PSM Implementation Tools and Outcomes

TOOLS NEEDED TO IMPLEMENT
PS ELEMENTS
Implementation of RBPS - Ashraf Elsayed

THE DESIRED OUTCOMES FROM
EACH ELEMENT
PSM Element Desired Outcomes

1. PS Culture 1- Management Walk through
2- PS Issues on management agenda
3- PS culture surveys
4- Assigned budget for PS activities
5- Designated Senior manager for PS system

TOOLS TO IMPLEMENT PS CULTURE
ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF TOOL

PS culture PS culture survey To initially assess
Management Walk (and periodically
through re-assess) PS
Culture with regard
to Key Principles
and develop action
plans to improve
Periodic self To monitor PS API RB 754 Tier 4
assessment/ culture
metrics

CULTURE SURVEY

CULTURE SURVEY

CULTURE SURVEY

CULTURE SURVEY

CULTURE SURVEY

CULTURE SURVEY

CULTURE SURVEY

CULTURE SURVEY

CULTURE SURVEY

API RB 754 Tier 4
Reflect site performance which comprised

of operating discipline and management
system performance.
It may identify opportunities for both
learning and systems improvement.

EXAMPLES OF TIER 4 INDICATORS
1) Schedule of process area PHA retrospective and revalidation completed

on time by fully qualified teams.
2) % past-due PS actions from incident investigations, hazard evaluations or

compliance audits.
3) % PS required training sessions completed with skills verification.
4) % PS required SOP reviewed or revised as scheduled.
5) % sampled PTW that met all requirements.

6) % emergency response drills completed as scheduled.
EXAMPLES OF TIER 4 INDICATORS
7) % inspections of SCE completed on time.

8) Response to safety critical inspection findings (e.g. nonfunctional PRDs and SISs). This
may include Proper approvals for continued Safe operations, sufficient safeguards, and
timeliness of repairs, replacement, or rerate.
9) % sampled MOCs and PSSRs that met all requirements and quality standards.
10) Key measures of fatigue risk management systems may include: % overtime, number of
open shifts, number of exceptions, etc.

EACH ELEMENT

2. Compliance with Standard 1-An accurate, complete, up-to-date, and accessible set of
documents, data, and information.
2-Categories of information include internal company guidelines,
consensus codes and standards, applicable regulations, and laws.
3-Guidance documents that may be created to help ensure efficient,
consistent conformance to standards

TOOLS TO IMPLEMENT COMPLIANCE
WITH STANDARD

Compliance PSM applicability or To identify covered Process risk
with standard process/risk screening PS processes and screening tool
document their
List/guideline/corporate boundaries
standards of relevant PS - To ensure safety
standards, codes, in all phases
regulations and laws - To comply with
over the life of the standards
process.

EACH ELEMENT

3.PS Competency 1- Low turn-over ratio.
2- Competence Assurance Program
3- Succession planning for safety critical positions.
4- Learning channels are available (news letters / media).

TOOLS TO IMPLEMENT PS COMPETENCY
PS Awareness Training for To communicate PSM www.CSB.gov
competency Employees operating, covered processes, Recognizing
maintaining and supporting boundaries, primary hazards Catastrophic
PSM Covered Processes and safeguards to personnel Incident warning
Signs in the
Process Industries
(CCPS,2011)
A short-term and long-term To identify, organize and IDP; individual
(with a 3-5 year outlook) fund activities (based on development plan
learning/ communication business case objectives)
plan/ strategy that support progress
toward organizational
PSM objectives and promote
PSM competency
TOOLS TO IMPLEMENT PS COMPETENCY
PS The framework of PS Targeted at multiple audiences, ICHEME PS competency
competency knowledge and ranging from front chemical operators, guide
expertise versus the mechanics and instrument technicians
desired competency through senior management,
level in a "super- matrix" including financial and business
format executives. Gaps between existing and
desired training levels can be
identified and potential remedies
suggested
A process to share PSM To develop action plans from learning - CCPS PS beacon
incidents and learning, as appropriate and to maintain a sense www.aiche/CCPS
both from internal and of vulnerability - Company internal
external PSM incidents incident sharing doc.

