Presentation on theme: "Process Safety Management Overview General"— Presentation transcript:
1 Process Safety Management Overview General Charles WilliamsProcess Safety Program Manager
2 Process Safety Management (PSM) ObjectivesDefine what is Process Safety ManagementReview the key elementsRegulatory requirementsProposed Penn State elementsDiscuss benefits of a Process Safety Management Program
3 Process Safety Management (PSM) Bhopal India – Union Carbide Plant (Dec. 3, 1984)> 2,000 people killed in 40 ton chemicalreleasePiper Alpha (July 6, 1988)167 men killed in explosion and fireFormosa Plastics (April 23, 2004)5 workers killed in explosion and fireBP, Texas City (March 23, 2005)15 deaths and more than 170others injured
4 Process Safety Management (PSM) Major disasters involving highly hazardous chemicals draw national attention, however, there have been numerous less notable releases. Hazardous chemical releases continue to pose a significant threat to employees, contractors and the publicSeveral key regulations have been developed to address the unexpected releases of toxic, reactive or flammable liquids and gases including OSHA’s Process Safety Management (29CFR ) standard and EPA’s Chemical Accident Prevention (40CFR 68) programEven well designed, constructed and operated unit operations can still pose the potential for an unexpected release of a highly hazardous chemical
5 Process Safety Management (PSM) State University of NY – Potsdam, HazMat Team response on August 13, 2013 after an employee noticed an ammonia leak in the college’s athletic facilitiesWATERTOWN DAILY TIMES - Hazardous materials teams from several agencies suit up Tuesday to investigate and clean up an ammonia leak in Maxcy Hall on SUNY Potsdam’s campus“Minor Ammonia Leak Closes Rink at Cottage Grove Ice Arena, South Washington Bulletin, MN (Jan. 2014)“What we’ve found is that the piping was supposed to be in a vault and it wasn’t” – City AdministratorCottage Grove Ice Arena – Park High School boys and girls hockey clubs.
6 Process Safety Management (PSM) Penn State has acknowledged the need to develop and implement a Process Safety Management Program with initial focus on ammonia refrigeration units (e.g. Pegula, Food Science - Berkey Creamery)PSM is an analytical method focused on managing processes to prevent releases of any highly hazardous chemical and subsequent catastrophic events – fires, explosions, or toxic releases
7 What is Process Safety Occupational Safety Process Safety Protecting against personal injuriesSlips, trips, falls, falling from height, chemical contactProcess SafetyProtecting against catastrophic incidentsFires, explosions, toxic releases resulting in significant loss of life, property or environmental impact
8 However, these efforts will not reduce the number of plane crashes! What is Process SafetyThe airline industry experiences many back and muscle strains to baggage handlers from lifting and carry luggageSignificant effort is spent trying to prevent these types of injuriesHowever, these efforts will not reduce the number of plane crashes!
9 What is Process Safety Occupational Safety Examples: Measures to prevent workplace illnesses, accidents, and injuriesExamples:Selection and use of PPEIndustrial hygiene monitoringShoring requirements for excavation projects
10 What is Process Safety Process Safety Examples: Identifying the hazards that could lead to fires, explosions, or toxic releases: catastrophic eventsExamples:Inspecting and maintaining equipmentto prevent loss of containmentUsing formal assessment program to reviewproposed changes to equipment or proceduresConducting hazard studies to identify the hazardsand appropriate safeguards for each process
11 Process Safety Management (PSM) After reviewing the basic causes of major Process Safety incidents, OSHA concluded that often there is a serious lack of knowledge either in the organization or at the operations level on basic Process Safety InformationOSHA considers 14 key elements of a PSM Program, however, our proposed program contains 17 key elements
12 Process Safety Management (PSM) Management SystemProcess Safety InformationProcess Hazard AnalysisOperating ProceduresTraining & AssessmentContractor Mgmt.Mechanical IntegrityMgmt. System to Address Action ItemsManagement of ChangeIncident InvestigationCompliance AuditsTrade SecretsEmployee ParticipationPre-startup Safety ReviewEmergency PreparednessProcess Hazard Analysis ReviewMaintenance Systems
13 PSM Key Elements Management System Process Safety Information Senior Leadership CommitmentWritten ProgramResponsibilities DefinedMetrics & Continuous ImprovementProcess Safety InformationProcess TechnologyChemical DataEquipment Data
14 PSM Key Elements Process Hazard Analysis Defined methodology to assess potential releases from processManagement System to Address Action ItemsPrioritization process based on risk rankingTransparent system to assign responsibility and timeframe to accomplish recommendationsTracking completion
15 PSM Key Elements Process Hazard Analysis Review Employee Participation Defined process & frequency to review the process hazard analysis and response systemsEmployee ParticipationDevelopment of PSM programProcess Hazard AnalysisIncident InvestigationOther elements
16 PSM Key Elements Operating Procedures Emergency Preparedness Steps for each operating phase during initial start-up, normal operations, temporary operations, emergency shutdown and start-up after emergency shutdownEmergency PreparednessDefined actions by individuals when a release occurs and other emergency scenarios
17 PSM Key Elements Training & Assessment Contractor Management Program outlining training requirements for Technicians, Contractors and other individuals that can impact covered processesContractor ManagementQualification program that factors in EHS performanceCommunicate access and safe work practices for covered areas
18 PSM Key Elements Mechanical Integrity Maintenance Systems Defined procedures to maintain the on-going integrity of process equipmentInspection and Testing requirementsMaintenance SystemsSafe Work Permit programHot Work PermitProgram associated with non-routine activities
19 PSM Key Elements Management of Change (MOC) Change management program that encompasses proposing changes to affected Departments prior implementationAuthorization required before implementing changePre-Startup Safety Review (PSSR)Program to conduct pre-startup assessments for new or modified facilities/equipment
20 PSM Key Elements Incident Investigation Compliance Audits Incidents that resulted or could reasonably have resulted in a catastrophic releaseTeam approach started within 48 hoursCompliance AuditsPSM Program evaluated by 3rd Party every 3 yrs.Trade SecretsMechanism to maintain confidentiality with individuals/group requiring Process Safety Information
21 Penn State Process Safety Model RegulationsStandardsBest PracticesIncidents & AccidentsIndustry GuidelinesTechnologyEquipmentProcess Hazard Analysis(Risk Evaluation)ProcessPersonnelRisk Management – Reduction/Control17 Management System Elements
22 Process Safety Management (PSM) Various Functions within our PSM Program:Ammonia Refrigeration TechniciansArea SupervisorsSafety OfficersFacility/Building ManagersCoachesEHS DepartmentHazMat TeamContractorsPolice ServicesInterns/StudentsEvent Staff
23 Process Safety Management (PSM) Program BenefitsFormal management system to enhance and preserve University’s critical equipmentPlatform to assist with improving operational effectivenessMechanism to engage and solicit input from various stakeholdersEmpower employees to be an active program participant with development and on-going sustainability
24 Why PSM at Penn State?Contractor started working on system while production was on-goingStandard procedure not followed – refrigeration being re-applied to tank considered “not normal”Employee operating equipment advised that he was fatigued at work due to being shorthanded and overworkedMaintenance employee identified a problem (post-accident) with valves in system not functioning as designed – was not identified previously since “no preventive maintenance program existed on that equipment
25 Why PSM at Penn State? The results of numerous system failures: Employee Injuries and Equipment Damage
26 Why PSM at Penn State? Borland Explosion – March 1, 1982 Are our systems robust enough to prevent a similar event today?
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