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7/23/2019 Process Saf Mgt
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Topic 3
Process Safety
Management
1
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Industrial Safety
2
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Process Safety Management
PSM is a performance (not specification) standard prevent or
minimize the consequences of catastrophic releases of chemicals
that are:
•
Toxic
•
Reactive
•
Flammable
•
explosive
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Process Safety Management (PSM)
PSM is the proactive identification,
evaluation and mitigation or
prevention of chemical releasesthat could occur as a result of
failures in processes, procedures,
or equipment.
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PSM Standard
1. Process SafetyInformation
2.
Process HazardAnalysis
3. Operating Procedures
4. Training
5.
Contractors
6. Pre-startup Safety
Review
7. Mechanical Integrity
8. Hot-work Permits
9.
Management of Change
10. Incident Investigations
11. Emergency Planning &
Response
12.
Compliance Safety
Audits
•
29 CFR 1910.119 - OSHA’s Process Safety
Management Standard
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Application
Highly Hazardous Chemical processing where – Toxic or reactive chemical(s) are present in
processes at or above a listed threshold quantity(Appendix A Material)
–
Flammable liquids or gases are present inprocesses in quantities 10,000 pounds and above
– Explosives or pyrotechnics are manufactured
6
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Chemical Name CAS # TQ (lbs)
Ammonia, Anhydrous 7664-41-710000 10,000
Chlorine 7782-50-51500 1500
Hydrogen Sulfide 7783-06-4 1500
NOTE: 1500 lbs. of Hydrogen Sulfide = 16,760 ft 3 at NTP
NTP – Normal Temperature and Pressure - is defined as air at
20oC (68°F) and 1 atm (14.7 psia, 0 psig, 30 in Hg, 760 torr)
STP – Standard Temperature and Pressure - is defined as air at
0oC ( 32oF) and 1 atm (14.7 psia, 0 psig, 30 in Hg, 760 torr)
Appendix A Examples
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Exclusion
An employer is exempted from the requirements of PSMwhen:
–
HC fuels used only for workplace consumption and if not a
part of a covered hazardous process
• (e.g., propane used for comfort heating, gasoline for vehicle refueling
–
Flammable liquids stored in atmospheric tank or transferredbelow NBP w/o chilling or refrigeration
–
Retail facilities
–
Oil, gas well drilling or servicing operations
–
Normally unmanned remote facilities
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1. Process Safety Information
• Chemicals
–
Toxicity, PEL, Physical Data, Reactivity and Corosivity,Thermal and Chemical Stability, Effects of Mixing Chemicals
• Process
–
Block flow or process flow diagram, Process chemistry,Maximum intended inventory, Safe upper/lower limits for
such items as temperatures, pressures, flows or
compositions, Consequences of deviations, e.g. runaway
reaction potential
• Equipment –
Materials of construction, P&IDs, Electrical Classification,Relief system design & design basis, Ventilation systemdesign, Design codes and standards, Material & energybalances, Safety systems
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2. Process Hazard Analysis
•
Systematic effort to identify and analyze the significance of
potential hazards associated with the processing or handling of highly hazardous chemicals
– PHA METHODS: What If?, Checklist, What If?/Checklist, HAZOP,FMEA, FTA etc
•
PHA focuses on Equipment, Instrumentation, Utilities, Human
Actions, External Factors•
PHA Must address Hazards of the process
– Engineering & administrative controls
–
Consequences of failure of controls
– Facility siting, Human factors
–
Evaluate potential effects to on-site personnel from failure ofcontrols
– Identification of previous incidents
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3. Operating Procedures
•
Provide clear instructions for safely conducting activities
involved in each covered process consistent with the processsafety information
• Address at least the listed elements
•
Operating procedures readily accessible
•
Reviewed as necessary to reflect current procedures and
changes
• Certified annually as current & accurate
•
Develop & implement safe work practices to provide for thecontrol of hazards during operations, e.g. lockout/tag out/confined space entry, opening equipment & pipes, facility entry
•
Apply to employees & contractor employees
•
Steps for each operating phase (start up, operation, shutdown)
•
Operating limits
•
Safety and health considerations
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4. Training
•
Process overview
•
Process hazards
• Operating procedures
• Emergency procedures
• Refresher training at least every 3 yrs
• Documentation
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5. Contractors
•
Employer’s Responsibility
–
Evaluate contractor’s safety performance & programs
