Process Safety
Management
…. and its Impact on the
Professional Engineering Community
PRESENTATION OVERVIEW
Brian D. Kelly P Eng
BriRisk Consulting Ltd.
Calgary AB T3G 5J6
Sept 14, 2010
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Process Safety Management is a comprehensive
framework of activities for managing the integrity of
a hazardous (chemical) operation. Its goal is to
eliminate (prevent and mitigate) loss of containment
incidents.
Loss of containment events can lead to fire,
explosion or toxic effects and may result in large
numbers of casualties.
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Occupational
Health and Safety
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Workplace rules
Worker training
Supervision
Individual behaviors
Safety equipment
Focus on individual
well being
Process Safety
• Collective commitment
• Addresses events over
which the individual
worker has little or no
control
• Focus on systems
• Broader impact –
events that could affect
groups of workers or
general public
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Early Development
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Process Safety concepts were first adopted by
companies that specialized in the production of
highly hazardous chemicals (DUPONT, ICI).
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1984 Bhopal, India chemical plant incident released
toxic gas into local community causing the deaths
of 3000 people.
Analysis indicated the accident was preventable
through formal management systems.
Industrialized nations formally adopted Process
Safety Management.
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PSM Protocols
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Several PSM protocols exist worldwide.
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OSHA 1910.119 (US) is legislated and requires
“designated” operations to comply with provisions of
14 element framework.
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Center for Chemical Process Safety (industry alliance)
recently developed a 20 element risk based
framework that better addresses people, process and
equipment issues.
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PSM element framework should be tailored to type of
operation.
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Canadian Requirements
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No formal PSM regulation per se.
CEPA 1999, section 200 (Environment Canada)
mandates the development and implementation of
emergency response plans for environmental
emergencies in designated high hazard industries.
Bill C-45 (Westray bill) includes amendments to the
criminal code of Canada.
– Legal duty for all persons directing work to take “reasonable
steps” to ensure the safety of workers and the public.
– Severe penalties for failing to ensure safety and integrity of
operating facilities.
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Learn from Experience
Manage Risk
Understand Hazards
and Risk
Commitment to PSM
PSM Structure
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Risk Based PSM Framework
Commit to Process Safety
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Process Safety Culture
Compliance with Standards
Process Safety Competency
Workforce Involvement
Stakeholder Outreach
Learn from Experience
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Incident Investigation
Measurement and Metrics
Auditing
Management Review and
Continuous Improvement
Understand Hazards and Risk
 Process Safety Information
 Hazard Identification and Risk
Analysis
Manage Risk
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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
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PSM Structure
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Each of the 20 elements of Risk Based Process
Safety is fully described in the CCPS Guidelines
book: Guidelines for Risk Based Process Safety,
Wiley, 2007, ISBN 978-0-470-16569-0.
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A better understanding of process safety may
be acquired through a participative workshop
with other professionals.
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Engineering Discipline
Involvement
CHEMICAL
CIVIL
MECH
ELECTRICAL
Process selection
Operating
conditions
Safe operating
envelope
Process design
Process control
Safeguards
Monitoring
Site layout
Elevated
structures
Grading
Drainage
Buildings
Facility siting
Infrastructure
Pressure
envelope
design
Rotating
equipment
Codes
Monitoring
Reliable power
Arc flash
protection
Area
classification
Grounding
bonding
GFIs
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Why Process Safety
Management?
PSM framework is essential to avoidance of loss
of containment incidents – these can put a
company out of business
 PSM drives rigor and discipline into an operating
organization
 An effective PSM framework will also address
smaller incidents including those not associated
with loss of containment
 PSM will improve the bottom line
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Executive Support
Executive support is required in the following
areas to ensure PSM success:
1. Financial – additional resources (people and
money) required for PSI, PHAs, training,
maintenance etc.
2. Production penalty – may need to suspend
production if warranted by serious process
safety concerns
3. Hold organization accountable – engage in
discussions with operations personnel about
process safety issues. Ask questions
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