PSM Introduction 0 • No System Available 1 • System available but no awareness 2 • System & Awareness available but no compliance 3 • Systems and awareness available and compliance as well. 4 • Excellence Level 5 • Best in World Class PSM Glossary Process Safety 1. Establishing Safety Culture 2. Management Commitment and Leadership 3. Implementation of PSM Model Main Reason behind World Big Disasters 1. Lack of Safety Culture 2. Failure of Multiple layer of protections 3. Inadequate Safety and Risk Management Program PSM Document Levels Level‐I • Corporate level documents approved by CEO e.g. HSE Policy Level‐II • Divisional Level documents approved by DO/DMs e.g. People Development Procedure Level‐III • Departmental Level documents approved by DM/UM e.g. Work Instructions PSM Elements Sr # Risk Based Sr# Culture Based MOC‐Technology 1 Management Commitment Process Safety Information 2 Policy and Principles Risk assessment & Process Hazard Analysis MOC‐Facility 3 Goals, Objectives and Plans 4 Integrated organized Structure Quality Assurance 5 Effective Communication 6 Mechanical Integrity 6 Motivation and awareness 7 Pre start up safety Review MOC‐Personnel 7 Training and Development 8 Audits and Observations Contractor Safety Management 9 Procedures and Performance Standards Emergency Preparedness and Contingency Planning 10 Line Management Accountability and Responsibility 11 Incidents Investigations 12 Safety Personnel 1 2 Technology Category 3 4 5 8 9 10 Facility Category Personnel Category PSM Elements PSM Elements‐Behavior Based 1. “Management Commitment” Commitment will exist from the top and works through line organization. Employee safety is as important as company assets, cost, reliability, quality and employee relations Management is responsible for safety of persons and company property Management commitment is to implement safety programs through various safety committees and conduct safety audits Top management will encourage all employees for off the Job Safety. 30% weight age in Annual performance appraisals for reward / accountability. 2. “Policy & Principles” Policy should be specific and signed by CEO HSE Policy should be displayed on all sign boards Principles should be derived from Policy Health, Safety and Environment at top most priority Working safely is the condition of employment Policy will meet Government NEQS and EPA standards Company will encourage off the job safety and awareness PSM Elements‐Behavior Based 3. “Procedure & Performance Standards” What we cover in Performance Standards? 1. Procedures: These are process oriented work which covers work instructions. 2. Rules: These are behavior oriented that we expect which covers general rules, safety rules and cardinal rules as well This element covers Major misconduct offences, Plant safety rules, General safety rules, Dress code, Plant traffic rules, safe work practices, FFL house keeping program I. Mandatory PPEs: • Safety Helmet • Safety shoes (excpet for truck drivers and pallaydar) • Safety goggles II. Conditional PPEs: • Hearing protection above 85 dB. • Dust masks at bags filling machines • Half face masks where Ammonia exposure less than 300 ppm • Full face masks where ammonia exposure less than 500 ppm • Chemical Suit while handling Acid/Alkali/Catacarb/Ammonia • Welding hood / Face shield while welding • Gum boots while working in drain channel, Cooling tower. • Safety harness at 5 ft above where handrail, midrail, proper scaffloding or permanent platform not present. PSM Elements‐Behavior Based 3. “Procedure & Performance Standards” III. Plant safety Rules / Policies: • • • • • • • • • • • Use of cell phone No smoking rules Dress code policy PTW system Safe Work Procedures Plant entry through IN/OUT registers during ON hours. Plant entry through duty coordination engineer during OFF hours. Housekeeping program PTW / Non PTW roads Vehicle operating rules Defensive driving program etc. PSM Elements‐Behavior Based 4. “Incident Investigations” Purpose of Incident Investigation? Incident investigation purpose is to find out the root cause and providing such sort of recommendations so that reoccurrence of the incident can be avoided. Incident? Unexpected occurrence that cause or might cause serious injury, health affects or environmental problem Which are the (8) Incident Classifications? 