Process Safety Management

Presented by:Ijaz Ahmad

DE (Process)

ContentsWhat is Hazards?What is Process Safety Management (PSM)?What’s Covered by PSM? What are the Process Hazards?What is Process Hazards Analysis (PHA)?What are the PHA techniques?

What is Hazard?An inherent physical or chemical

characteristic that has the potential for causing harm to people, the environment, or property

ExamplesHydrogen sulfide – toxic by inhalationGasoline – flammableMoving machinery – kinetic energy, pinch

points

Hazard Management:The World as It Was Before

Good people

… doing good things

The Rising Case for Change

2,500 immediate fatalities; 20,000+ total

Many other offsite injuries

1984 – Bhopal, India – Toxic MaterialReleased

HAZARD:Highly Toxic

Methyl Isocyanate

The Rising Case for Change1984 – Mexico City, Mexico –Explosion

300 fatalities(mostly offsite)

$20M damagesHAZARD:

Flammable LPGin tank

Process Safety Management

What is Process Safety Management (PSM)?The proactive and systematic identification, evaluation, and mitigation or prevention of chemical releases that could occur as a result of failures in process, procedures, or equipment.

Process Safety ManagementThe main objective is to prevent the release

of highly hazardous chemicals; such as toxic, reactive, flammable and/or explosive substances, which may cause harm to personnel, property, production, the environment and the company reputation.

What’s Covered by PSM? Process Safety

InformationEmployee InvolvementProcess Hazard AnalysisOperating ProceduresTrainingContractorsPre-Startup Safety

Review

Mechanical IntegrityHot WorkManagement of

ChangeIncident

InvestigationEmergency Planning

and ResponseCompliance AuditsTrade Secrets

What’s Covered by PSM?...

Process HazardsHAZARDOUS MATERIALS + PROCESS CONDITIONS

•Flammable materials•Combustible materials•Unstable materials•Reactive materials•Corrosive materials•Shock-sensitive materials•Highly reactive materials•Toxic materials•Inert gases•Combustible dusts

•High temperatures•Extremely low temperatures•High pressures•Vacuum•Vibration/liquid hammering•Rotating equipment•Ionizing radiation•High voltage/current•Erosion/Corrosion

Process Hazards Analysis

PROCESS HAZARDS ANALYSIS

What can go wrong?

How likely is it?

What are the consequences?

PROCESS HAZARDS ANALYSIS STRUCTURE

FOUNDATION FOR PROCESS HAZARDS ANALYSIS

HistoricalExperience

PHA Methodology

Knowledge and Intuition

Process Hazard Analysis…Process Hazards Analysis is the predictive

identification of hazards, their cause & consequence and the qualitative estimation of likelihood and severity.

Process Hazard Analysis…IDENTIFIES HAZARDS, estimates likelihood and severity, suggests improvements.

USE ON EVERY PROJECT

QUALITATIVE - based on experience, knowledge and creative thinking.

Most often done by MULTIDISCIPLINARY TEAM

Several methodologies available HAZOP What-if/Checklist FMEA Fault Tree Analysis

HAZOPRigorous review of the design and

operability of a system;Identify potential hazards and/or

operability problems;Uses guidewords & parameters;Drawings broken into Nodes are assessed.

What – If / Checklist Requires experienced and knowledgeable

team members; A series of “what if” questions are asked for

each system / subsystem; Each question represents the potential for

equipment failure or an error in operating procedure.

FMEA Initially used in aerospace and

automotives to predict the reliability of complex products;

The method determines how and how often the components of a product could fail;

Evaluates the effects of failures on a system.

Fault Tree Analysis Developed by Bell Laboratories for the

US Air Force; Focuses on the possibility of one

undesired event occurring; Maps the complex relationships that can

cause the event by including all of the contributory factors that are known.

Selecting the “Right Method” Purpose of the study; Type of results desired; Type of information available; Relative risks associated with the

chemicals, the process and/or the facility location;

PHA team experience level; Past Incidents; Development stage of facility.

Corrective Action Management and Closure

“Due diligence” can only be shown if every effort has been made to implement and verify that the actions needed to make the process safe have been taken.

The Closure Loop Assign responsibility to recommendations; Document the resolution of

recommendations; Acceptance, rejection, substitution, or

modification of any recommendation must be documented;

Rejection of a recommendation must be communicated to the study team.

ANY QUESTION?