Preface

 Much attention is on Major Accident Hazard Category industry

particularly involving Hydrocarbon/Chemical process, while
hazard anywhere is a potential cause for harm.
 Systems like OHSAS, EMS, PSM, ISRS offer guidance to
build a strong edifice for structured Safety Management
System.
 The stress in this PPT is on beneficial application of elements
of PSM to suit one’s own context.
 This PowerPoint builds on the earlier paper published in
SCRIBD on “Process Safety Management” under reference to
CFR 1910-119 and covered by its print /publication rights.

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 Why Focus on MAHAC
Process Industry
 Complexity of Reactions
 Diversity and spread
 Domino/Cascade effects-Offsite
 High Inventories, Nature of materials
 Severity of impact

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Industry product--Consumer
Benefits
 Audio Cassettes Paints
 Bubble gum Perfumes
 Cooking Gas Petrochemicals
 Detergents Pharmaceuticals
 Fertilisers Plastics
 Leather chemicals Semiconductors
Masking tapes Tyres etc
 Oils

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Process Safety Management
1.Process Safety Information
2.Process Hazard Analysis
3.Standard Operating Procedures
4.Training
5.Contractor control
6.Pre-start up safety review
7.Mechanical Integrity

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 PSM Contd
8.Non-routine work authorisations
9.Management of Change
10.Investigation of incidents
11.Emergency Preparedness
12.Compliance audit
13.Employee participation

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Process Safety information:

 Chemistry-
 Critical Process Parameters—Runaway, Unstable,
 NFPA ratings—Health, Reactivity, Flammability and
Water reactive
 Toxic, Corrosive, explosive, Radioactive,
carcinogenic data
 TLV, STEL, PEL, Odour threshold values
 Incompatibility Matrix, Interlock matrix

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 Hazard Analysis—(AIChE
Ref)
Typical Applications
Activity Technique
 Design PHA
 Detailed Engineering Fault Tree / Event Tree
Analysis
 Construction / Startup Checklist/Safety
Review

 Pilot Plant Operation / HAZOP

 Routine Operation

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 Process Hazard Analysis
(Contd)
 Decommissioning What–If, Checklist
Analysis
 Expansion HAZOP/Relative
Ranking
 R&D What – If
 Incident Investigation What– If / FMEA /
HRA

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 Operating Procedures
 Process parameters, Equipment operation details
 Normal start-up
 Emergency Shutdown
 Contingency shutdown
 Manual operation safeguards
 Do’s and Don’ts
 Equipment release/takeover steps
 Instrumentation controls, MSDS, Specs

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 SOP review need
Typical:
 Change of Process

 Change of chemistry

 Change of Operating parameters.

 Modifications

 Equipment changes.

 Layout changes

 Lessons Learnt/Operational experience

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 Training
• Identification of training need
• Skill gap analysis
• Job performance need
• New Process /Equipment modification need Behavioural, Functional and New Hire need

 Permits
 Familiarity to Legislation
 Hazard analysis and Risk assessment
 Engineered controls
 Industrial hygiene
 Audits and inspections
 Contractor Safety Management
 Chemical Hazards and Control measures
 Emergency preparedness
 Fire & Explosion hazard prevention
 Electrical Safety
 Static electricity
 Pre-start up safety checks
 Storage area safety
 Chemical Safety Datasheets
 Vehicle & Fleet Safety
 Off-the-Job Safety
 Fire protection systems
 Incident prevention and investigation

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 Training contd..
• Preparation of Training Calendar
• Identification of Trainers/Faculty
• Training attendance sheet record
• Training card fill-up with feedback
• Re-training if required
• A Process Map for Employee competency
development.

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 Training
Training Subjects:
• Pre-start up safety checks

• Permits

• Familiarity to Legislation

• Hazard analysis and Risk assessment

• Engineered controls

• Industrial hygiene

• Audits and inspections

• Contractor Safety Management

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 Training subjects
• Chemical Hazards and Control measures
• Emergency preparedness
• Fire & Explosion hazard prevention
• Electrical Safety
• Static electricity
• Storage area safety
• Chemical Safety Datasheets
• Vehicle & Fleet Safety
• Off-the-Job Safety
• Fire protection systems
• Incident prevention and investigation

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 Contractor Control
 Selection criteria-Track record, Background check
 Training, I.D, Restricted access familiarity
 Methods statement:- Work, JSA
 Tools/ Equipment/Work area checklist-review
 Joint inspections-Compliance monitoring
 Performance review Meetings:- Incidents, Audits,
Violations
 Focus items identification/Implementation
 Permits
 Insurance cover

