A Report For
ONE DAY SEMINAR
ON
PROCESS SAFETY MANAGEMENT IN MANUFACTURING
INDUSTRY
Organised By:
Gujarat Safety Council, Vadodara.
Prepared By:
Overview on Process Safety Management:
Before the implementation of the process safety management we need to study out
the high hazard processes (HHP) and the low hazard processes (LHP) that are being
carried out at the plant.
There needs to be an acute development of a safety culture at the plant to ensure a
better implementation of process safety management. To ensure this every
individual should lead by example.
What is a process near miss ?
A process near miss is termed as an incident where the standard operating
conditions (SOC) are overhauled.
What is a process safety incident ?
Any incident caused due to the misguiding actions in any plant operations is termed
as a process safety incident. For example leakage or spillage during transfer of
chemicals, release of toxic vapors in the vent etc.
What Is Process Safety Management (PSM) ?
Process Safety Management is the application of management principles and system
for the identification, understanding and control of process hazards to protect
employees, facility, assets, public in vicinity and the environment.
The industries involving the high hazard processes are likely to implement the PSM
and the industries involving the low hazard processes are likely to implement PSM in
parts or gradually.
There needs to be a management system for workplace safety to be able to
effectively implement the process safety management.
The workplace safety incidents occur from frequently performed individual actions
that may lead to personal injury and is due to peresonal actions.
The failures of PSM can result in infrequent and rare incidents with injuries and
fatalities to community and environmental impact, they are majorly caused due to ill
functioning of process and systems.
The PSM critical equipments need to be identified for better functioning of the
process safety management.
The equipment that contain material that is PSM critical which when released can
cause a PSM incidentis termed as a PSM critical equipment.
Why do we need PSM ?
The processes occuring at any manufacturing plant are involved with errors that may
lead to incident and require management control. The errors are as below:
1. Unadequate knowledge of process technology.
2. Obselete operation or emengency procedures.
3. Unauthorized/Inadequate equipment designs or modifcations.
4. Inadequate inspection or maintenance programs.
5. Inadequate job knowledge and training.
6. Inadequate supervision.
7. Failures of communicating the details of porcess technology.
Benefits of PSM:
1. Avoidance of Catastrophic events.
2. High producvtivity and cost savings.
3. High efficiency by consolidation.
4. Improved quality and customer satisfaction.
5. Improved labour and employee relations.
Issues Related to PSM:
1. Safety Culture
2. Facility Siting
3. Risk Awareness
4. Risk Management
5. Process Upset Management
6. Atmospheric Vent and Release
7. Alarm Management
8. Incident Investigation
9. Human Resource Procurement and training
Operational Discipline:
Operational discipline is the management commitment to do all the jobs in the right
time and in the right manner.
An organisation is said to have operational discipline when each and every employee
is dedicated and commited to do the work the right way and at the right time.
Operational discipline is an inherent part of process safety management and also
plays a vital role in achieving good safety culture.
Characteristics of Operational Discipline:
1. Leading by example.
2. Functioning capability and sufficient resources.
3. Employee involvement.
4. Active lines of communication.
5. Strong team work.
6. Common shared values.
7. Up to date documentations.
8. Practice consistent with procedures.
9. Absence of shortcuts.
10. Excellent housekeeping.
11. Pride in the organisation.
14 Elements of PSM Effectiveness:
PSM
Technology Facilities Personal
Process Safety Information Quality Assurance Training & Performance
Process Hazard Analysis Prestartup Procedure Contractor
Operating Procedure and Mechanical Integrity Incident Investigation
Sale Practices
Management of Management of subtle Management of personal
Technology Change changes change
Emergency planning and
resources
Auditing
Enlisting the PSM Elements:
1. Control on hazardous substances
2. Employee Participation
3. Process safety information
4. Process hazard analysis
5. Operating Procedures
6. Employee training
7. Contractors Management
8. Mechanical Integrity
9. Hot work Management
10. Management of change
11. Incident Investigation
12. Emergency planning and response
13. Compliance audits
Major Chemical Industry Related Accidents:
1. Feyzin Explosion, France 1966
2. Flixborough, UK 1974
3. Seveso, Italy 1976
4. San Juanico LPG disaster, Mexico City 1984
5. Bhopal Gas Disaster, India 1984
6. Schweishalle, Switzerland 1986
7. Baia Mare Cyanide spill, Romania 2000
8. Enschede Fireworks, Netherlands 2000
9. Grande Paroise fertilizer plant explosion, France 2001
10. Texas city refinery explosion, Texas USA 2005
