Transcript Slide 1

Application of the Process
Safety Management
Standard in Canada
Presented by:
Holly Elke,
CRSP, CSP, CMQ/OE
Senior QHSE Advisor
SH&E System & SPM Solutions
Process Safety Management
Process Safety Management
Also called Safety Systems
Management or Process
Safety Management;
 The purpose is to manage
the risk to personnel,
property, production, the
environment and the
company reputation.
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Process Safety Management
Regulated in 1992 by OSHA.
 Known as the Process Safety
Management (PSM) Standard
of Highly Hazardous
Chemicals, Explosives and
Blasting Agents: OSHA 29
CFR 1910.119.
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Process Safety Management
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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 humans.
Process Safety Management
Processes that involve:
 Explosives, blasting agents
and pyrotechnics;
 Chemicals, above a specified
quantity in Appendix A of the
PSM std;
 Flammable liquid or gas in
excess of 10000 lbs.
Must have a PSM program.
Process Safety Management
Key parts of a PSM program:
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Employee involvement;
Process Safety Information
(history, MSDS, P&ID’s, etc.) ;
Process Hazard Analysis;
Operating Procedures and
Practices;
Employee Training;
Process Safety Management
Key parts of a PSM program:
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Contractor Management;
Pre- Startup Safety Review;
Mechanical Integrity – critical
equipment & QA;
Non routine Work Authorizations;
Managing Change (beyond
replacement in kind)
Process Safety Management
Key parts of a PSM program:
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Investigation of Incidents;
Emergency Preparedness
Compliance Audits – verify
effectiveness of PSM program.
API 750 Process Hazards
Management has similar
requirements
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
Qualitative Risk Analysis
Process Hazards Analysis is
the predictive identification
of hazards, their cause &
consequence and the
qualitative estimation of
likelihood and severity.
Qualitative Risk Analysis
Frequency of Exposure  Probability Loss = Likelihood
FREQUENCY OF EXPOSURE:
4321-
Frequent (at least daily)
Occasional (> 1 occurrence per month)
Rare (< 2 occurrences per year)
No significant exposure (once every 3 years)
PROBABILITY OF LOSS:
4321-
Expected (“Happens often”; > 1 per month)
Occasional (< 2 occurrences per year)
Rare (< 1 occurrence every 3 years)
Very Rare (“Once in the life of the facility”)
Qualitative Risk Analysis
SEVERITY
CATEGORY
Severity 
Likelihood
= Risk
Ranking
HEALTH
SAFETY
ENVIRONMENTAL
IMPACT
FINANCIAL
LOSS
PUBLIC
IMPACT
Catastrophic –
mutual aid required
Major environmental
impact to
neighbouring
receptors (public
streams, vegetation,
air, ground water)
Extensive
damage &
extended
downtime
(Corporate)
Serious
impact - large
community
Major
downtime
(Division /
Area)
Serious
impact - small
community
6
One or more
fatalities
5
Serious injury
- permanent
disability, lifethreatening
occupational
illnesses
Significant Event full disaster
response
Off-site release or
repeated noncompliance issues
with potential for
significant adverse
impact
4
Serious injury
- disabling
occupational
illnesses
Serious threat emergency
response (external
agencies involved)
Contained within the
facility - large impact
or repeat noncompliance issues
Minor
damage or
downtime
(Department)
Minor –
families
affected
3
Temporary
disability minor injuries,
acute health
effects
Important
occurrence potential
emergency
response
Contained within
facility - minimal
impact & regulatory
reporting required
Minor
damage or
downtime
(Individual
processes)
Minor –
limited no. of
individuals
affected
First Aid or
less
Noticeable
occurrence reportable
Contained within
facility with no
adverse impact below reportable
levels
Minor
damage & no
downtime
Minimal to
none
2
Qualitative Risk Analysis
Severity
Likelihood
1
2
3
4
1
1
2
3
4
2
2
4
6
7
3
2
6
7
8
4
3
7
8
9
RANK 1 AND 2:
Lower priority. May require further study and/or action, as resources are
available.
RANK 3 TO 6:
Medium priority. Should be considered serious and appropriate action
should be taken.
RANK 7 TO 9:
Very high priority. Immediate action should be taken to reduce risks to a
level as low as practicable.
Qualitative vs. Quantitative
PROCESS HAZARDS ANALYSIS
IDENTIFIES HAZARDS, estimates
likelihood and severity, suggests
improvements.
RISK ANALYSIS
ASSESSES HAZARDS
USE ON EVERY PROJECT
SELECTIVE - use when other
methods prove inadequate or
excessive in cost.
