Process Safety

Management
Presented by:
Ijaz Ahmad
DE (Process)

Contents
What is Hazards?
What is Process Safety Management (PSM)?
Whats Covered by PSM?
What are the Process Hazards?
What is Process Hazards Analysis (PHA)?
What are the PHA techniques?

What is Hazard?
An inherent physical or chemical

characteristic that has the potential for

causing harm to people, the
environment, or property
Examples
Hydrogen sulfide toxic by inhalation
Gasoline flammable
Moving machinery kinetic energy, pinch

points

Hazard Management:
The World as It Was Before

Good people
doing good things

The Rising Case for

Change
1984

Bhopal, India Toxic Material

Released

2,500

immediate
fatalities;
20,000+ total
Many other
offsite injuries

HAZARD:
Highly Toxic
Methyl Isocyanate

The Rising Case for

Change
1984 Mexico City, Mexico Explosion
300 fatalities
(mostly offsite)
$20M damages

HAZARD:
Flammable LPG
in tank

Process Safety Management

What is Process Safety

Management (PSM)?
The proactive and

systematic
identification,
evaluation, and
mitigation or prevention
of chemical releases
that could occur as a
result of failures in
process, procedures, or
equipment.

Process Safety
Management
The main objective is to prevent the release

of highly hazardous chemicals; such as toxic,

reactive, flammable and/or explosive
substances, which may cause harm to
personnel, property, production, the
environment and the company reputation.

Whats Covered by PSM?

Process Safety

Information
Employee Involvement
Process Hazard Analysis
Operating Procedures
Training
Contractors
Pre-Startup Safety
Review

Whats Covered by
PSM?...
Mechanical Integrity
Hot Work
Management of

Change
Incident
Investigation
Emergency Planning
and Response
Compliance Audits
Trade Secrets

Process Hazards

HAZARDOUS MATERIALS + PROCESS CONDITIONS

Flammable materials
Combustible materials
Unstable materials
Reactive materials
Corrosive materials
Shock-sensitive materials
Highly reactive materials
Toxic materials
Inert gases
Combustible dusts

High temperatures
Extremely low temperatures
High pressures
Vacuum
Vibration/liquid hammering
Rotating equipment
Ionizing radiation
High voltage/current
Erosion/Corrosion

Process Hazards Analysis

PROCESS HAZARDS ANALYSIS STRUCTURE

PROCESS HAZARDS ANALYSIS

What can go
wrong?

How likely is
it?

What are the

consequences?

FOUNDATION FOR PROCESS HAZARDS ANALYSIS

Historical
Experience

PHA
Methodology

Knowledge
and Intuition

Process Hazard Analysis

Process Hazards Analysis is the predictive

identification of hazards, their cause &

consequence and the qualitative estimation of
likelihood and severity.

Process Hazard Analysis

IDENTIFIES HAZARDS, estimates
likelihood and severity, suggests
improvements.
USE ON EVERY PROJECT
QUALITATIVE - based on
experience, knowledge and creative
thinking.
Most often done by
MULTIDISCIPLINARY TEAM
Several methodologies available
HAZOP
What-if/Checklist
FMEA
Fault Tree Analysis

HAZOP
Rigorous review of the design and

operability of a system;
Identify potential hazards and/or
operability problems;
Uses guidewords & parameters;
Drawings broken into Nodes are assessed.

What If / Checklist
Requires experienced and knowledgeable

team members;
A series of what if questions are asked for
each system / subsystem;
Each question represents the potential for
equipment failure or an error in operating
procedure.

FMEA
Initially used in aerospace and

automotives to predict the reliability of

complex products;
The method determines how and how
often the components of a product could
fail;
Evaluates the effects of failures on a
system.

Fault Tree Analysis

Developed by Bell Laboratories for the

US Air Force;
Focuses on the possibility of one
undesired event occurring;
Maps the complex relationships that can
cause the event by including all of the
contributory factors that are known.

Selecting the Right Method

Purpose of the study;
Type of results desired;
Type of information available;
Relative risks associated with the
chemicals, the process and/or the facility
location;
PHA team experience level;
Past Incidents;
Development stage of facility.

Corrective Action Management and Closure

Due diligence can only be shown if
every effort has been made to
implement and verify that the actions
needed to make the process safe
have been taken.

The Closure Loop

Assign responsibility to recommendations;
Document the resolution of

recommendations;
Acceptance, rejection, substitution, or
modification of any recommendation must
be documented;
Rejection of a recommendation must be
communicated to the study team.

ANY QUESTION?