1.

Identification of Hazardous Substances:

Identify and classify all hazardous substances used, stored, or produced in the facility, including
chemicals like methyl isocyanate (MIC) in the case of the Bhopal disaster.

2. Process Mapping:

Map out the entire production process, including storage, handling, and transportation of hazardous
materials, to understand potential points of failure and exposure.

3. Hazard Analysis:

Conduct a thorough hazard analysis to identify potential scenarios leading to accidents or releases,
considering factors like equipment failure, human error, external events, etc.

4. Consequence Analysis:

Evaluate the potential consequences of identified scenarios, including the extent of damage to
personnel, environment, and property.

5. Likelihood Assessment:

Assess the likelihood of each identified scenario occurring based on historical data, industry
standards, and expert judgment.

6. Risk Quantification:

Quantify the risks associated with identified scenarios using risk matrices or similar tools, considering
both the severity of consequences and the likelihood of occurrence.

7. Risk Prioritization:

Prioritize identified risks based on their severity and likelihood to focus resources on the most critical
areas needing mitigation.

8. Process Safety Management (PSM):

Management Leadership: Establish clear leadership commitment to process safety, including top
management involvement in setting policies, providing resources, and fostering a culture of safety.

9. Employee Involvement:

Involve employees at all levels in process safety management, including training, hazard
identification, and decision-making processes.

10. Process Safety Information (PSI):

Maintain comprehensive documentation of process safety information, including equipment

specifications, operating procedures, and safety data sheets for hazardous substances.

Process Hazard Analysis (PHA): Conduct periodic process hazard analyses to identify, evaluate, and
mitigate potential hazards and risks associated with the process.
Operating Procedures: Develop and implement clear operating procedures for normal operations,
startups, shutdowns, and emergency situations, emphasizing safety protocols and risk mitigation
measures.

Training and Competency: Provide regular training to employees on process safety, including hazards
associated with their tasks, emergency response procedures, and the proper use of safety
equipment.

Mechanical Integrity: Establish programs to ensure the mechanical integrity of equipment and
facilities, including regular inspections, maintenance, and testing to prevent equipment failures.

Emergency Preparedness: Develop and maintain emergency response plans and procedures to
effectively respond to incidents, including communication protocols, evacuation plans, and medical
response capabilities.

Incident Investigation: Establish procedures for investigating incidents and near-misses to identify
root causes, implement corrective actions, and prevent recurrence.

Auditing and Management of Change (MOC): Conduct regular audits of process safety management
systems to ensure compliance and effectiveness. Implement robust management of change
processes to assess and control risks associated with process modifications.

Contractor Management:

Implement procedures to ensure that contractors working on-site adhere to process safety
requirements and standards.

Community Outreach:

Engage with the local community to communicate risks, emergency response procedures, and
mitigation measures, fostering transparency and trust.

Certainly, here are 14 specific points related to Process Safety Management (PSM) concerning the
Bhopal gas disaster:

Hazard Identification:

Failure to adequately identify and assess the hazards associated with storing and handling methyl
isocyanate (MIC) and other hazardous chemicals.

Risk Assessment:
Lack of comprehensive risk assessment procedures to evaluate potential scenarios leading to a major
accident, including inadequate consideration of equipment failures and human error.

Process Safety Information (PSI): Incomplete or outdated documentation of process safety

information, including missing safety data sheets, equipment specifications, and operating
procedures for MIC handling.

Process Hazard Analysis (PHA): Insufficient or inadequate process hazard analyses to identify and
mitigate risks associated with the storage, handling, and use of MIC, including inadequate
consideration of worst-case scenarios.

Operating Procedures: Lack of clear and effective operating procedures for handling MIC, including
inadequate emergency shutdown procedures and failure to implement proper maintenance and
inspection protocols for safety-critical equipment.

Training and Competency: Inadequate training and competency assessment for personnel involved in
MIC handling, including insufficient training on emergency response procedures and the proper use
of personal protective equipment.

Mechanical Integrity: Failure to maintain the mechanical integrity of safety-critical equipment,

including storage tanks, valves, and safety systems, leading to the potential for equipment failures
and releases.

Emergency Preparedness: Inadequate emergency preparedness and response plans for managing a
major chemical release, including inadequate communication systems, evacuation procedures, and
medical response capabilities.

Incident Investigation: Lack of effective incident investigation procedures to identify root causes and
implement corrective actions following previous incidents and near-misses involving MIC handling.

Management of Change (MOC): Inadequate management of change procedures to assess and

control risks associated with modifications to the MIC storage and handling processes, including
insufficient consideration of potential safety implications.

Auditing and Inspection: Failure to conduct regular audits and inspections of process safety
management systems to identify deficiencies and ensure compliance with safety standards and
regulations.
Contractor Management: Inadequate oversight and control of contractors involved in maintenance,
repairs, and modifications to facilities handling hazardous chemicals like MIC, including insufficient
training and supervision.

Community Engagement: Lack of effective communication and engagement with the local
community regarding the risks associated with MIC handling, emergency response procedures, and
mitigation measures.

Regulatory Compliance: Failure to comply with relevant safety regulations and standards governing
the handling and storage of hazardous chemicals, including inadequate reporting of safety incidents
and non-compliance with safety recommendations.

Addressing these points through improved process safety management practices could help prevent
similar incidents in the future and ensure the safety of workers, surrounding communities, and the
environment.