– Inform contractor of potential hazards: fire, explosion, toxic
release, applicable plant safety rules
– Develop/Implement safe work practices
– Evaluate contractor performance
•
Contractor Responsibilities
– Advise employer of any unique work hazards of contracted work
– Each employee follow all applicable work practices & safety rulesof the facility
–
Ensure each employee is trained in necessary work practices
–
Ensure each employee is instructed in known fire, explosion, ortoxic release problems related to his/her job
– Document that understanding of training has been evaluated,
verified
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6. Pre-startup Safety Review
•
Done when: –
New processes
–
Modified process
•
Pre-startup Review Verifies
–
Construction: conforms to design –
Procedures: adequate, in place
–
PHA recommendations resolved or implemented
– Management of change requirements met
–
All affected workers trained
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7. PSM Mechanical Integrity
• Pressure vessels, storage tanks, Pumps, Piping
systems & components, Relief & vent systems,devices, Emergency shutdown systems
• Controls: monitoring devices, sensors, alarms,interlocks
•
Written procedures• Training: process hazards, job tasks
• Inspections
• Testing
•
Corrective action
• Records
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8. Hot Work Permits
•
Welding, cutting, brazing• Control of ignition sources
• Verify safe conditions
• Authorization
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9. Management of Change
• Establish written procedures
•
Develop management support
•
Evaluate safety of any changes to:
– process chemicals facility
–
technology equipment
•
MOC Procedures Must Address
–
Everything except “replacement in kind”
–
Temporary as well as permanent changes
–
Technical basis for change
–
Safety & health effects –
Modified operation procedures
–
Time necessary for change
–
Authorization for change
–
Ways to inform & train workers before change
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10. Incident Investigation Goals
• Goals
–
Identify incident causes and implement steps to prevent
reccurrence
• Implementation
–
Every incident
–
Prompt investigation –
Knowledgeable team
–
Documentation & report
– Recommendations & findings
–
Resolutions & corrective actions
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11. Emergency Planning Response
• Develop Emergency Action Plans
• Pre-plan for catastrophe
• Train & equip workers
• Drills
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12. Compliance Safety Audits
•
Certify all elements of standard• Knowledgeable audit team
• Report & recommendations
• Address all finding & recommendations
•
Conduct every three years
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Appendices
A: List of chemicals
B: Sample block & flow diagrams
C: Compliance guidelines
D: References
Each of the 20 elements of Risk Based Process Safety is fullydescribed in the CCPS Guidelines book: Guidelines for Risk Based
Process Safety, Wiley, 2007, ISBN 978-0-470-16569-0.
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C o m m
i t m e n t t o P S M
U n d e r s t a n d H a z a r d s
a n d R i s k
M a n a g e R i s k
L e a r n
f r o m E x p e r i e n c e
PSM Structure
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Commit to Process Safety
•
Process Safety Culture• Compliance with Standards• Process Safety Competency• Workforce Involvement• Stakeholder Outreach
Understand Hazards and Risk
•
Process Safety Information•
Hazard Identification and Risk Analysis
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• Measurement and Metrics• Auditing• Management Review and
Continuous Improvement
Risk Based PSM Framework
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PSM Structure
•
Each of the 20 elements of Risk BasedProcess Safety is fully described in the CCPS
Guidelines book: Guidelines for Risk BasedProcess Safety, Wiley, 2007, ISBN
978-0-470-16569-0.
•
A better understanding of process safety may
be acquired through a participative workshop
with other professionals.
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Engineering Discipline Involvement
CHEMICAL
Process selection
Operating
conditionsSafe operating
envelope
Process design
Process control
Safeguards
Monitoring
CIVIL
Site layout
Elevated
structuresGrading
Drainage
Buildings
Facility siting
Infrastructure
MECH
Pressure
envelope
design
Rotating
equipment
Codes
Monitoring
ELECTRICAL
Reliable power
Arc flash
protectionArea
classification
Grounding
bonding
GFIs
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Summary
PSM is proactive and systematic identification,
evaluation, and mitigation or prevention of
chemical releases that could occur as a result
of failures in process, procedures, orequipment.
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END OF
SECTION 1.3
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