QC-PSM-PCY-00-0002

PROCESS SAFETY MANAGEMENT

Rev.2
11-Nov-2012

PROCESS SAFETY INFORMATION (PSI)

POLICY

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TABLE OF CONTENTS

1. INTRODUCTION ........................................................................................................... 2
2. SCOPE / PURPOSE ..................................................................................................... 2
3. DEFINITIONS ................................................................................................................ 2
4. PSI POLICY .................................................................................................................. 3
5. STORAGE AND ACCESSIBILITY ................................................................................ 3
6. REVISION / UPDATE OF PSI DOCUMENTS ............................................................... 3
7. PERMANENT MOC CLOSURE STATUS REPORTING .............................................. 3
8. PSI INTERNAL AUDIT.................................................................................................. 4
9. PSI / EDMS TRAINING ................................................................................................. 4
10. RESPONSIBILITIES ..................................................................................................... 4
11. REFERENCES .............................................................................................................. 5
12. APPENDICES ............................................................................................................... 5
13. GLOSSARY .................................................................................................................. 6

Rev.
2

Issue Date
11-Nov-12

Prepared
By

Amendment Description
Periodic Revision

Modified to address the PSI Audit

and reporting requirements.
Next Scheduled Periodic Review: November/2015
1

22-03-2009

QC-PSM-PCY-00-0002

Reviewed
By

Mathew

Managers

Mathew

DES

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Approved
By
Senior
Management
Senior
Management

PROCESS SAFETY MANAGEMENT

PROCESS SAFETY INFORMATION (PSI)
POLICY

QC-PSM-PCY-00-0002
Rev.2
11-Nov-2012
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1. INTRODUCTION
Complete and accurate written information concerning process chemicals, process technology,
and process equipment is essential to an effective Process Safety Management (PSM) program
and to a Process Hazards Analysis (PHA). This will enable the employer and the employees
involved in the process to identity and understand the hazards posed by those processes
involving highly hazardous chemicals.
The information detailed in this policy is intended to comply with the following PSI elements:

OSHA 29 CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals.

o

Sub section: (d ) Process Safety Information

O.E 3.3 Process Safety Information and Process Hazard Analysis

2. SCOPE / PURPOSE
This policy applies to all Process Safety Information (PSI) documents listed in the Evergreen
Engineering Document List) within Q-Chem and RLOC facilities.

3. DEFINITIONS
Process Safety Information (PSI): Information pertaining to the hazards of the highly
hazardous chemicals used or produced by the process, information pertaining to the
technology of the process, and information pertaining to the equipment in the process.
PSI Documents: Definitions of the identified individual PSI documents are provided in the
Section 13 Glossary.
OSHA: Occupational Safety & Health Administration (US Department of Labor, USA)
NFPA: National Fire Protection Association
EDMS: Electronic Document Management System
OE: Operational Excellence
MOC: Management of Change (MOC)
PSSR: Pre-Startup Safety Review
TWR: Technical Work Request
COE: Correction of Error
RIM Group : Records and Information Management Group in Technical department ,
Q-Chem, Mesaieed
DCC : Document Control Center in Technical department, RLOC

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POLICY

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4. PSI POLICY
Intent of PSI elements shall be met through diligent maintenance of PSI documents as identified
in Evergreen Engineering Document List. This list identifies all the PSI documents in the
facility.
Evergreen Engineering Document List describes the responsibilities, owner discipline,
review/approval level, accessibility and location of the identified PSI documents in QChem/RLOC facilities.
All the PSI documents shall be updated and published through EDMS or Plant Central Library
as part of any modification in the facility. The red-line mark up of PSI documents and
corresponding source updating applications/databases shall be updated within 30 days and 90
days respectively from the approval of start-up for the changes implemented in the facility.
In addition to the PSI documents, the Evergreen Engineering Document List also identifies other
non-PSI engineering documents which require update. These are included in the list for
business/operational reasons other than PSI.

5. STORAGE AND ACCESSIBILITY

EDMS is the central repository of all finished/approved PSI documents in the facility. The latest
version of PSI documents housed in EDMS shall be used for any operational use and reference
purposes. Printed or electronic documents kept by individuals for their personnel purposes shall
not be used for any operational or authentic reference and modification purposes.

6. REVISION / UPDATE OF PSI DOCUMENTS

The PSI element requires management of PSI to ensure all safety related information is current,
readily available and accessible to all affected employees.
The modification of the PSI documents shall occur through the use of the following work
processes:

MOC
TWR
COE

Latest version of PSI documents shall be used for approved modification purpose and the same
shall be obtained from EDMS through check-out process.
PSI document update as part of the above work processes shall be in accordance with
Engineering Data Modification and Update Procedure (TE-DCC-PRO-00-0015).

7. PERMANENT MOC CLOSURE STATUS REPORTING

Permanent MOC closure status report based on PSI document update shall be sent to PSM
Group on a monthly basis by Technical RIM/DCC Group. The report shall contain information
about total permanent MOCs received and its overdue status, if any, based on the red-line and
source update of PSI documents within 30 days and 90 days respectively.

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8. PSI INTERNAL AUDIT

Internal audit shall be carried out by Technical RIM/DCC Group once in six (6) months to ensure
that all the PSI documents are up to date, properly maintained, available and accessible to all
affected employees on a 24 x 7 basis. Internal Audit shall be carried out in accordance with the
Operational Excellence Element 3.3 Process Safety Information protocol requirements

9. PSI / EDMS TRAINING

Training on PSI and EDMS shall be provided to all employees as part of General Orientation
Training (GOT) and New Employee Orientation (NEO). Training has to be provided by
authorized RIM personnel and Training Group Department, working in tandem as per Global
Training Matrix.

