FUNDAMENTAL OF

PROCESS SAFETY MANAGEMENT SYSTEM (PSM)

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Trainer Profile

Muhammad Imtiaz
Chemical Engineer
Associate Safety Professional (BCSP USA)
NEBOSH IGC
ISO 45001 Lead Auditor
Train The Trainer by HABC

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Objective & Content of Training:

Objectives:
• To provide basic understanding of Process Safety Management System
• To provide overview on how hazards are being managed inside the Process Industries

Contents:
• Comparison between Occupational Safety and Process Safety?
• Introduction to Process Safety Management (PSM).
• Evolution of PSM
• PSM Standards
• 14 Elements of OSHA PSM ( 29 CFR1910.119)
• Basic knowledge and understanding of Process Safety Elements and their working

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Occupational Safety: What is Wrong in these Pics

NOT USING
NOT USING
FACE SHIELD,
HELMETS,
WELDING GLOVES,
HAND GLOVES
SAFETY SHOES,
EQUIPMENT IN BAD
HELMET
CONDITION

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What is PSM:
• Application of Management System Controls to a manufacturing or chemical process in
way that process hazards are identified understood and controlled so that process related
injuries and incidents are prevented.

PSM is all about

“Keeping Highly Hazardous Chemicals in Containment”

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Occupational vs. Process Safety:
Occupational Safety Process Safety
Easily Observable Difficult to Observe
Low Impact Broad Impact
Individual Oriented System Oriented
Examples: Examples:
Slip Trip and Fall Fire
Electrocution Explosion
Hearing Loss Release of Toxic and
Minor Injury Hydrocarbon
Safeguards: Safeguards:
PPEs Mechanical Integrity Program
Ventilation PSVs, Interlocks 6
Housekeeping Safety through design
Guardrails

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PSM Major Incident History:
Seveso – Italy Chernobyl – USSR Phillip Disaster – USA Venezuela-South America
No Death 31 - Fatalities 23 - Died 48 – Fatalities

. . . .
1975 1984 1988 2005 2015
1976
. 1986
. 1989
. 2012
.

Flixborough – UK Bhopal – India Piper Alpha – UK Texas City – USA Zhangzhou – China
18 - Fatalities 3000+ - Fatalities 167 - Fatalities 15 - Fatalities 19 - Injured

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Evolution of Standards

1985 1985 1986 1990 1992 1998 2004

CCPS Community Right to know Clear Air Act OSHA PSM CSB IEC 61511
Awareness and act
Emergency
Response

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PSM Standards:

 14 Elements – OSHA –PSM Rule 29-CFR-1910.119

 22 Elements – DuPont- Process Safety Management System

 20 Elements - AIChE CCPS

 14 Elements - CSChE Canadian Society for Chemical

Engineering

 20 Elements – EU Energy Institute

 Some large corporations may also sell their custom systems

or services for implementing PSM

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Bridge Concept:
Auditing
PSM systems are not created
once and implemented once.

It is an
Process Safety Information ON- GOING PROCESS
Employee Participation

Hazard Canyon

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Element 01: Employee Participation

• Employee Involvement in Process Safety Management System

• Involvement in open and effective communication
• Engaging contractor partners
• Continuous development to maintain competency
• Participation in stakeholder's outreach
• Employee Access to Information

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Element 02: Process Safety Information

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Element 02: Process Safety Information: Hazards Of Chemicals

Hazards Of Chemicals
PEL, TLV

• Raw Materials
• Products
• Chemicals added to
Environment
MSDS Physical Data
the process
Impact
• Intermediate Products
• Reaction products
resulting from any
special activity
• Catalysts
Chemical
properties

Hazard information communicated to and readily available to all relevant

employees

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Element 02: Process Safety Information: Process Design Basis

PFD

Data
history, Operating
inspections instructions
etc.