1. 2. 3. 4. 5. 6. 7. 8. Injuries Occupational illness Process Safety Incident Violation of safety procedures Operational upsets Vehicle Incidents Equipments Failure Others Incident Investigations‐ Behavior Based Element Which are the (5) types of Injuries? 1. 2. 3. 4. 5. Fatality LTI RWC MTC FAC (It will hit the safe million man hours & TRIR) (It will hit the safe million man hours & TRIR) (It will hit the TRIR) (It will hit the TRIR) • • All injuries are reportable, All injuries are recordable except FAC. Decision regarding classification of injury will be made by HSE UM and Medical Officer. TRIR means? All recordable injuries will be used in calculating Total Recordable injuries rate TRIR Formula. TRIR = (Total recordable injuries)*200000/ Man‐hours LTIR = (No of lost time injuries)*200000/ Man‐hours Incident Investigations‐ Behavior Based Element Fire? Any unplanned combustion with visible smoke / flame which is not a part of design basis and is not covered by any valid work permit. First Aid Case? One time treatment and any follow up visit for the purpose of observations for minor scratches, cut and burns which dont require prescription / medical care. Medical Treatment Case? Any treatment administrated by outside specialized doctor under standing order by Fatima Medical Officer. Restricted Work Case? Any injury that restrict employee to perform his normal duty. Fatality? Death resulting from work injury or occupational illness Incident Investigations‐ Behavior Based Element Occupational illness? Any illness caused by plant environmetal factors. Operational Upset? Any incident caused by mal operation or human error. Process safety incident? Any incident that directly involve process equipments and material. Lost Time Injury? Any injurt that prevent employee from perfoming regular assigned duties at workplace. Lost Workdays? Those days on which employee remain absent due to injury. Incident Investigations‐ Behavior Based Element Incident Reporting Protocol? 1. 2. 3. 4. 5. Within 24 hours all incidents reporting is required by relevant area incharge Within 48 hours flash report should be circulated by HSE Within 72 hours Incident detail report should be submitted on IR‐I format if score is < 75 Within 7 days Incident detail report should be submitted on IR‐3 format after issuance of flash report if score is 75~129 Within 15 days Incident detail report should be submitted on IR‐3 format after issuance of flash report if score is >129 Type of Incident Forms? 1. 2. 3. 4. 5. 6. 7. 8. IR‐1 (Initial report) IR‐2 (score sheet) IR‐3 (Detail report) IR‐4 (Flash report) IR‐5 (Off the Job Report) IR‐6 (Gov. intimation in case of LTI / Fatality) IR‐7 (Waiver form) IR‐8 (Vehicle Incidents) Integrated Organized Structure‐ Behavior Based Element Executive HSE Committee: Chairman: Arif‐ur‐Rehman Co‐chairman: Riaz Chaudhary Secretary: Mudassir Amin Members: All DMs Sub HSE (Process) North Committee: Chairman: Co‐chairman: Secretary: Members: Rehman Hanif Asad Waheed Shahbaz Ali All area UMs + HSE UM + Process UM Integrated Organized Structure‐ Behavior Based Element Sub HSE (Process) South Committee: Chairman: Co‐chairman: Secretary: Members: Asad Waheed Rehman Hanif Shahbaz Ali All area UMs + HSE UM + Process UM Sub HSE (Mechanical) Committee: Chairman: Co‐chairman: Secretary: Members: Javed Iqbal Iftikhar Ahmed Asghar Bilal All area maintenace UMs + HSE representative + QA/QC UM Integrated Organized Structure‐ Behavior Based Element Sub HSE (E&I) Committee: Chairman: Co‐chairman: Secretary: Members: Toufeeq Ahmed Rana Asghar Humanyun Zahir All area E&I UMs + HSE UM Sub HSE (IRRC) Committee: Chairman: Co‐chairman: Secretary: Members: Rehman Hanif Showkat Ali Khan Muhammad Usman Abdul Ghani, Naveed Ahmed, Aleem Ansari, Ejaz Ahmed, M. Amjad, Ejaz Farooqi. Integrated Organized Structure‐ Behavior Based Element Sub HSE (Off the Job) Committee: Chairman: Co‐chairman: Secretary: Members: Brig. Syed Showkat Ali Mudassir Amin Agha Safdar Ejaz Farooqi, Sami Sheikh, Khalid Javed, Col. Sarfraz, Dr. Humayun, Hamid, Nadeem Aslam, Waqas Ahmed Tech. Sub HSE (OHIH) Committee: Chairman: Co‐chairman: Secretary: Members: Asad Waheed UM‐Lab Col. Sarfraz Dr. Humayun, Saima Khurshid, Ali Qureshi, Humanyun Zahir, Atiq MWH Motivation and Awareness –Behavior Based Element How we achieve high standard of safety performance? 