QUALITATIVE - based on
experience, knowledge and creative
thinking.
QUANTITATIVE - requires
extensive data and special
expertise.
Most often done by
MULTIDISCIPLINARY TEAM
Done by ONE OR TWO SPECIALLY
TRAINED PEOPLE
Several methodologies available
 What-if or Hazid
 What-if/Checklist
 HAZOP
 FMEA
 Preliminary Hazards Analysis
Also called:
• Hazan
• Risk Assessment
• Probabilistic Risk Assessment
(PRA)
• Quantitative Risk Assessment
(QRA)
Elements of Facility Risk
A systematic approach that considers
the following process components:
 Process Design and Technology;
 Operational & Maintenance
Activities & Procedures;
 Non Routine Activities &
Procedures;
 Emergency Preparedness plans/
procedures;
 Training Programs.
Process Hazards
HAZARDOUS MATERIALS + PROCESS CONDITIONS
Flammable materials
Combustible materials
Unstable materials
Reactive materials
Corrosive materials
Asphyxiates
Shock-sensitive materials
Highly reactive materials
Toxic materials
Inert gases
Combustible dusts
High temperatures
Extremely low
temperatures
High pressures
Vacuum
Pressure cycling
Temperature cycling
Vibration/liquid
hammering
Rotating equipment
Ionizing radiation
High voltage/current
Erosion/Corrosion
Human Factors or Errors
HUMAN FAILURE
ERRORS
SLIPS
• Competency exists
• Intentions are correct
• Slips occur while
carrying out habitual,
routine, skill based
activity.
VIOLATIONS
MISTAKES
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Deliberate actions
Different from those prescribed
Carries known associated risks
Ignores operational procedures
Violation errors occur because of a
perception of lack of relevance, time
pressure or laziness.
Incorrect intention
Inadequate knowledge
Incorrect information processing
Inadequate training
Mistakes occur because of incorrect
assumptions or incorrect “tunnel
vision” application of rules.
Site or Location Hazards
Adjacent facilities;
 Nearby communities;
 Transport availability;
 Availability of Utilities;
 Topography/ average
weather conditions;
 Environmental sensitivity;
 Layout considerations regulations,
standards location/spacing, occupancy,
extreme process conditions.
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Environmental Issues
“LIVING” ENVIRONMENT
POTENTIAL IMPACTS
Human impacts:
Chronic and acute exposure to
toxic materials through
contaminated drinking water,
agricultural products and air
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Allergies
Eye irritation
Lung damage
Genetic mutations
Poisoning
Wildlife impacts:
• Migratory routes
• Critical habitats for endangered
species
• Genetic mutations
Domestic Animal Impacts:
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Contamination of feed & water
Genetic mutations
Poisoning
Impact on agriculture and food
supply
Micro/Macro biological Impacts:
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Ecosystems
Food chain
Surface and ground water
Air quality
Eradication of species
The Deviation List
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DEVIATION
MEANING
1.
Low / No Flow
Reduction / partial or total loss of flow.
Ex. Valve closed.
2.
High Flow
Excessive Flow.
Ex. Control valve malfunction.
3.
Reverse / Misdirected Flow
Process stream not following primary path.
4.
Leak / Rupture
Leak - minor leak Ex. - Flange leak.
Ex. Rupture - exchanger tube ruptures.
5.
Loss of Containment
Serious facility leak.
Ex. Storage tank leaks - are adequate dykes and berms in place?
6.
Hydraulic Surge
Pressure wave.
Ex. - Water Hammer. Consider high flow.
7.
High Pressure
Above design pressure or MAWP.
8.
Low Pressure
Below operating pressure.
Ex. Pump failure.
9.
Vacuum
Condensing of gases, loss of liquid level.
Ex. Maintenance - steaming of vessels.
10.
HP / LP Interface Pressure
Introduction of high pressure into a low pressure system.
Ex. DP across control valve when flow on one side is 600 psig and flow
on other side is 900 psig.
11.
High Temperature
Higher than design temperature.
Ex. Temperature control valve failure.
PHA Methodologies
Hazard & Operability Study;
 What-IF, Checklist or What
If/Checklist study;
 Failure Mode and Effects
Analysis (FMEA, FMECA);
 Fault Tree Analysis (FTA);
 Or an appropriate equivalent
methodology (Hazid, Hazcan)
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PHA Methodologies
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.
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What – If / Checklist
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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
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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
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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”
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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
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Assign responsibility to
recommendations;
Use a flexible CAR management system
that leaves a “paper trail”;
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.
QUESTIONS ?