PSM Practice

PHA Sharing
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Objective
• Review requirements of PHA standard 25a
and recent changes
• Share and propagate training and
implementation experience to augment PHA
IA skills in the AP region.
• Identify developmental opportunities for PHA
delivery resources
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Evolution of Process Safety and Risk

Management in DuPont
Chronology
• Early powder mills and explosion hazards – 1802
• Many fatalities including DuPont family members - 1921
• Process reviews - 1950s
• Louisville incident - August, 1965
• PHRs - 1965-1979
• Company experience - 1978
• Process hazards management concept - 1979
• Updated process safety and risk management guidance -
1986, 1992, 1997, 1998, 2003, 2009
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50+ Year History of Process-Related Fatal

Injuries;
Five Year Groups
55 60 65 70 75 80 85 90 95 00 05
Years
59 64 69 74 79 84 89 94 99 04 08

Explosions 9 5 27 8 6 4 0 0 0 0 1

Fires 2 2 7 0 1 0 1 0 0 0 0

Toxic 6 2 1 1 0 1 0 0 0 1 0

Other 3 4 2 1 2 2 3 4 1 0 0

TOTAL 20 13 37 10 9 7 4 4 1 1 1

Process Safety Management is a journey not a destination

 5

DuPont PHA Standards

S21A
PSM

S25.3A S25.6A
S25A
Toxic Gas Consequence
PHA Analysis
Releases

S25.2A
Facility
Siting
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S21A Requirements

• Each site manufacturing, handling,

using, or storing Hazardous Substances
will develop a detailed PSM program, so
that process hazards are identified,
understood, and controlled to prevent
process-related injuries and incidents.

Process Hazards Analysis is one of

fourteen required elements.
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Process Safety and Risk Management

Model
 8

S25A Process Hazards Analysis

l Process Hazards Analysis will be conducted consistent with the
requirements of S21A and S25A.

t Planning and Preparations

t Hazards Identification
t Consequence Analysis
t Hazards Evaluation
t Human Factors
t Facility Siting
t Inherently Safer Process
t Developing and Managing Recommendations
t Report Documentation
t Management Systems

S25A was revised in February 2009

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Team Preparations •Leader Responsibilities

• Organize the study
• Direct Activities
•Team Preparations • Maintain thoroughness and consistency
• Review Charter • Guide the analysis to completion

• Discuss boundaries • Keep team on schedule

• Inform management of progress
• Set expectations
• Issues meeting notes
• Establish schedule • Complete the final report on schedule
•Team Charter •Member Responsibilities

• Responsibilities • Participate actively

• Give priority to PHA assignments
• Tasks
• Tour facilities periodically
• Objectives • Identify major hazards
• Establish alignment • Make specific recommendations
and commitments • Conclude and document the if process
Copyright © 2006 E. I. du Pont de Nemours and Company. All rights reserved. studied is safe to operate
 10

Process Information Inputs to PHA

The PHA team must have an up-to-date Process Information
Package before the PHA has begun. The package includes:
• Hazards of Materials
• Process Design Basis
• Equipment Design Basis
• PI&Ds
• Operating Procedures
• Standard Operating Conditions
• Management of Change Documents
• Related Incident Investigation Reports
• Prior PHAs form the same process
• PHAs from similar processes
Copyright © 2006 E. I. du Pont de Nemours and Company. All rights reserved.
 11

PROCESS HAZARDS ANALYSIS FORMULA

PHA = HI + CIM+ FT+CA+PHR + FS + HF + ISP + STORM + D + MR + FU

HI = Hazard Identification
CIM = Chemical Interaction Matrix
Identify and Understand
FT = Field Tour
CA = Consequence Analysis
PHR = Process Hazards Review
FS = Facility Siting Analysis
Analyze, Assess and mitigate
HF = Human Factors Analysis
ISP = Inherently Safer Process Analysis
STORM = Safe To operate & Recommendation
D = Documentation
Own, Commit and Act
MR = Management Review
FU = Follow-up of Recommendations

“A Combination of Science and Skill ”

Copyright © 2006 E. I. du Pont de Nemours and Company. All rights reserved.