1. 2. Internal Motivation External Control Type of Awards for Reward and Recognition? 1. 2. 3. 4. 5. • 1. No LWI award No Recordable injury Award Best near miss award Best spot the hazard Best D Level Committee award Best Housekeepign Award Best Emergency Squad Award Motivation and Awareness –Behavior Based Element Performance impairment means? Safety priorities on lower sides, Unsafe practices, lower productivity, increasing TRIR Causes of Performance impairment? Stress, Illness, Injury, Color Blind, Noise, Dust, odor, Sleep Deprivation. Infractions means? Acts that do not constitute misconduct unless repeated. e.g. Not using PPEs, away from plant without permission, log sheets auto filling, offensive language, refusal to follow instructions Cardinal Rules means? Acts that constitutes misconduct. PSM Elements Sr # Risk Based Sr# Culture Based MOC‐Technology 1 Management Commitment Process Safety Information 2 Policy and Principles Risk assessment & Process Hazard Analysis MOC‐Facility 3 Goals, Objectives and Plans 4 Integrated organized Structure Quality Assurance 5 Effective Communication 6 Mechanical Integrity 6 Motivation and awareness 7 Pre start up safety Review MOC‐Personnel 7 Training and Development 8 Audits and Observations Contractor Safety Management 9 Procedures and Performance Standards Emergency Preparedness and Contingency Planning 10 Line Management Accountability and Responsibility 11 Incidents Investigations 12 Safety Personnel 1 2 Technology Category 3 4 5 8 9 10 Facility Category Personnel Category Process Safety Information‐ Risk Based Element 1. Process Safety information PSI: PSI package covers all documents identifying hazards involves in process. 1. Hazard of Material 2. Process Design Basis 3. Equipment Design Basis Hazard of Material: This covers all MSDS covering reactivity data, environmental impacts of all substances used in Company and its communication to all employees. Process Design Basis: This covers PFD, P&ID, Side reactions, run away reactions, SOPs, WI, Maximum indented inventories, data history, alarm and interlock summary, operating guideliness, Standard operating conditions. Revision and new process technology. Equipment Design Basis: This covers PSVs, Vents, Pumps, Compressors, Isometrics, Electrical drawings, Ventilation System, Fire protection system, Agitator design, Instrument design, Emergency System. Process Safety Information‐ Risk Based Element What is Safety Critical Device? SCD are those devices whose failure can result release of unwanted chemicals that can adverse affects on 1. Serious Injuries 2. Property damage 3. Health & Environmental Impacts What SCD identification is important? 1. To keep more Management focus on SCDs always in healthy conditions 2. Address SCDs in stringent PM plans • To keep check these device when not in service Define HHP? High hazardous process will be those part of our plant process whose process release or ignition can cause; (steam at 300 psig, pressurized fuel etc) 1. Fatality 2. Significant Property damage 3. Serious Environmental Impacts • Offsite Impacts Process Safety Information‐ Risk Based Element Define LHO? 1. 2. 3. 4. Low hazardous Operation will be those part of our plant process whose process release or ignition can have low potential towards; (steam at 75 psig, fuel at 1 psig etc) Fatality Significant Property damage Serious Environmental Impacts Offsite Impacts What will be covered in SCD List? 1. 2. 3. 4. • Equipments containing hazardous and toxic material like Ammonia / NA tank Containment Control like PSVs and PRVs Shutdown Control like Interlock instruments Equipment at d/s of containment control like BDH Safety Equipments and Emergency communication like Smoke detectors, Fire Detectors 1. Active Mitigation Measures like Fire Hydrants • Passive Mitigation Measures like Dykes around storage tanks 1. Service and Utility System like Inert system, earthing and grounding. Process Safety Information‐ Risk Based Element Safety Critical Top Level Document: It is the responsibility of TSM to develop and maintain Top level document. Safety critical top level document should be a part of PSI package and any revision to this document must be reviewed by Sub‐HSE‐ P and approved by Exec‐HSE chairman. Safety Critical Equipments List: SCD list contains the following; 1. Storage tank, pump, pressure vessel and piping system. 