PS BEACON

EACH ELEMENT

4.Workforce involvement Active engagement of workers at all levels of the
organization, and a correspondingly greater sense of worker
ownership and commitment

TOOLS TO IMPLEMENT WORKFORCE
INVOLVEMENT
ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF

TOOL
Workforce Specific Employee - To document and
Involvement Participation Plan communicate PSM related
workforce
involvement opportunities
- To comply with
Government regulations if
applicable

EACH ELEMENT

5.Stakeholder Outreach 1- Successful communications with relevant stakeholders
that build trust and good will.
2- Communication plans, messages, tools, brochures,
training materials, and records.

Tools to Implement Stakeholder Outreach

TOOL
Stakeholder Hazard Assessment To identify areas of concern in Guidelines for
Outreach Study and/or Facility worst case and alternative release Evaluating
Siting Study API 753 scenarios for PSM covered Process Plant
processes Buildings for
Stakeholder Outreach - To identify off site and onsite External
Plan organizations, people, facilities and Explosions, Fires,
processes that may be affected and Toxic
- To document how to Releases, 2nd
communicate hazards, safeguards Edition (CCPS,
and to both develop and 2012) RBPS book
Implementation of RBPS - Ashraf Elsayed communicate ERP for releases
EACH ELEMENT

6.Process Knowledge Management 1- Accurate, complete, and up-to-date information to
support PS activities at each life cycle phase
2- A system to store and retrieve this information.

TOOLS TO IMPLEMENT PROCESS
KNOWLEDGE MANAGEMENT
ELEMENT TOOL PURPOSE OF TOOL EXAMPLE

OF TOOL
Process List of PS Information for To ensure process Engineers Guidelines
Knowledge each covered PSM process, understand what types of PSI are for PS
Management that covers: needed and the scope/ complexity of Document
- Hazards of the materials the information ation
- Hazards of the equipment -To ensure appropriate information is (CCPS,
- Hazards of the Process considered for PHA and Changes 1995)
-To ensure regulatory
requirements for PSI are met
EACH ELEMENT

7.HIRA 1- Guidelines for planning and conducting studies,
2- Documented understanding of the risks of the process or activity,
3- Documented risk tolerance criteria,
4- Possible risk control measures, resolutions, and implemented actions,
5- Documented understanding of the residual risks after control measures are
taken,
6- Completed risk analysis reports.
7- Recommendations for improving asset integrity, procedures, training as
well as up-to-date action item tracking lists and risk communication
materials.
TOOLS TO IMPLEMENT HIRA
TOOL
HIRA Guideline/Procedure to To identify the appropriate HIRA tools for processes Guidelines
detail the process to follow - To ensure the appropriate personnel participate for Hazard
for HIRA - To ensure the appropriate personnel review and Evaluation
approve recommendations and action plans Procedures,
Action tracking system -To ensure that recommendation action plans are 3rd
resourced and tracked to resolution edition
(CCPS, 2008),
EGPC
guideline
Software tool for To allow quicker more efficient, and consistent OPEN PHA,
documenting hazard completion of PHA worksheets, etc PHA PRO,
studies, such as HAZOP, -To enable better team review/consensus by BOW-TIE,
LOPA, FMEA, and projecting the tables/checklists SAFETI
associated Checklists -To allow easy incorporation of risk ranking, LOPA
calculations, etc.
EACH ELEMENT

8.Operating Procedures Current, accurate, and useful written instructions that apply to routine
tasks.

TOOLS TO IMPLEMENT OPERATING
PROCEDURES

Operating Procedure to detail the To ensure process owners include Guidelines for
Procedures process to follow in the following in procedures: writing Effective
Developing SOP - Operating phases (i.e. SD, SOP (CCPS, 1996) -
startup, normal operations,
emergency operations, etc.)
- SOE
- Hazard information
- Safety systems and their
functions

EACH ELEMENT

9. Safe work Practices An integrated system of procedures and permits.

TOOLS TO IMPLEMENT SAFE WORK
PRACTICE

Safe Work Safe Work To ensure appropriate PTW,
Practice Procedures/Permits for risk assessment and Handover,
highly hazardous tasks/ safety precautions Procedures,
locations, including the are taken for highly LOTO,
following: hazardous tool box talk,
- Hot Work tasks/locations TRA,
- Confined Space Entry Isolation procedures.
- Lockout/Tagout
- line Breaking
- Access Control