10. RESPONSIBILITIES
10.1.

Responsibility Matrix
Responsible Areas

As an owner of PSI Policy/element, responsible

for the development and implementation of PSI
policy and associated procedures in the Facility.
Periodic modification and update of the PSI
policy, as and when required

Q-Chem
Mesaieed

RLOC

Engineering
Superintendent

Technical
Superintendent

Engineering
Superintendent

Technical
Superintendent

RIM Group

DCC Group

RIM Group

DCC Group

RIM Group

DCC Group

Revision/update and implementation of PSI

policy and responsible to update PSI documents
in a timely manner.
Responsible for managing and publishing PSI
documents in all relevant locations and ensure
that PSI documents are readily accessible to all
affected employees whenever they need the
same.
Organize and coordinate the PSI internal audit
once in every six months.
SME for PSI element in the Facility

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11. REFERENCES
a. 29 CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals OSHA
Regulation
b. Engineering Data Modification and Update Procedure (TE-DCC-PRO-00-0015)
c. Management of Change/Pre-Start Up Safety Review Procedure (QC-PSM-PRO-00-0003),
Management of Change (MOC) / PSSR.

12. APPENDICES
I.

Evergreen Engineering Document List

a. TE-DCC-LST-00-0001 - Q-Chem
b. TE-DCC-LST-30-0001 - RLOC

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13. GLOSSARY
The glossary of terms of Process Safety Information (PSI) identified in the Evergreen
Engineering Document List is as follows:
Material Safety Data Sheets (MSDS): MSDS describes the physical and chemical properties;
physical and health hazards; routes of exposure; precautions for a safe handling and use;
emergency and first aid procedures, and control measures pertaining to the hazardous
chemicals used in the facility.
Process Chemistry: A description of the process chemistry addressing chemical reactions
from reactants through intermediates to final product, and required utility systems.
Process Flow Diagrams: A display of the major components used in the process and the
connections between the major components, including direction of flow and utility systems.
Material and Energy Balance: The information on unit material and energy balance for feed,
product, and important intermediate streams.
Data Sheets (Mechanical/Electrical/Instrument): The description of safe upper and lower
limits for temperatures, pressures, flows or compositions, design code and material of
construction.
Line Classification Index (LCI): Index that describes the following information of each line:
o
o
o
o

Line Number;
Fluid or Service;
Piping Specification, including material of construction;
Design conditions; and Design Code, etc.

Process Hazard Analysis (PHA): The description of analysis after identifying, evaluating and
controlling the hazards of processes involving highly hazardous chemicals in the facilities.
Piping and Instrumentation Diagrams (P&IDs): The illustrations of the piping; associated
equipments, instrumentation and control for the process.
Electrical Hazards Area Classification: Classification of each area of the facility with respect
to its potential for causing an electrically generated fire and/or dust explosion as defined by
NFPA or equivalent local codes/regulations. Areas that require no classification do not have to
be designated as such.
Relief System Design and Design Basis: A description of each relief device (including rupture
discs) in a unit. The minimum information required for a relief device is the relief device number,
relief device location description (e.g., vessel, exchanger or line number), to where the device
relieves (e.g., flare, acid relief, atmosphere, or process), set pressure, the critical design basis
(e.g., fire, blocked liquid outlet or steam failure), relief device type, required relief rate, relief
device size, and either the maximum relief capacity of the relief device or the required relief
device size.

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Ventilation System Design HVAC and/or pressurization systems in associated buildings and
systems used for dust control and/or personnel exposure control. Information shall include design
basis, materials of construction, and ventilation layout drawings. HVAC systems designed entirely
for comfort are not included. Also, ventilation/purging systems for instrumentation and electrical
enclosures that are not intended for occupancy (See Building Siting Procedure (HSE-SAF-PRO00-0014) are not included.
Fire Protection/Gas Detection System: The description of information of detection and
suppression systems and safety systems that includes fire water, gas detection, sprinklers.
Deluge and FM 200 systems. The information includes design basis and materials of
construction.
Maximum Intended Inventory of Hazardous Chemicals: List of the maximum intended
inventory levels of process chemicals used within the facility, including portable containers.
Consequences of Deviation: A list of possible consequences if a process variable deviates or
is allowed to deviate from the normal target operating range or safe upper and lower operating
limits.
Instrumented Protective Systems: The information related to the instrumented systems
installed to prevent personnel injury or equipment damage by taking equipment or the process
to a safe state, this includes;
o
o
o
o
o
o
o

Control Interlock Narratives

Cause and Effect Drawings
Complex Loop Narratives
Instrument Calculations
Instrument Index/Alarm and Control Summary
Control System/DCS/PLC
Instrument Logic Diagram

Instrument Loop/Wiring and Panel/Junction Box Diagram: The drawings that depict the
detailed information for a specified control loop; wiring, and panel/junction box related
information of the process instruments in the facility.
Instrument Location Plan: Drawings that depict the locations of the process related
instruments in the facility.
Equipment Data Books: The vendor supplied data that includes equipment number,
service, material of construction, design condition, and applicable code for stationary and
rotating equipments and original vendor drawings, etc.
Project Specifications: The Engineering Procurement and Construction (EPC)
specification/requirements for development of new facility as mentioned in the contractual
terms and conditions and/or procurement of different kind of equipments, materials,
documentation as per the project engineering codes and standards as a part of ongoing
facility modification project.

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