2. PSVs, PRVs Vents Devices. 3. Dikes and Drainage System 4. Fire Protection Equipments. 5. Electrical ground and bonding. 6. Emergency alarms and communication systems. 7. Safety critical monitoring system (Interlock, ESD) Process Safety Information‐ Risk Based Element PSI package document availability List: Process Engineering: 1. Safety critical top level document for all operating units. 2. Process Specifications 3. Process design basis Mechanical Engineering: 1. 2. 3. 4. Mechanical Specifications Mechanical / Civil Drawings P&IDs Project Close out document Production: 1. Safety critical top level document ‐Copy 2. Operating Manuals. 3. Updated P&ID in control room Maintenance (Equipment / E&I): 1. Equipment repair record 2. Vendor Manuals 3. E&I loops drawings QA ‐ Risk Based Element Quality Assurance Steps: (Starting from Procurement) • • • • • • Specs preparations. Purchase Order preparations Material of Construction Drawing and documentation Technical Review Vendor selection QA/QC plan for fabrication and installation: • Development of inspection briefs • Defining hold points • Fabrication in Vendor shop • Construction • Developing QA checklist (Document Deficiencies Checklist) • Certification • Auditing QA ‐ Risk Based Element • • • • • • • • • • Purchase order identifies the specification, product must comply with. Proper material of construction are selected Applicable data sheet and drawings to be included. Technical reviews are essential to ensure that specification/ purchase order comply with codes and procedures. Vendor selection is done based on vendor’s capability, safety record, past performance and similar job reference, quality control program, financial stability. Reviews to be carried out by experience personnel of various interfaces like Inspection, Process, Operation, safety and Maintenance Quality control plans (procedure, hold points, check lists) shall be developed by relevent project, maintenance or E&I engineer . Inspection/ accepance test and techniques should be conducted to ensure that fabrication is done as per specification. On material arrival, inspection must be based on pre‐defined check list. Once a QA plan for any SCD is developed, it should be made part of PSI package for equipment maintenance, repair or replacement. QA and MI‐ Risk Based Element Quality Assurance and Mechanical Integrity? QA ‐> deals from Purchase Order to erection MI ‐> deals from commissioning to Normal Operation throughout the life Quality Assurance: Quality assurance means establishment and implementation of the procedures that ensures that equipments are fabricated inaccordnace with design specs, assembled and installed properly. Mechanical Integrity: Purpose of MI is target to eliminate breakdown maintenance by doing preventive maintenace of all SCD with defined frequency if not tested then one must raise HSE Waiver for it. Waiver recommendation authority is with HSE Manager and its Approval Authority is with Exec. HSE Chairman. Operation UM responsibility is to ensure PM plans. Performance test run of fire water Responsibility? Process Engineering Section RAGAGEP? Recognize and generally accepted good engineering practices. Repair? • Returning detoriated equipment piece to its original design condition. • Repair history should be kept in equipment file or system file as appropriate MI‐ Risk Based Element • Mechanical Integrity addresses; – Equipment testing and inspection – Predictive and Preventive Maintenance – Reliability Engineering – Maintenance Procedures – Quality Control Procedures – Training and Performance of Maintenance Personnel • All SCDs should have inspection, testing and PM activities schedule containing atleast following information; – Equipment tag number and description – Task‐ A specific maintenance or inspection activity – Procedure reference – Frequency – Data Sheet Reference – Man hours Required – Shutdown required MI‐ Risk Based Element PM plans Responsibilities: Maintenance/ Inspection Department Responsibility: – E&I is responsible to develop, trigger and steward plans for SC instrumentations, electronic