11

Process SafetyProcess SafetyManagementManagement

…. and its Impact on the Professional Engineering Community

Brian D. Kelly P EngBriRisk Consulting Ltd.Calgary AB T3G 5J6

Sept 14, 2010

PRESENTATION OVERVIEWPRESENTATION OVERVIEW

22

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.

33

Occupational Health and Safety

Process Safety

• Workplace rules• Worker training• Supervision• Individual behaviors• Safety equipment• Focus on individual

well being

• 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

44

Process Safety concepts were first adopted by companies that specialized in the production of highly hazardous chemicals (DUPONT, ICI).

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.

Early DevelopmentEarly Development

55

Several PSM protocols exist worldwide. OSHA 1910.119 (US) is legislated and requires

“designated” operations to comply with provisions of 14 element framework.

Center for Chemical Process Safety (industry alliance) recently developed a 20 element risk based framework that better addresses people, process and equipment issues.

PSM element framework should be tailored to type of operation.

PSM ProtocolsPSM Protocols

66

Canadian Canadian RequirementsRequirements

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.

77

Co

mm

itm

ent

to P

SM

Co

mm

itm

ent

to P

SM

Un

der

stan

d H

azar

ds

Un

der

stan

d H

azar

ds

and

Ris

kan

d R

isk

Man

age

Ris

kM

anag

e R

isk

Lea

rn f

rom

Exp

erie

nce

Lea

rn f

rom

Exp

erie

nce

PSM StructurePSM Structure

88

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 FrameworkRisk Based PSM Framework

99

PSM StructurePSM Structure 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.

A better understanding of process safety may be acquired through a participative workshop with other professionals.

1010

Engineering Discipline Involvement

CHEMICAL Process selectionOperating conditionsSafe operating envelopeProcess designProcess controlSafeguardsMonitoring

CIVILSite layoutElevated structuresGradingDrainageBuildingsFacility sitingInfrastructure

MECHPressure envelope designRotating equipmentCodesMonitoring

ELECTRICALReliable powerArc flash protectionArea classificationGrounding bondingGFIs

1111

Why Process Safety Why Process Safety Management?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

1212

Executive SupportExecutive Support

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

Executive support is required in the following areas to ensure PSM success: