Process Safety Standard
&
Practices
Filename
GPCA Responsible Care Workshop
Team
Faisal Malallah…….. Team Leader
Vijay Kumar………... EQUATE
Tariq Alauddin………Sipchem
Yunus Qasim……….. Sabic
Andrew Blue………... LR Energies
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Agenda
Introduction
Development of Code
Process Safety Management
 Management Practice
 Guidance/ Examples
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Introduction
 Process Safety Management (PSM) is the application of
management principles and systems for identification,
understanding and control of process hazards to prevent
process-related injuries and accidents.
 The code has 12 management practices
 The code discusses guidance, examples and self
assessment notes.
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Development of code
• Team was formed by the GPCA Responsible Care
committee.
• Team members shared their process safety
management standards and implementation
strategies.
• Aligned with CCPS(Center of Chemical Process
Safety).
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Development of code
• Team discussed each and every requirement
and how their respective industries are
complying.
• Considered industrial development in the
region while developing code.
• Listed out examples for better understanding.
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EH&S
PSM Excellence
Implementation
Management Practice: PS-1
Leadership by senior management through policy,
goal setting, participation, communications and
resource commitments in achieving continuous
improvement of performance.
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PSM Excellence
Implementation
Management Practice PS-1: Examples
Implementation of PSM at EQUATE:
•
EQUATE has vision and
values statement and
commitment from
management.
•
These are documented in
EH&S Policies and
procedures, that are
approved by VP operations.
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PSM Excellence
Implementation
Management Practice PS-1: Examples
Implementation of PSM at EQUATE:
•
VP operations and CEO conduct site visits
•
Follow ODMS(Operating Discipline Management
System). This has 10 sections and section 6.08 is
process safety.
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PSM Excellence
Implementation
Management Practice: PS-2
Current, complete documentation of process
design, operating parameters and procedures and
information relating to the hazards of material and
process technology should be maintained and
readily available.
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PSM Excellence
Implementation
Management Practice PS-2: Examples
Implementation of PSM at EQUATE:
•
EQUATE follows IVPP and
EDMS system for
documentation of engineering
drawings and Procedures.
•
All PIDs, PFDs, PDS, MSDS
plant layouts etc.,
documentation is saved
electronically.
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PSM Excellence
Implementation
Management Practice PS-2: Examples
Implementation of PSM at EQUATE:
•
Procedures mention safe operating conditions and
their operating limits and immediate actions required
by Operators in case of alarms.
•
Procedures are available
electronically
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PSM Excellence
Implementation
Management Practice: PS-3
Consideration and mitigation should be given to the
potential of safety effects during design,
construction and start up phases of expansions,
modifications and new facilities, utilizing
established engineering practices consistent with
recognized codes and standards.
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PSM Excellence
Implementation
Management Practice : PS-3
The reviews should include but not limited to:
•
•
 H a z a rd s a re c o n ta in e d b y
Process Hazard
m u ltip le p ro te c tive b a rrie rs
 B a rrie rs m a y h a ve w ea k n e s s e s
o r ‘h o le s ’
 W h e n h o le s a lig n h a z a rd
e n e rg y o r c h e m ic a l is re le a s e d ,
re s u ltin g in th e p o te n tia l fo r
h a rm
 B a rrie rs m a y b e p h ys ic a l
e n g in e e re d c o n ta in m e n t o r