Process
Design
Basis

Standard
Alarm and
Operating
interlock
Conditions

Maximum
intended
inventories

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Element 02: Process Safety Information: Equipment Design Basis

PSV, PRVs

Material of Vent
construction systems

Material and Equipment

Energy Design P&IDs
Balance Basis

Detection
Instrument
and
& Electrical
suppression
Schematics
system
Fire
protection
systems

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Element 03: Process Hazard Analysis

High

Frequency
Med
Inherently Safer Low
Design
V Lo

Consequence Consequence
Inspections & Tests

Hazard
Procedures and
Training

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Element 03: Process Hazard Analysis

HAZOP
• Identify systematic set of activities to Identify, Assess and
Evaluate risk at facilities, throughout their life cycle.
LOPA

• PHAs must be done for:

• New facilities. FMEA

• Existing facilities - cyclical reviews. Tools

for PHA
• Mothballing a process facility. FTA

• Dismantling a process facility.

What if

ETA

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Element 03: Process Hazard Analysis: New Project Facilities

• As early as possible during basic data development

Screening
PHA

• Before Project authorization to review screening PHA

Pre- • Review any changes in scope or design intent
Authorization
PHA

• After design release for design review

Detailed PHA • Must be completed, documented and authorized prior to startup

• Initial review of Process

Baseline PHA • Foundation for future cyclic PHA or Revalidation

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Element 03: Process Hazard Analysis: Existing Facilities

• Throughout the • Very little change

life of facility in process
• Frequency not • Incorporate
exceeding 5 Years learnings from
incidents and
others
Cyclic Revalidation

Modification Redo
• Inadequate PHA
quality
• During major or • Multiple serious
minor incidents
modification • Significant
through MOC number of MOCs
process done

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Element 04: Operating Procedures

Development of documented, current and accurate instructions to conduct the operating

activities in a consistent and safe manner

Requirements

To be updated after
Consistent with Information from incident, change in
Emphasis on HSE Review frequency Training of workforce
PSI PHA chemicals or
improvement

“Everyone Doing it right EVERY TIME”

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Element 04: Operating Procedures

PTW System

Security bypass

Management Access Control

of Procedure

Safe Work Practices

Zero Energy
Specific Mode of Consequence
SOL OJT
responsibilities operations of Deviation
Line breaking

Emergency Stop
buttons
Isolation
Procedure

PPEs Management

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Element 05: Training

To ensure that workers preform a task to a minimum standard, to maintain their proficiency, or to
upgrade their skills. Performance reviews determine when these actions are required.

What is Training?
• Practical instruction in job tasks or methods
• Enable workers to meet minimum performance standards
• Performed before the worker is allowed to perform the task on their own
• Followed by performance assurance to confirm that the worker is performing the tasks correctly
and that they posses the knowledge, skills, and abilities (KSAs) required for their position

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Element 05: Training

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Element 06: Contractor Safety

To ensure that contract workers work according to safe work practices and that they don’t increase
the operational risk of the facility

Piper Alpha:
• The safety valve which was removed earlier, was removed by a contractor that had been hired to
inspect/ test it.
• The contractor had not been trained properly in the safe work practices needed for the task.
• The incident investigation also determined that the inadequate emergency response training
given to contractors on the rig contributed to the high loss of life

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Element 06: Contractor Safety

Job Skill and

Provide Competence
SWP

Access Hazards
Control Com
Hazard Contractor Training
Company Awareness Resp
Resp

Reporting
Assess Contractor
of Safety
Performance Injury Log
Obs

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Element 07: Pre-Startup Safety Review:

Not a
design
review
More Than 40% of the
Not a accidents in the chemical
Risk
Review industry occur during startup
Is a final
Check Point
and
verification

PSSR Applies to

Replacement
Shut down for Introduction of New or modified Out of service for
New Process with non Extensive repair
Modification New Chemical piping system a period of time
identical

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Element 08: Mechanical Integrity

This element focuses on the design, installation and maintenance of equipment from when it is fabricated to
its retirement to ensure it is fit for use.

• This has been a leading cause of accidents in the process industries.

