design Basis Documented (Calculations, Schematics, Drawings
etc) for:
PSVs, PRVs and Vent systems
Protective Safety Systems – ESD, Shutdown and Isolation
Systems etc.
P&IDs
Interlock Instrument / Electrical Schematics / Settings
Alarms, Communication Systems and Monitoring Device
Electrical Classification
Fire Protection Systems, including Fire Water Supply
Detection and suppression systems
8. Equipment Design Basis – SC
Equipment
Equipment Specification Drawings and
Sheets
Quality Assurance Inspection Reports.
Design codes and standards employed.
Pump specifications and characteristics
Piping systems / Pipe and Valve Codes.
Electrical Diagrams, Electrical Grounding and
Bonding design.
9. Equipment Design Basis –
Miscellaneous
Equipment design basis documentation to be
included when relevant to process safety for:
Architectural and Civil Engineering Drawings.
Piping Flexibility Analysis (including special or spring
hangers and sliding supports).
Equipment Arrangement Drawings.
Insulation, Paint and Tracing Codes.
Plant and Area Maps (e.g., Underground Services).
Control of Vendor Manuals
11. SC Equipment List Development
Process
Identify HHP (Higher Hazard
Process) Criteria
Identify Hazardous
Substances
OSHA and EPA Regulated
Chemicals
List Major Safety Critical
Equipment
Define Management of PSI
Package
Team Methodology
Documentation of SC
Equipment
Safety Critical Equipment
Lists
Make SC Top Level
Document
Mention SC Equipment on
P&IDs
12. Contents of SC Top Level Document
A
Identification of
Hazardous
Substances
B
Criteria of
Higher Hazard
Process (HHP)
C
Identification of
HHP activities
E
Identification of
Safety Critical
Equipment
(Excluding
Devices)
D
Criteria of
Safety Critical
Equipment
F
Management of
Safety Critical
Top Level
Document
13. Identify Hazardous Substances
List each Hazardous Chemical Quantity in area
Concentrations
Hazardous event and identify applicable chemicals on the
site “safety critical hazardous substances” list (attachment).
Each chemical should be in one of three groups as follows:
OSHA / EPA regulated chemicals
EPCL standard for HHP chemicals and
Area concern critical chemicals.
Operating Area is responsible for:
Considering a Chemical as Safety Critical based on
thresholds
Document precisely what exactly is and what is not safety
critical.
Chemical Classification Table shall be developed to ascertain
that the area has considered all the chemicals.
14. HHP Criteria – OSHA / EPA / DuPont
Various activities may require a Risk Based Consequence
Analysis to classify them as HHP or LHO activities
Sr. No. Criteria Threshold Standard Remarks
1
High and Moderate Acute
Toxicity Materials
Substance
Specific (VCM &
Cl2)
OSHA, EPA
Regulated
Chemicals
OSHA, EPA
2
Quantities of Pressurized
Fuel Gases
Pressure > 5 psig
irrespective of
quantities
DuPont Criteria
Fuel gas for
canteen, shops
colonies
exempted
3 Other Hazardous Chemicals MSDS Based MSDS Based MSDS Based
4 Steam More than 300 More than 300
15. Chemical Classification Index / Table
Identification of HHP / LHO Activities
Sr.
No.
Criteria HHP LHO Justification
1 Yes --
Significant Quantities of
Hazardous Chemical
2 Yes --
Significant Quantities of
Hazardous Chemical
3 Yes --
Significant Quantities of
Hazardous Chemical
4 Yes -- > 300# steam
5 -- Yes < 300# steam
6 -- Yes Low Hazardous Substance
Area:
Unit: Post Classification: HHP
18. Define Management of PSI Package
Management process must be defined for the
following:
Maximo (CMMS)
P&I Diagrams
Mechanical Integrity / Quality Assurance
Database
Procedures
Other Documentation
19. Contractor Owned Equipment
Short / Long Term Contractor Owned Equipment
PSI package to be developed and maintained by the
contractor and provided to the plant.
Contractor Owned Equipment PSI Package
Technical Department to identify the SC Documents
Needed.
Planning to ask these documents from Contractor
Contractors to provide the key SC documents.
Area receiving services to document receipt of key SC
Documents.
20. Employee Communication
PSI package shall be communicated to:
Employees who start-up the new facility
Employees who are involved in the ongoing Operation.
All relevant employees must have access to PSI
Employees shall know the location of various
sections of the PSI package and
Who to contact if they have a need to review the
information.
21. 22
PSI Management Systems
Records Management
The PSI package and associated records be
well-maintained.
PSI Package Review - Each area must
review the PSI package at intervals not to
exceed 03 years:
No additional review is required, if any of
these items are in operating manuals which
are already Updated on 03 years cycle.
