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Process Safety Management: Kharil Ashidi B. Abdul Jabar Q-SHE-S Dept Nippon Steel Engineering Co., LTD

Process Safety Management (PSM) involves applying management principles and systems to identify, understand, and control process hazards to protect people, assets, and the environment. PSM has 14 elements including process safety information, process hazard analysis, operating procedures, contractor management, and emergency response. It requires understanding process technologies and hazards, facility design and maintenance, and ensuring personnel are properly trained. When these elements are properly implemented through management systems, process safety can be achieved. However, past incidents demonstrate that failures in technology, facilities, or personnel can lead to catastrophic events when critical factors like management of change, emergency response, or maintenance are not followed. Rigorous application of PSM is needed to control hazards and prevent major accidents.

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502 views37 pages

Process Safety Management: Kharil Ashidi B. Abdul Jabar Q-SHE-S Dept Nippon Steel Engineering Co., LTD

Process Safety Management (PSM) involves applying management principles and systems to identify, understand, and control process hazards to protect people, assets, and the environment. PSM has 14 elements including process safety information, process hazard analysis, operating procedures, contractor management, and emergency response. It requires understanding process technologies and hazards, facility design and maintenance, and ensuring personnel are properly trained. When these elements are properly implemented through management systems, process safety can be achieved. However, past incidents demonstrate that failures in technology, facilities, or personnel can lead to catastrophic events when critical factors like management of change, emergency response, or maintenance are not followed. Rigorous application of PSM is needed to control hazards and prevent major accidents.

Uploaded by

Kay Aay
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Process Safety Management

Kharil Ashidi B. Abdul Jabar


Q-SHE-S Dept
Nippon Steel Engineering Co., Ltd.
What Is Process Safety Management

Process Safety Management is the


application of management principles and
systems to the identification, understanding,
and control of process hazards to protect
employees, facility assets and the
environment.
What Is Process Safety Management
.
14 Elements

 Application  Pre-Start up Safety


Review
 Employee Participation
 Mechanical Integrity
 Process Safety
Information  Hot Work (Non-routine
Work Authorizations)
 Process Hazard Analysis
 Management of Change
 Operating Procedures
 Incident Investigation
 Employee Training
 Emergency Planning and
 Contractors Response
 Compliance Audits
Process Safety Management

TECHNOLOGY

FACILITIES

PERSONNEL
Technology
Process Technology

 Process Technology describes the process and


operation
 Understanding the hazards is the first step
 Consists of three parts
The 3 Parts of Process Technology

 Hazards of Materials
 Process Design Basis
 Equipment Design Basis
Process Hazards Analysis

Process Hazards Analyses identify, evaluate, and


control hazards
- orderly and methodical approaches
- many people involved
Procedures & Safe Practices

 Provide clear understanding of operating parameters


and limits for safe operation

They explain the consequences of problems and the
steps necessary to correct and or avoid them

Developed and documented for each process
Management of Change - Technology

 Changes may invalidate prior assessments


 All changes must be rigorously reviewed
 Sites must have procedures to manage
changes.
Technology
Industrial Incident #1 Bhopal, India

1984 A large amount of water was put into a methyl


isocyanate tank. The resulting overpressure and related
system failures caused the tank to vent and a large cloud of
gases was released and drifted onto the nearby densely
populated area. The severity of this accident makes it the
worst recorded within the chemical industry, with fatalities
estimated in the thousands, ~2,800 from the immediate
release and possibly up to 15,000 related deaths since.
Technology
Industrial Incident #1

Contributing Factors:
 plant modification/change - HAZOP
 not recognizing safety critical systems and
their operability
 design codes
 training and competence
Technology
Industrial Incident # 2 Oppau, Germany

1921 Two explosions at the BASF plant killed 430


and destroyed 700 homes. Blasting powder was
being used to breakup storage piles of ammonium
sulphate and ammonium nitrate. This procedure
had been used 16,000 times without mishap. The
4,500 tons of the mixture exploded and left a crater
250 feet in diameter and 50 feet deep.
Tough stuff to set off. But when it goes, it goes !
Toulouse Grande Paroisse
 On Friday September 21,2001 at 10:15 am…..
Technology
Industrial Incident # 2

Contributing Factor:
 not recognizing hazards of materials
Facilities
Quality Assurance

Quality Assurance “bridges the gap” between


design and installation:
 fabrication and parts meet specifications
 delivery to the right location
 properly assembled and installed
Pre-Startup Safety Review

Provides a final check for new or modified


equipment to ensure the facilities are
“ safe to operate “
Mechanical Integrity
Process related equipment that contains
highly hazardous chemicals must be
maintained from the time of design
throughout the life of the facility.