EACH ELEMENT
10. Asset 1- Reports and data from initial inspections, tests, and other activities to verify
integrity and that equipment is fabricated and installed in accordance with design specs and is
reliability fit for service at startup.
2- Results from ongoing ITPM tasks, performed by trained or certified
personnel and based on written procedures that conform to generally accepted
standards, that help ensure that equipment remains fit for service.
3- Controlled repairs and adjustments to equipment by trained personnel using
appropriate written procedures and instructions.
4- A system to control maintenance work, repair parts, and
maintenance materials needed for the work to help ensure that equipment
remains fit for service.
5- A quality assurance program that helps prevent equipment failures that could
result from use of faulty parts/materials or improper fabrication, installation, or
repair methods Implementation of RBPS - Ashraf Elsayed
TOOLS TO IMPLEMENT ASSET
INTEGRITY AND RELIABILITY

OF TOOL
Asset A List/ spreadsheet that covered all PS To ensure PS covered equipment is Mechanical
Integrity equipment, facilities and their identified, along with their safety Integrity List
And installation, maintenance and function, test and inspection (asset
inspection types and frequencies, as frequencies and types of test and register)
Reliability
well as the regulatory standards/ inspections
practices they are based on.
A guideline for Mechanical Integrity To ensure that tests and Inspection MI Test and
Test and inspections are based on codes and standards Inspections
(CCPS 2006)
Software tools for managing To ensure tests are performed on SAP (maint.)
maintenance and/ or the overall schedule, adequately documented, Palladio (RBI)
Mechanical Integrity program and results reviewed/analyzed $190k
EACH ELEMENT
11. Contractor 1. The creation of a list of pre-qualified candidate contract firms.
Management 2. The selection of specific contractors with strong safety programs and
good safety records.
3. The preparation of contract employers and their employees to safely
provide their services based upon an understanding of relevant risks,
facility safety controls and procedures, and their personal safety
responsibilities.
4. The safe delivery of the contracted services, with improved quality and
productivity.
5. Appropriate documentation of the contractor screening and selection
process, the contractor's safety performance during the performance of
its services, and any other issues relevant to the evaluation of the
contractor for potential selection for future services.
TOOLS TO IMPLEMENT CONTRACTOR
MANAGEMENT

OF TOOL
Contractor A checklist/ TRA that identifies hazards To ensure PS hazards and their associated TRA,
Management safeguards are identified before work is Contractor and
undertaken Client Relations
to Assure PS
(CCPS, 1996),
EGPC guideline
overview training and safety To ensure knowledge of hazardous
requirements materials and processes are conveyed to
the Contractor
PTW to communicate hazards and To ensure hazards of planned tasks are PTW
required safeguards communicated and the associated
safeguards to be employed
EACH ELEMENT

12 . Training and 1- A set of job performance standards and a list of initial and ongoing
Performance training needs for each job position.
Assurance 2-A set of training materials should be developed for each training need
that will be met by internal resources. For other training needs, a list of
approved suppliers should be developed.
3-A training record should be provided for each worker showing that
person's training needs, the dates on which initial training and any
refresher training was satisfactorily completed, and a schedule of future
training classes.
4-The work team should document an appropriate approach for
verifying performance and provide examiners with the resources (model
tests, observation checklists, etc.) necessary to test workers.
TOOLS TO IMPLEMENT TRAINING AND
PERFORMANCE ASSURANCE

Training And A checklist/template ( To ensure that training workflow
Performance often referred to as a required training is and matrices
Assurance Training Matrix) for identified for each
Training Verification job, completed on
schedule, and
adequately
completed/
documented

TRAINING MATRIX

EACH ELEMENT

13. MOC A properly reviewed and authorized change request that identifies
and ensures the implementation of risk controls appropriate to the
proposed change.

