Process Safety Management
Kharil Ashidi B. Abdul Jabar
Q-SHE-S Dept
Nippon Steel Engineering Co., Ltd.
What Is Process Safety Management
Process Safety Management is the
application of management principles and
systems to the identification, understanding,
and control of process hazards to protect
employees, facility assets and the
environment.
What Is Process Safety Management
.
14 Elements
Application Pre-Start up Safety
Review
Employee Participation
Mechanical Integrity
Process Safety
Information Hot Work (Non-routine
Work Authorizations)
Process Hazard Analysis
Management of Change
Operating Procedures
Incident Investigation
Employee Training
Emergency Planning and
Contractors Response
Compliance Audits
Process Safety Management
TECHNOLOGY
FACILITIES
PERSONNEL
Technology
Process Technology
Process Technology describes the process and
operation
Understanding the hazards is the first step
Consists of three parts
The 3 Parts of Process Technology
Hazards of Materials
Process Design Basis
Equipment Design Basis
Process Hazards Analysis
Process Hazards Analyses identify, evaluate, and
control hazards
- orderly and methodical approaches
- many people involved
Procedures & Safe Practices
Provide clear understanding of operating parameters
and limits for safe operation
They explain the consequences of problems and the
steps necessary to correct and or avoid them
Developed and documented for each process
Management of Change - Technology
Changes may invalidate prior assessments
All changes must be rigorously reviewed
Sites must have procedures to manage
changes.
Technology
Industrial Incident #1 Bhopal, India
1984 A large amount of water was put into a methyl
isocyanate tank. The resulting overpressure and related
system failures caused the tank to vent and a large cloud of
gases was released and drifted onto the nearby densely
populated area. The severity of this accident makes it the
worst recorded within the chemical industry, with fatalities
estimated in the thousands, ~2,800 from the immediate
release and possibly up to 15,000 related deaths since.
Technology
Industrial Incident #1
Contributing Factors:
plant modification/change - HAZOP
not recognizing safety critical systems and
their operability
design codes
training and competence
Technology
Industrial Incident # 2 Oppau, Germany
1921 Two explosions at the BASF plant killed 430
and destroyed 700 homes. Blasting powder was
being used to breakup storage piles of ammonium
sulphate and ammonium nitrate. This procedure
had been used 16,000 times without mishap. The
4,500 tons of the mixture exploded and left a crater
250 feet in diameter and 50 feet deep.
Tough stuff to set off. But when it goes, it goes !
Toulouse Grande Paroisse
On Friday September 21,2001 at 10:15 am…..
Technology
Industrial Incident # 2
Contributing Factor:
not recognizing hazards of materials
Facilities
Quality Assurance
Quality Assurance “bridges the gap” between
design and installation:
fabrication and parts meet specifications
delivery to the right location
properly assembled and installed
Pre-Startup Safety Review
Provides a final check for new or modified
equipment to ensure the facilities are
“ safe to operate “
Mechanical Integrity
Process related equipment that contains
highly hazardous chemicals must be
maintained from the time of design
throughout the life of the facility.
Mechanical integrity focuses on system
integrity to contain hazardous materials.
Mechanical Integrity
Deals with:
Maintenance procedures
Training and performance of employees
Quality control
Equipment tests and inspections, including
predictive and preventative maintenance
Management of “Subtle” Changes
Subtle Changes have led to catastrophic events!
All process changes, including those within the
“documented” process technology, but are not a
replacement-in-kind, must receive appropriate review
and authorization.
Facilities
Industrial Incident # 5 Flixborough, England
1974 At the Nypro(UK) chemical facility, a
large quantity of cyclohexane vapor was
released when a 20 inch “makeshift”
bypass pipe ruptured. The resulting
massive vapor cloud explosion killed 28
workers.
Facilities
Industrial Incident # 5
Contributing Factors:
management of change procedures
design codes
maintenance procedures - recommissioning
plant layout - position of occupied buildings
emergency plan
Facilities
Industrial Incident # 6 Chernobyl, Ukraine
1984 Technicians at the power plant allowed the
fourth reactor to fall to low power levels as part of a
“controlled experiment”. The reactor overheated
causing a meltdown of the core. Explosions blew
the top off the reactor building releasing radioactive
material into the atmosphere for over 10 days. 31
workers were killed and the extent of lingering
health effects has been significant and subject of
debate. It is now entombed.
Facilities
Industrial Incident # 6
Contributing Factors:
management of change procedures
equipment/facility design
procedures and safe practices
emergency shutdown plan
Personnel
Training and Performance
Trained employees are an absolute requirement,
and be physically able, mentally alert and
capable of using good judgment.
Training qualification must be documented.
Contractors
For contractors working in and around
highly hazardous material processes, or
performing maintenance/repair on or near
a covered process ……….
they are required to comply with same
regulations and guidelines as industry
/site!
Incident Investigation & Reporting
Investigations are essential to improve
performance
The objective is to find the contributing factors and
implement corrective actions(s)
The degree of the investigation will depend on
severity or potential
Management of Change - Personnel
People are the essential ingredient:
process experience
knowledge and skill in managing Process
Safety
maintain minimum experience level and
knowledge through personnel and
organizational changes
Emergency Planning & Response
Planning and training for potential
emergencies are essential for effective
response
Auditing
Auditing must be used to assure that all
elements of Process Safety Management
are being implemented properly.
Proper auditing must include positive and
corrective feedback
Personnel
Industrial Incident # 3 Pasadena, Texas
1989 During maintenance work on a
reactor settling leg, a large release of
flammable vapor occurred at the Phillips
66 chemical complex. The result was a
massive vapor cloud explosion, followed
by a series of further explosions and
fires.
Personnel
Industrial Incident # 3
Contributing Factors:
site and industry standards for maintenance
not followed
training and competence
work permit system - contractors
positioning of occupied buildings
Personnel
Industrial Incident # 4 Mexico City, Mexico
1984 A major fire and a series of catastrophic
explosions occurred at the government owned
and operated PEMEX LPG Terminal.
Approximetly 500 people were killed and the
facility was destroyed. After the intial release, the
first BLEVE occurred. For the next 90 minutes, a
series of BLEVEs followed as other LPG vessels
violently exploded. It started with a ruptured line
and was made worse by failed safey systems and
layout.
Personnel
Industrial Incident # 4
Contributing Factors:
plant layout - the positioning of vessels
emergency isolation
survivability of critical systems
emergency plan and site access
Thank you very much
Please contact for any questions
Kharil Ashidi
Tel: +6012 202 3381
E-mail: kharil_ashidi@yahoo.com.sg
