Syllabus PME 531 Process Safety Management

Course Objectives: Course addresses management and engineering design concepts required for process safety in chemical and biotechnology systems, with pharmaceutical manufacturing applications. Basis is Process Safety Management (PSM) model from OSHA and the Center for Chemical Process Safety of AIChE. Content focuses on sound engineering principles and practices as they apply to industrial situations, project design, risk mitigation, process and equipment integrity, and engineering codes and standards. Includes calculation of risk assessment scores and cost justification factor; HAZOPs study methodology using P&IDs; safety valves, rupture discs, explosion venting, and emergency scrubbers design considerations; MSDS uses; overall control, reduction, and prevention of hazardous materials incidents; case studies. This course will review the 12 elements of the Process Safety Management (PSM) model. PSM systems were developed as an expectation/demand of the public, customers, in-plant personnel, stockholders and regulatory agencies because reliance on chemical process technologies were not enough to control, reduce and prevent hazardous materials incidents. PSM systems are comprehensive sets of policies, procedures and practices designed to ensure that barriers to major incidents are in place, in use and effective. The objectives of this course are to: 1. Define PSM and why it is important 2. Describe each of the 12 elements and their applicability 3. Identify process safety responsibilities 4. Give real examples and practical applications to help better understand each element 5. Share experiences and lessons learned of all participants 6. Assess the quality and identify enhancements to your site PSM program Course Outline: Element #1 Accountability: Objectives and Goals Accountability is the obligation to explain and answer for ones actions that are related to company expectations, objectives and goals. Accountability must be built into each element of the process safety management system. There are 9 accountability components: continuity of operations, continuity of systems, continuity of organization, quality process, control of exceptions, alternative methods, management accessibility, communications and company expectations. Element #2 - Process Knowledge and Documentation Capturing process knowledge is the foundation on which many aspects of a process safety program are built. Many companies have formal procedures for maintaining and making available this information in process safety or process libraries. There are 7 "process knowledge and documentation" elements: chemical and occupational health hazards, process definition and design criteria, process and equipment design, protective systems, normal and upset conditions (SOPs), process risk and management decisions and company memory. These elements are important to keep in mind throughout the life cycle of an operation

Element #3 - Process Safety Review Procedures for Capital Projects Why are process safety reviews needed. Review the 5 Phases of a Typical Major Capital Project, Appropriation Request Procedures, Siting, Plot Plan, Hazard Reviews, Process Design and Review Procedures, Project Management Procedures and Controls. Element #4 - Process Risk Management Elements of process risk management are: Hazard identification, risk analysis of operations, reduction of risk, residual risk reduction, process management during emergencies, encouraging clients and suppliers to adopt similar risk management practices, selection of businesses with acceptable risks. Element #5 Management of Change Management of change includes the following components: change of process technology, change of facility, organizational changes with potential safety impact, variance procedures, permanent changes, temporary changes. Element #6 - Process and Equipment Integrity The components of the process and equipment integrity element are: reliability engineering, materials of construction, fabrication and inspection procedures, installation procedures, preventive maintenance, process, hardware and systems inspection and testing, maintenance procedures, alarm and instrument management, demolition procedures. Element #7 - Human Factors There are 3 significant components of this element: Operator/process and operator/equipment interfaces; administrative controls vs hardware; human error assessment. Element #8 - Training and Performance The components of the training element are: definition of skills & knowledge, design of operating and maintenance procedures, initial qualifications assessment, selection & development of the training program, measuring performance and effectiveness, instructor program, records management, ongoing performance and refresher training. Element #9 - Incident Investigation Define and review major incidents, third-party participation, follow-up and resolution, communication, incident recording, reporting and analysis, near-miss reporting. Element #10 - Company Standards, Codes and Regulations Company standards, codes and regulations exist to define the minimum acceptable safe practices and provide consistencies at all locations. They assist engineers in making design decisions and are an aid to plant personnel in the safe operation of their site. They define the companys commitment and interpretation to federal or state legislation. Element #11 Audits and Corrective Actions Audits validate whether a sites PSM program is adequately doing what is expected and whether the expectations are appropriate. The components of an audit program include: PSM system audits, process safety audits, compliance reviews, internal/external auditors and corrective actions.

Element #12 Enhancement of Process Safety Knowledge Enhancement of Process Safety Knowledge equals continuous improvement. This can give a competitive advantage to a company that strives to look for new technology or benefit from its historical information via better yields, quality, productivity and less lost time due to incidents. Management can improve process safety knowledge by encouraging employees to attend trade shows or seminars, contribute to process safety-oriented research and share non-proprietary information via benchmarking.

Course Material:
Text book(s) "Plant Guidelines for Technical Management of Chemical Process Safety", by the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers ISBN 0-8169-0499-5 Additional Text (Optional) Fundamentals of Process Safety, by the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers ISBN 0-85295-431-X Additional Reading and Reference Materials used in Course Development "Guidelines for Technical Management of Chemical Process Safety", by CCPS Center for Chemical Process Safety of the American Institute of Chemical Engineers ISBN 0-8169-0423-5 "Guidelines for Safe Process Operations & Maintenance", by the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers ISBN 0-8169-0627-0 "Guidelines for Auditing Process Safety Management Systems", by the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers ISBN 0-8169-0556-8 "Guidelines for Implementing Process Safety Management Systems", by the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers ISBN 0-8169-0590-8 "Guidelines for Integrating Process Safety Management, Environment, Safety, Health, and Quality", by the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers ISBN 0-8169-0683-1 PSM Program, Merck & Co., Inc., Rahway, NJ Website for information on ordering above books: aiche.org/pubcat/ Supplemental Reading: Chemical Process Safety, Fundamentals with Applications, Second Edition by Daniel A. Crowl & Joseph F. Louvar Published by Prentice Hall, Inc. ISBN 0-13-018176-5 Bhopal, Anatomy of a Crisis, by Paul Shrivastava Ballinger Publishing Compnay ISBN 0-88730-084-7

Other useful URLs: osha.gov/SLTC/processsafetymanagement/aiche.org/ccps/

Grades:
Week 0 Pretest (no deduction for incorrect answers Pre-Course Questionnaire Week 1 Questions Week 2 Questions Week 3 Questions Week 4 Questions Week 4 Extra Credit Questions Week 4 Submit Term Paper Topic Week 5 Questions Week 6 Questions Week 7 Mid-Term Exam Mid-Term Exam Extra Credit Submit Term Paper Outline Term Paper Outline Week 8 Questions Week 9 Questions Week 10 Questions Week 11 Questions Week 12 Week 12 Questions Submit Term Paper Term Paper Extra Credit Paper Week 13 Final Exam Final Exam Extra Credit Discussion Participation Grand Total Minus Extra Credit Total Basis for Grade Points 50 50 60 50 50 50 50 50 50 50 400 50 50 100 50 50 50 50 50 50 500 100 500 100 200 2810 300 2510 Percent 2.0% 2.0% 2.4% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 15.9% 2.0% 2.0% 4.0% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 19.9% 4.0% 19.9% 4.0% 8.0% 112.0% 12.0% 100.0%