TOOLS TO IMPLEMENT MOC

OF TOOL
MOC MOC tool (with processes to create a unique identifier - To ensure appropriate resources are front
and assign a change level based on scope/ complexity of allocated for the scope of the change in line data
the change) for each change. this can be either: terms of H&S reviews/ assessments.
- A simple paper-based form accompanying the hard - To ensure an orderly process is followed
solutions
copy Implementation information for the change (with for those assessing/ reviewing and www.fida
the unique identifier and change level logged Onto a approving the change ta.com
separate Tracking spreadsheet) -To ensures changes are not "lost" $60k
- A sophisticated database/ IT driven process that -To ensure that important implementation
requires Electronic signatures for the change to steps/ action plans are not missed,
proceed. including hazard reviews, procedures,
A hard copy or electronic set of Questions that training, PSSR, etc.
identifies the major hazards and the scope of those -To ensure Regulatory requirements for PS
executing the Change and other business regulations are met
An integrated or separate process to To ensure that organizational changes do

manage specified Organizational Changes not adverse impact the PSM system or its
Implementation of RBPS - Ashraf Elsayed performance
Key Steps
Implement Change 8
Obtain Approval 7
List Key Completion Steps 6
Complete Risk Assessments 5
Review Documentation 4
Identify Controls 3
Consider Impacts 2
Identify the Change 1
EACH ELEMENT

14. Operational Readiness process and startup authorization is reviewed and
Readiness documented on forms

TOOLS TO IMPLEMENT OPERATIONAL READINESS
Operational PSSR process A process review/timeout to ensure PSSR Process

Readiness critical steps are taken that will prevent description
PS incidents, prior to hazardous
chemicals being introduced to a process.
This includes startups after a:
• Project
• Operational Shutdown
• Emergency Shutdown
• Maintenance Shutdown
PSSR Ensures critical pieces of equipment (e.g. Guidelines for
chicklists/pro valves aligned), procedures, training, Performing
cedures maintenance and PSI are updated prior Effective PSSR (CCPS,
to start-up 2007)
CHECKLIST Implementation of RBPS - Ashraf Elsayed
EACH ELEMENT

15. Conduct of 1-A clear chain of command, defined authority, and accountability
Operations for reliable work performance in accordance with approved
procedures and work practices should also be established.
2-A policy describing the organization's overall expectations for
worker conduct and specific procedures and goals for implementing
those policies.

TOOLS TO IMPLEMENT CONDUCT OF
OPERATIONAL

Conduct of Tools for managing the To ensure reliable, Conduct of Operations
Operational People, Process, and Plant consistent, and correct and Operations
aspects of a facility in a execution of the policies, Operational
consistent, disciplined way procedures, and practices Discipline: For
- Recognition and that make up a facility's Improving PS in
disciplinary action system. risk management system Industry (CCPS, 2011)
- proper and safe
communication tools.

EACH ELEMENT
16. Emergency Effective and tested emergency response plans, trained and
Management equipped response teams, and effective methods of protecting (1)
personnel who could otherwise be harmed by the incident (including
emergency response personnel), (2) the environment, and (3)
property, both offsite and onsite

TOOLS TO IMPLEMENT EMERGENCY
MANAGEMENT

TOOL
Emergency ERP, effective training, To ensure effective, Guidelines for
Management realistic drills, ERT, and tested ERP, trained Technical
effective consultation with and equipped response Management
stakeholders, and team and effective Planning for On-
adherence to methods of protecting Site (CCPS, 1995)
plans/procedures personnel, the RBPS book,
in advance of an incident environment, and property

EACH ELEMENT
17. Incident Investigation 1- Basic data for all recorded incidents, including those that do not
qualify for immediate investigation (trend-only incidents),
2- analysis reports for RCAs,
3- identification of the causes of the incidents that are investigated,
4- recommendations (lessons learned and action items) that will
reduce the risk of similar incidents

TOOLS TO IMPLEMENT INCIDENT
INVESTIGATION

Incident Incident Investigating -To ensure consistent Guidelines for
Investigation Forms (5 WHY) required information is Investigation Chemical
gathered and communicated for Process Incidents, (CCPS,
Incidents 2003)
RCA Methodology -To ensure formal investigations are SCAT chart from DNV
conducted consistently and $125 for BOX (10 chart)
accurately 2 chart for each field
Software tools for -To enable consistent and complete Incident XP software (CG
reporting, investigating, reporting, thorough Risk, no need for at least
and approving incident documentation, and provide first year)
reports; performing comprehensive management of
RCA; and for managing corrective actions
the corrective Actions
LEVEL I INVESTIGATION TECHNIQUE
The Problem: A worker slips and falls, and suffers
an injury.
1st Why: There was a puddle of oil on the plant
floor.  originally developed by Sakichi Toyoda
2nd Why: Oil spilled from a compressor. and later used at Toyota during the
evolution of its manufacturing
3rd Why: An oil leak from the compressor was not methodologies
detected.  Although this method is simple and
4th Why: The compressor was not inspected on a effective in guiding the supervisor and
line manager to dig deeper, it is not
regular basis and repaired (if required). designed to reach the root cause. It is
5th Why: The compressor was not in the suitable only for Level ONE
maintenance system. Investigation.
SCAT Chart
to analysis the data gathered on the accident to identify
management system failures

EACH ELEMENT

18.Measurements and A set of metrics that are sensitive enough to help facility
Metrics management monitor the performance and efficiency of the
RBPSM system on a near-real-time basis.