OST, Motors, Sirens, Emergency communication. – Inspection to develop, trigger and steward Vessels, Equipments, Tanks, Line, Check valves, Exchangers Plans. – Machinery to develop, trigger and steward Rotary equipments inspection and OST plans. – Establish and define frequency of each device and finalize them after review by operations UM. – Frequency should be assigned as per the requirement of SCD not as per its do‐ability. Frequency not to exceed by 2 years. – Prepare a monthly PM plan on ERP. Operations Responsibility: – Ensure that all Scheduled PM plans are tested and device returned to its service safely. – Review the PM plans for any comments. – Approved PM plans should be available with operations team. – Waiver will be taken for overdue inspection plan whichever is the responsible for delay. MI‐ Risk Based Element MI‐ Risk Based Element • • • • Record Keeping – Each equipment, system or assembly shall have a master file in which all the inspection reports, recommendations and follow up documentation resides. – The inspection and testing record should be kept for the life of the equipment. PM Pland Recommendations – Analyze the inspection results to verify the integrity – Accepted recommendations shall be tracked till their completion/closure. – PM plan recommendations should be specific and do able, have target date that is agreed by respective section. Reliability Engineering – Reliability engineering analysis conducted for SCD to evaluate how long a system can be operated safely before maintenance/replacement. Procedures and Training – Mechanical Integrity Procedures must be prepared covering technical as well as administrative scope of maintenance department. – Relevant interfaces are responsible for the training of their staff on the procedures and testing methodologies. Contractor Safety Management‐ Risk Based Element Contractor: A Contractor is any person / organization who works for FFL but not the employee of FFL Steps for Contractor Safety Management 1. 2. 3. 4. 5. 6. • • • Contractor pre‐qualification (HSE performance and record) Contract Preparation (FFL HSE requirements as part of contract) Bid meetings, Bidding, Contract items, Post contract items Orientation and Training Monitoring + Supervision Contract Evaluation and Record Award of contract shall not be based solely on price Cost terms. A bonus/ penalty clause in the contract is essential to force contractor deliver quality job execution with safety. Contractor shall be supervised in the area through “Contractor Administrator” Process Hazard Analysis‐ Risk Based Element 2. Define PHA? Process Hazard Analysis is the systematic study to identify, evaluate and control hazardous of process using multidiscipline team. By doing this we reduce the risk to an acceptable level. PHA Techniques? 1. 2. 3. 4. What If (Usually done on design stage) HAZOP (Basic Engineering Stage) FMEA (Usually done in instruments case) FTA ( Fault Tree Analysis) When to conduct PHA? 1. 2. 3. • 1. 2. 3. Mothballing Stage Dismantling Stage 1st PHA 10~20% of the design stage 2nd PHA 100% completion of design stage 3rd PHA Pre‐start up stage after erectiion completion (Base line PHA) Existing Facilities Cyclic PHA PHA Frequency? • • 5 years for HHP loop 10 years for LHO loop Management of Change‐ Risk Based Element Define MOC? Analytical review of the change occurring on plant, After review its authorization at certain defined level before implementation so that Risk can be reduced. MOC‐Technology? Approval: 1. Document Change 2. Operational Change Relevant DM for Non SC, Exec‐HSE Chairman for SC Non SC‐ UM, SC Alarm trip set point and Non SC logic change‐ Sub HSE‐P Chairman, SC logic change‐ Exec. HSE Chairman TSD Manager Sub HSE‐P Chairman 3. Analytical Change 4. Test Run Authorization MOC‐Facility? 1. Facility Change 2. Temporary Change 3. Subtle Change Sub HSE –P/M/E&I Sub HSE‐M/E&I Area Unit Manger MOC‐Personnel? Personnel change can be done if below stated is satisfactory and C.I. remain within range. 1. Job Specific Knowledge 2. PSM Knowledge (DM will review C.I. the above once in 2 years) 3. If with the personal change C.I. drop below the cetain defined level then address throguh training or direct hiring the experience staff. Management of Change‐F‐ Risk Based Element Facility Change‐MOC: 1. 