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Pre-commission checks
• Physical Check up
• Construction/ Modification debris pull out
• Punch List Job Completion certification
• P & ID Validation
• Internal cleaning- De-dusting and by Utilities
• Degreasing, Acidising, Passivating,
• Pressure testing
• Inerting/Box-up
• Blinds List

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 PCC- Contd..
• Check up of Machinery /Equipment
• Check of Vents/Drains, Traps
• Check all Utility connections
• Labeling and ID
• Flow direction markers
• Valves functionality including Remote
control

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 PCC--Documents
• Check of Field and Panel Instrumentation,
Zero checks and calibration, Alarms/Trips
checks
• Field Electrical gear checks—Swtichgear,
Transformers, Capacitors, MCC, FLP
appliances.
• SOP availability
• Check of Communication systems
• O & M Manuals
• Catalogues & Specifications

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 Mechanical Integrity:
 Visual Inspection
 Leak testing
 Hydrotest
 NDT
 MP
 Wet fluorescent magnetic particle
 DP

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 MI- Methods
 X-Ray
 Eddy Current
 Acoustic emission
 Thermal imaging/Infrared
 Vibration analysis

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 MI Aids-Contd
 Boroscopy
 Defectology (Destructive testing)
 Dimensional inspection
 Residual/Remnant Life Analysis
 Plant Life Extension Studies
 Reliability Engineering studies
 Corrosion monitoring

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 Attention spots
 During fabrication
 Weld/Post weld
 Heat treatment—Local treatment, Furnace
treatment, Temperature control, Rate of
heating/Cooling
 Casting
 Forging

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 Focus spots
 Elbows
 Bends
 Pipe supports
 Spring hangers
 Vents/Drains
 Nozzles
 Shells/Heads

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 Heat treatment
in MI
 Annealing
 Normalising
 Quenching
 Hardening
 Tempering

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 Non-routine work practices
 Cold Work
 Hot Work, Confined Space entry,
 Line breaking, Clearing Jams
 Excavation, Electrical Line clearance, Lock out/Tag
out , Work at heights,
 Bye-pass authorisations

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 Checklists
Typical: (Entry to Confined space)
Isolating, Pump out, Emptying, Blinding, Tagging, De-
pressuring, Cooling, Removal of sludge/sediments,
Gas freeing, Evacuating, Ventilating, Gas testing,
Permit preparation/ Issue, Head count, Inspection-
pre-entry, Protection of Personnel/ neighbourhood
equipment, Rescue, Evacuation, (Buddy/Lifelines),
First aid/Fire fighting appliances, Certified
Tools/ELCB, Permits display, Name board,
Compliance monitoring, Renewal conditions- Gas test
frequency, STOP WORK Conditions etc

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 Restoration
 Verification of Job
 Approval/acceptance
 Surrender and closure sign off of permit
 File record, Retention, Disposal (Doc Control)

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Change Management
Reasons:
• SHE
• Productivity, Throughput increase
• Change of Equipment
• Change of Procedure
• Change of Process Chemistry & Technology
• Facility Change
• General Modifications & Changes

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Change Mgt -Pre-requisite.
• Nature of Change-Temp/Perm
• PHA/HAZOP
• Authorisation required
• Checklist,Approval forms
• SOP
• Training & Certification
• PDCA Validation Timetable
• Payout projection

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Change Mgt-- Considerations
• Design Codes/Standards
• Relief systems, Pipe supports,
• Expansion Loops, Insulation, Valves
• Fabrication Standards
• Material of Construction
• Engineered controls:-
Fail Safe Instrumentation, Detectors, Alarms
and Trips, Earthing, Bonding,etc

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Change Management--Docs
• Section Block diagram
• P & ID, Utilities Matrix
• Isometric drawing
• Elevation/Plan
• Change identification
• External approvals as needed
• Lighting, Ventilation and Noise factors
• OEM Catalogues and Specifications

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 Incident investigation
 Involve
 Inspect
 Inquire
 Implement
 Integrate

Information share

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 Analysis
 Fact Finding
 Root Cause Analysis:- QC, Ishikawa, 5 Why
concept,
 Corrective action plan
 Preventive Action Plan
 Problem statement, Data collection, Evaluation,
Review discussion, PDCA, Implementation

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 Incident--What it Means
 Property Damage /Personnel harm
 Plant Start-up Delays
 Restricted Output
 Downtime
 Repairs Cost
 Insurance Costs
 Public Reaction
 Societal impact
 Economic Impact
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 On Site Emergency Plan
KEY ELEMENTS—ON-SITE EMERGENCY PLAN
• Basic Objectives

• Essential Elements

• Definition of Emergency

• ERT (Emergency Response Team) Organisation

• Communication Aids/Means

• Response

• Guidelines for Response Team

• Duties of Team Members

• Roles of Non-ERT Personnel and visitors

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 OSEP--Contd
Control and Protection Measures:
 Forward Control Centre