• Poor design
• Poor installation
• Poor maintenance
• Undetected deterioration
• Improperly performed maintenance

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Element 08: Mechanical Integrity

Pressure
Vessel
Equipment
Tests
Safety Storage
systems Tanks

Training and
Inspections
Performance

MI Control and Applicable Piping

interlocks on system
Addresses

Maintenance Reliability
Procedures Engineering
Emergency
Relief
Shutdown
devices
System

Quality Vent
Control Systems

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Element 08: Mechanical Integrity

MI
Requirements

Inspection Recommendation
Detailed SCE RAGAGEP Management of Defeat Analysis
Frequency Follow-up
Management Plan Overdue SCE

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Element 08: Mechanical Integrity

Equipment Suitable

Quality Assurance
for process
application Flange

Maintenance Procedures
Tightening
Training

Trainings
Proper installation
consistent with design PSV Consistent
Management with
procedures
Acceptance of
Material and Spare Pressure
Parts Testing
Etc.
Positive Material
Identification Program

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Element 09: Hot Work Permit

Avoid Hot Work in the area

Isolate and Remove combustibles and

flammables

Remove fire hazard at least 35ft from the work

area

Confine Heat and Spark

Roles and Responsibilities and Fire Watch

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Element 10: Management of Change:

Technology
Process Change
Chemicals

Personnel Technology

Test Run
MOC Subtle
Types Change
Scope

Procedures Equipment

Temporary • Maximum 12 Months

Change
Replacement
• 6-month review.
in Kind

RIK are the repairs made to, or the replacement of equipment and piping
using items that meet the design specification of the item it is replacing

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Element 10: Management of Change
Activities not require MOC

• Examples of activities that does not require MOC are:

• Changes in tag description.

• Process alarm setting changes, set point limit changes within defined SOL.
• Using chemical hoses for routine functions that is documented in SOP.
• Drain process vessel in preparation for maintenance.

Common weakness:
• Failure to recognize the need to manage change
• Failure to recognize change RCA of the MOC weaknesses:
• Intentionally by passing the MOC process • Lack of management support
• Inadequate risk review of the proposed change • Awkward or inefficient MOC program
• Failure to properly mange the risk of the change • Lack of awareness or understanding
• Failure to properly design the change
• Failure to install the change as designed
• Failure to notify personnel and update procedures/ other documents

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Element 10: Management of Change:

Ref: Process safety Management, Process Improvement Institute by William Bridges

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Element 11: Incident Investigation:

Investigating any incidents or near misses to determine the root cause

Essential
Features

Encourage Management Start of Investigation Investigation

Root Cause Action Items Analysis
reporting Participation investigation Efforts Team

Management
System

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Element 12: Emergency Planning and Response

Planning for emergencies, practicing them, training employees, contractors and local authorities.

• QRA • SIP
• HAZOP • CMC
• Risk • Shut down
Assessment • Fire
• Natural equipment
Disasters activation
Basis of
Action Plan
Planning

Roles and Rescue

Responsibilities operation

• Employee • Medical
• Contractor & Assistance
Visitor • External
• CMC Support

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Element 13: Auditing

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Element 14: Trade Secret

• Any formula, pattern, device or compilation of information.

• A process of manufacturing or treating materials.
• PFD, P&IDs, MSDS, Audit Reports, Investigations, HAZOP, LOPA, Design Limits etc.

• Main PSM Elements where trade secret information is most likely contained and needed for implementation
• Compiling- Process safety information
• Developing- Process hazard analysis
• Developing- Operating procedures
• Involved in- Incident investigations
• Involved in – Emergency planning and response
• Involved with – Conducting compliance audits

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 PSM ELEMENTS Linkage
Linkage Between PSM Elements:
Input to PHA
Incident
Process & EQ design basis Investigation
Hazards of Chemicals
PSI Consequence Analysis, SCE
Process Hazard
Safety Critical Equipment
Analysis
Mechanical
Integrity Consequence of
Process design, SOL, Max OL
deviation

Operating
Based on Consequence Analysis
Procedures Input to OP

Emergency
SCE, Hazards of Chemicals
Planning & SCE
Response Management
SWP / PTW

For any
Change
Take input from PSI and update PSI PHA of Change
Ensure QA and
Trng. on Change in
Update plan
approved documents / MOC
facility Trng. on Change in
approved documents /
Implement Change
Ensure PM Plan facility

Trng. on Approved
Procedure
PSSR

Feedback to PSSR Team

Contractor
Training Feedback to PSSR Team
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Safety
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