2. 3. 4. 5. Any change in ESD hardware or software. Replacement with low grade material or replacement with low rating motor. Safety devices / System modification. Change in Material of Construction. Building modifications which could affect structural integrity, Emergency response, construction inside plant which may affect fire fighting. 6. Addition of new catalyst or filteration media. 7. Consumables like Lube Oils and Analyzer Test Standards. 8. Addition or deletion of components or hardware. 9. Change to process control hardware or software. 10. Changes to assembly points. 11. Temporary equipments attach to process. 12. Rerating of piping and equipments. 13. Introduction of new head count RFID system MOC‐Change process: 1. Pacakage development 2. Peer review 3. Funtional Review 4. Review Features 5. Change Approval in Sub‐HSE committe Management of Change‐F‐ Risk Based Element Temporary Change‐MOC: 1. Box up of leaks 2. Temporary electrical connections 3. Equipment repair using non conforming spares. 4. Machinery repair where there is deviation from standard. 5. Flushing of line with the media not specified in the procedure. 6. Installation of temporary winch or lift. 7. Installation of temporary PC instead of PLC or display unit for trending. 8. Instalaltion of porta cabins. Note: All temporary changes complex in nature should be reviewed through Sub‐ HSE forum. Timeline shoul be set for this change. These changes shoudl be stewarded in Exec‐HSE by respective setion and if exceed the target date then waiver is required. Exec‐HSE committe should that these changes revert back to original state. Temporay change will be initiated by other than operation engineer. Management of Change‐F‐ Risk Based Element Subtle Change‐MOC: 1. Replacement of type of valve , gate to globe valve. Be note that replacement of globe to gate valve will require facility change. 2. Minor rerouting of piping 3. Replacement of type of belts V‐Belt with power belt. 4. Replacement of different brands bearings or vendors. 5. High grade piping installation 6. High horse power motor installation Note: Subtle change will usually be initiated by other than operation engineer. Its approval authorization is up to Area UM in case change of high budget then approval authority will be respective DM. PSSR‐ Risk Based Element Define PSSR? Pre Start up safety review is the final check point for new and modified facilities to confirm that all PSM elements are properly addressed and facility is safe to start up. PSSR is final safety check before close out of project. PSSR Applicable only for: 1. 2. MOC‐Facility Subtle Change (If UM demands) PSSR team mandatory members: 1. 2. 3. 4. 5. Safety Engineer Lead Area Owner Process Engineer Project Engineer Concerned Sections Define BC? Before commissioning points need to be attended before facility start up if not attended and facility started then raise IR‐I Define AC? After commissioning points need to be attended after facility start up with defined target dates Emergency Response Planning‐ Risk Based Element Why Emergency Preparedness and Planning? Emergency preparedness and in depth planning is essential to get outcome of these efforts in terms of mitigation of the emergency impacts on 1. Personnel 2. Environment / Facility 3. Prompt Control on Emergency Success of Emergency Preparedness and Planning? Everyone of us present on site to follow ROLE STATEMENT. How Surrounding Communities can be saved? By launching CAER program “Community awareness on Emergency Response” How we can seek help from Government in ERP? By involving Civil Authorities in our Emergency Preparedness and planning e.g. involvement of NDMA “National Disaster Management Authority” Emergency Response Planning‐ Risk Based Element • In case of Emergency, Who will do what: – Maintenance Manager will remain in his office (safe heaven) and coordinate with MCC for any further action. – UM will remain in their offices (if located in Safe heaven) or come to nearest Assembly area and get in touch with Operation UM for any maintenance support required. – Maintenance staff will stop their work safely, gathered at nearest Assembly area and informed their supervisor about their location so that they can be called in case of any emergency job. THANKS