b e h a vio ra l c o n tro ls d e p e n d e n t
o n p e o p le
 H o le s c a n b e la te n t/in c ip ie n t,
o r a c tive ly o p e n e d b y p e o p le
H a z a rd
P ro tec tive
‘B a rrie rs ’
Facility siting
•
Plot plans
•
Process Design and review procedures
•
Project management procedures and
controls
W e a k n es se s
O r ‘H o le s ’
A c c id e n t
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PSM Excellence
Implementation
Management Practice PS-3 : Examples
EQUATE uses LPP(Loss Prevention Principles)
and Process Risk Management Standard(PRMS)
4 levels of Risk analysis
F ig. 2: T he D ow R isk M anag em en t P ro cess (O v erview )
L E V E L 1 : P R O C E S S H A Z A R D S A N A L Y S IS
– T rig g e rs : A ll p la n ts a nd p ro je c ts , s ign ific a n t c h a n g e s or
M e rg e r & A c q u is itio n s , go v e r n m e n t r e g ula tio ns
• F ir e & E x p lo s ion In d e x (F E I)
• C h e m ic a l E x p o s u re In d e x (C E I)
• R C /P H A Q u e s tio n na ir e
• L O P A T a rg e t F a c to r s
• G o v e rn m e n t R e q u ir e d R e v ie w s
RCPHA, LOPA target Factors, CEI/FEI calculations
are level 1
L E V E L 2 : R IS K R E V IE W
– T rig g e rs : F & E I> 1 2 8 , C E I> 2 0 0 , L O P A Ta r g e t F a c to r > 7 ,
g o v e rn m e n t re g u la tio n s , C E I s c e n a r io s w ith E R P G -3
b e y o n d th e D ow p ro p e rty b o u n da r y
[N o te : L e v e l 2 R is k R e v ie w s a p p ly o nly to th e p o rtio n o f
th e p la n t w hic h e x c e e d s th e Tr ig g e r c r ite ria ]
• C a u s e -C o n s e q ue n c e p a ir (s c e n a rio) Id e n tific a tio n
• L O P A (T e c h n o lo g ie s n e w to D o w a re H A ZO P ’d )
• E x p lo s io n Im p a c t e v a lua tio n
– T rig g e rs : LO P A T a r g e t > 8 or L O P A in a p pr o p ria te .
• S tr u c tu re d S c e n a rio A n a ly s is
(e .g ., H A Z O P , W h a t-If, e tc .)
L e ve l 1 :
P R O C E S S H A Z A R D A N A L Y S IS
Level 2:
R IS K R E V IE W
Level 3
E N H A N C E D R IS K
L E V E L 3 : E N H A N C E D R IS K R E V IE W
R E V IE W
– T rig g e rs : LO P A P r o te c tio n G a p > 0 o r L O P A is d e e m e d to b e a n
im p r op e r to ol fo r e v a lu a tio n y e t r is k is lik e ly to e x c e e d th e B us in e s s
E le v a tio n C rite ria .
L4:
• D o s e A d ju s te d C o n s e q ue n c e A n a ly s is
QRA
• S c r e e n fo r Q R A
L E V E L 4 : Q U A N T IT A T IV E R IS K A S S E S S M E N T
– T rig g e rs : In d iv id u a l R is k c o n tou r s in o ff-s ite po p u la tio n
e x c e e d s B u s in e s s E le v a tion C rite r ia , g o v e rn m e n t re g u la tio n s
• C o m b in a tion o f C o n s e q u e n c e A n a ly s is , F re q u e n c y of Im pa c t
For
• F o c u s eGPCA
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e s t r is k a c tiv-itie
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PSM Implementation
Management Practice PS-3 : Examples
Level 2 is complete LOPA and risk analysis for
CEI/FEI higher than threshold
Level 3 Enhanced risk review(if LOPA gaps exists)
Level 4 is QRA
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PSM Excellence
Implementation
Management Practice : PS-4
Periodic assessment and documentation of
process hazards and implementation of actions
and credible emergency procedures to minimize
risks associated with chemical operations,
including the possibility of human error should be
established.
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PSM Excellence
Implementation
Management Practice PS-4 : Examples
At EQUATE
Every 3 years revalidation of RCPHA for existing
facilities
Every 5 years revalidation of LOPA
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PSM Implementation
Management Practice PS-4 : Examples
LPP gap assessment for all retrofits requirements
during RCPHA cycle
Review of CEI and FEI during RCPHA
Emergency response plans reviewed during RCPHA
cycle
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PSM Excellence
Implementation
Management Practice : PS-5
A process of safety reviews on all new and
modified facilities during design and prior to start
up.