Mechanical integrity focuses on system


integrity to contain hazardous materials.
Mechanical Integrity

Deals with:
 Maintenance procedures
 Training and performance of employees
 Quality control
 Equipment tests and inspections, including
predictive and preventative maintenance
Management of “Subtle” Changes

Subtle Changes have led to catastrophic events!

All process changes, including those within the


“documented” process technology, but are not a
replacement-in-kind, must receive appropriate review
and authorization.
Facilities
Industrial Incident # 5 Flixborough, England

1974 At the Nypro(UK) chemical facility, a


large quantity of cyclohexane vapor was
released when a 20 inch “makeshift”
bypass pipe ruptured. The resulting
massive vapor cloud explosion killed 28
workers.
Facilities
Industrial Incident # 5

Contributing Factors:
 management of change procedures
 design codes
 maintenance procedures - recommissioning
 plant layout - position of occupied buildings
 emergency plan
Facilities
Industrial Incident # 6 Chernobyl, Ukraine

1984 Technicians at the power plant allowed the


fourth reactor to fall to low power levels as part of a
“controlled experiment”. The reactor overheated
causing a meltdown of the core. Explosions blew
the top off the reactor building releasing radioactive
material into the atmosphere for over 10 days. 31
workers were killed and the extent of lingering
health effects has been significant and subject of
debate. It is now entombed.
Facilities
Industrial Incident # 6

Contributing Factors:
 management of change procedures
 equipment/facility design
 procedures and safe practices
 emergency shutdown plan
Personnel
Training and Performance

 Trained employees are an absolute requirement,


and be physically able, mentally alert and
capable of using good judgment.
 Training qualification must be documented.
Contractors

For contractors working in and around


highly hazardous material processes, or
performing maintenance/repair on or near
a covered process ……….

they are required to comply with same


regulations and guidelines as industry
/site!
Incident Investigation & Reporting

 Investigations are essential to improve


performance
 The objective is to find the contributing factors and
implement corrective actions(s)
 The degree of the investigation will depend on
severity or potential
Management of Change - Personnel

People are the essential ingredient:


 process experience
 knowledge and skill in managing Process
Safety
 maintain minimum experience level and
knowledge through personnel and
organizational changes
Emergency Planning & Response

Planning and training for potential


emergencies are essential for effective
response
Auditing

Auditing must be used to assure that all


elements of Process Safety Management
are being implemented properly.

Proper auditing must include positive and


corrective feedback
Personnel
Industrial Incident # 3 Pasadena, Texas

1989 During maintenance work on a


reactor settling leg, a large release of
flammable vapor occurred at the Phillips
66 chemical complex. The result was a
massive vapor cloud explosion, followed
by a series of further explosions and
fires.
Personnel
Industrial Incident # 3

Contributing Factors:
 site and industry standards for maintenance
not followed
 training and competence
 work permit system - contractors
 positioning of occupied buildings
Personnel
Industrial Incident # 4 Mexico City, Mexico

1984 A major fire and a series of catastrophic


explosions occurred at the government owned
and operated PEMEX LPG Terminal.
Approximetly 500 people were killed and the
facility was destroyed. After the intial release, the
first BLEVE occurred. For the next 90 minutes, a
series of BLEVEs followed as other LPG vessels
violently exploded. It started with a ruptured line
and was made worse by failed safey systems and
layout.
Personnel
Industrial Incident # 4

Contributing Factors:
 plant layout - the positioning of vessels
 emergency isolation
 survivability of critical systems
 emergency plan and site access
Thank you very much
Please contact for any questions
Kharil Ashidi
Tel: +6012 202 3381
E-mail: [email protected]

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