 Emergency Control Centre

 Assembly Points

 Escape Routes

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 OSEP--Contd
Reference Information:
 Risk Scenarios and Impact Distances

 Built-in Safeguards

 List of Fire & Safety Equipment—Quantity and

Spread
 Fire Protection System Layout drawing

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 OSEP--Contd
 List of Firsts Aid and Personal Protective Equipment
—Quantity and Spread
 Other ER Equipment Quantity and Spread
 Ambient Air Quality Monitoring equipment
 List of Antidotes
 Drawing of Drains
 MSDS

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 OSEP--Contd
 Layout/Plot Plans
 Wind Direction Details
 List of Key Contact Persons
 Key Notification Telephone Numbers
 Neighbourhood Charts/Maps
 List of Contractors

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 OSEP--Contd
 Operational Emergency Handling Procedures
 Spill Response Chart
 Incompatible Chemicals Chart
 IED/Malicious damage emergency response
checklist
 Storm/Earthquake other natural perils response
checklist
 Civil defence plan guidance notes

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 OSEP--Contd
Off-Site Emergency Services—
Contact Particulars:- List of
• Hospitals and Medicare Points
• Subject Matter Specialists, Medicare
Specialists
• Pharmacies/Medical Stores
• Neighbourhood Industries, NGOs, Voluntary
Organisations, District Crisis Group Response
Authorities

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 Compliance Audits
 Self-Internal, Corporate,
 Statutory
 Industry Specific--OISD
 External-3rd Party
 BIS 14489
 5-Star
 PSM (USA CFR)
 OHSAS/EMS
 ISRS
 Loss Prevention/Risk Management Specialists

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 Good Audits
 Clarity in Scope definition
 Standards referenced
 Audit methodology—LPRM Specialist- Core competency,No
rigid formats, No boundaries,
Out of the Box approach, Bare all/ Tell all
Partners/ Benchmark Facilitators-Reputation driven.
 Pre-audit survey/information input
 Physical visit—Opening meeting,
Site co-ordinators, Physical tour, Interaction, Documents
review, Audit notes, Draft sum-up, Closing meeting, Focus
area identification, Action plan Roadmap, Final report

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 Employee Participation
 Emphasis during advertisement/interview
 During Class/Hands-on/Refresher training
 SOP write-up
 O & M review
 Area audits/pep talks/permits preparation
 Site safety committees
 As internal faculty to train fresher
 Planning/Organising promotional activities
 Off-the –Job/Externally
 Continual improvement Implementation

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 What to do
 View First-aid events as Fatality
 Train/Train/Train/Audit/Audit/Audit
 RCA/CAP/PAP
 Fact find not fault find
 Implement not ignore
 Share & Learn
 CARE

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 Where it leads to
 Reputation Management
 Global Outlook
 International Standards
 Track record protection
 Accountability for Quality/Impact
 Engineered Controls
 Administrative Measures
 PPE
 Partnership Approach
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 Summary-Where to start
LEVERAGE FROM
 LESSONS LEARNT-DOCUMENT

 INTERNAL EXPERIENCES

 GROUP INFORMATION SHARE

 NETWORKING

APPLY:
SYSTEM DRIVEN APPROACH
SELF-REGULATORY CONCEPT
EVERYONE’S RESPONSIBILITY
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 List of abbreviations
BIS Bureau of Indian Standards
CAP Corrective action plan
CARE Constant accident reduction (removal) efforts
DP Dye penetrant
EMS Environment management system
ERT Emergency response team
FLP Flameproof
FMEA Failure mode effects analysis
HAZOP Hazard operability
HRA Human ranking analysis
ID Identity
IED Improvised explosive device
ISO International organization for standardization
ISRS International safety rating system
JSA Job safety analysis

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 Contd
LPRM Loss prevention and risk management
MAHAC Major accident hazard category
MCC Motor control centre
MI Mechanical integrity
MP Magnetic particle
MSDS Material safety data sheet
NDT Non destructive testing
NGO Non governmental organisations
O&M Operation & Manual
OEM Original equipment manufacturer
OHSAS Occupational health & safety assessment series
OISD Oil industry safety directorate 
P &ID Piping & instrumentation diagram
PAP Preventive action plan
PDCA Plan, develop, check and accept
PEL Permissible exposure limit
PHA Process hazard analysis
PPE Personal protective equipment
PSM Process safety management

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 Contd
QC Quality circle
RCA Root cause analysis
SHE Safety, Health & Environment
SOP Standard operating procedure
STEL Short term exposure limit
TLV Threshold limit value

Acknowledgments--Preface

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