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PSM Excellence
Implementation
Management Practice PS-5 : Examples
At EQUATE
PSSR(Pre Start up Safety Review) for new and
modified facilities
Punch listing line by line and equipment
FIE(Functional Input and Evaluation) checklist is
completed.
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PSM Excellence
Implementation
Management Practice PS-5 : Examples
Operating/ Start up and shutdown procedures are
reviewed every 3 year cycle or whenever changes
occurs.
Actions from all reviews are tracked by AITS.
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PSM Excellence
Implementation
Management Practice : PS-6
Management of changes to chemical operations to
maintain or enhance the original safety case
designed into facility.
PSV
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PSM Excellence
Implementation
Management Practice PS-6 : Examples
Management of Change
• EQUATE has a well developed web based
management of change tool.
• The tool is developed in house.
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PSM Excellence
Implementation
Management Practice : PS-7
Documented maintenance and inspection
programs that insure facility integrity is effective.
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PSM Excellence
Implementation
PS-7: Equipment Integrity
Design and installations
Equipment tests and inspections, including predictive and
preventative maintenance
Maintenance procedures
Quality control
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PSM Excellence
Implementation
Management Practice PS-7 : Examples
At EQUATE
GMISS(Global Mechanical Integrity Safety Standard) is
followed.
This includes registration of hazardous equipment and
identifying inspection intervals.
Risk Based Inspections(RBI) is conducted
All inspection records
are maintained in SAP
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PSM Excellence
Implementation
Management Practice : PS-8
Establishment of procedures and work practices
that ensure safe operation and maintenance of
facilities.
Individual
manage
human interaction
Barrier
•operating procedures
•process alarms
emergency response
•Emergency procedures
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Excellence
Implementing
PS & RM Programs
Management Practice PS-8 : Examples
At EQUATE
A procedure use policy exists, mentions on identifying
hazards and their controls plan, classifying procedures
and review and training requirements.
All operators are trained on job specific procedures
prior to their start of work.
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PSM Excellence
Implementation
Management Practice : PS-9
Identification of skills, knowledge and
competencies necessary for the employees to
maintain proficiency in safe work practices
associated with safety critical activities.
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Excellence
Implementing
PS & RM Programs
Management Practice PS-9 : Examples
EQUATE has a well documented training system, both
online and classroom trainings are conducted
Employees and contractors included, EH&S and job
specific training provided
Training identified through a training matrix
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PSM Excellence
Implementation
Management Practice : PS-10
Investigation, reporting, appropriate corrective
action and effective sharing of lessons to identified
stakeholders of each incident which resulted or
could have resulted in a serious process safety
incident.
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EH&S
Excellence
Implementing
PS & RM Programs
Management Practice PS-10 : Examples
A web based AICR tool exists.
EH&S incidents investigated independently by
EH&S functions
AICR investigation presented to all Production
leaders
Lessons Leveraged to
other departments
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PSM Excellence
Implementation
Management Practice : PS-11
Measurement of performance, audits for
compliance and implementation of corrective
actions to be established.
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EH&S
Excellence
Implementing
PS & RM Programs
Management Practice PS-11 : Examples
A well established auditing program both internal
and external
Internal by EH&S expertise center
External every 3-5 years by a team of Dow
expertise(8-10 auditors) for 15 days
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PSM Excellence
Implementation
Management Practice : PS-12
Establish a learning culture of process safety
information and knowledge from both internal
sources and through established networks.
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Excellence
Achieving
operating excellence
Management Practice PS-12 : Examples
EQUATE sends employees for training at
conferences outside and at Dow sites for training
and learning new developments.
Global Process safety expertise meet at Dow site
once a year for sharing their learnings.
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Excellence
Achieving
operating excellence
A well implemented PSM program
Incident Rate
Business growth
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