TOOLS TO IMPLEMENT MEASUREMENT
AND METRICS

Measurement Metrics that are sensitive To identify evolving ANSI/ API RP 754
and Metrics enough to help facility management system (PS Performance
management monitor the weaknesses and make Indicators)
performance and efficiency of adjustments to RBPS
RBPS system on a near real- element work activities
time basis And communicated before they degrade
To the appropriate Personnel into a "failed" state (in
for routine Monitoring terms of performance or
efficiency)

EACH ELEMENT

19.Auditing 1- A systematic auditing program in place
2- Audit action tracking and closeout system in place

TOOLS TO IMPLEMENT AUDITING

Auditing Auditing and/or Self- To ensure requirements are Guidelines for
Assessment protocols exist Auditing PSM (CCPS
2011).
Audit protocols/checklists To identify significant risks Guidelines for
covering various aspects of a and potential regulatory Acquisition
facility, its processes, and its deficiencies prior to an Evaluation and Post
PSM and SMS acquisition merger Integration
To ensure that potential (CCPS, 2010)
gaps between the old and
new company's standards
are recognized and
addressed during
EACH ELEMENT

20.Management Review and 1- Internal memorandum summarizing the review, any
Continuous Improvement deficiencies or inefficiencies noted, and recommendations for
improvement or corrective action.
2- Management review meetings are established in the
management calendar

TOOLS TO IMPLEMENT MANAGEMENT
REVIEW AND CONTINUOUS IMPROVEMENT

Management Management review team To provide regular RBPS book
Review and meets regularly with the checkups on the Action tracker
Continuous individual responsible for each health of PSM system
Improvement element to present program systems in order to
documentation and identify and correct
Implementation records, offer any current or
direct observations of expected deficiencies
conditions and activities, and before they might be
answer questions about revealed by an audit
program activities or incident
EXAMPLE SCHEDULE FOR MANAGEMENT
REVIEWS
Month Topic (Element)

January Operations (15)
February Knowledge (6), MOC(13)
March Asset Integrity (10)
April Procedures (8)
May Outreach (5), Emergency (16)
June Contractors (11)
July Culture (1), Involvement (4)
August Incidents (17)
September Safe Work (9), Readiness (14)
October Competency (3), Training (12)
November Standards (2), Risk (7)
December Metrics (18), Audits (19), Management Review (20)
FOLLOW UP ON DECISIONS

PSM Implementation Tools and Outcomes

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PSM Implementation Tools and Outcomes

Uploaded by

Copyright:

Available Formats

TOOLS NEEDED TO IMPLEMENT

Implementation of RBPS - Ashraf Elsayed

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF TOOL

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Reflect site performance which comprised

Implementation of RBPS - Ashraf Elsayed

1) Schedule of process area PHA retrospective and revalidation completed

2) % past-due PS actions from incident investigations, hazard evaluations or

3) % PS required training sessions completed with skills verification.

4) % PS required SOP reviewed or revised as scheduled.

5) % sampled PTW that met all requirements.

7) % inspections of SCE completed on time.

Implementation of RBPS - Ashraf Elsayed

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF TOOL

Implementation of RBPS - Ashraf Elsayed

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF

Implementation of RBPS - Ashraf Elsayed

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE

PSM Element Desired Outcomes

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF TOOL

Implementation of RBPS - Ashraf Elsayed

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF TOOL

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE

PSM Element Desired Outcomes

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE OF TOOL

Implementation of RBPS - Ashraf Elsayed

Implementation of RBPS - Ashraf Elsayed

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed

ELEMENT TOOL PURPOSE OF TOOL EXAMPLE

An integrated or separate process to To ensure that organizational changes do

PSM Element Desired Outcomes

Implementation of RBPS - Ashraf Elsayed