Process safety management (PSM) is a management system that is focused on prevention of, preparedness for, mitigation of, response to, and restoration from catastrophic releases of chemicals or energy from a process associated with a facility.
Unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving HHCs have been reported for many years. Incidents continue to occur in various industries that use HHCs which may be toxic, reactive, flammable, or explosive, or may exhibit a combination of these properties. Regardless of the industry that uses these HHCs, there is a potential for an accidental release any time they are not properly controlled. This, in turn, creates the possibility of disaster. Recent major disasters include the1984 Bhopal, India,incident resulting in more than 5,200 deaths; theOctober 1989 Phillips Petroleum Company, Pasadena, TX, incident resulting in 23 deaths and 132 injuries; theJuly 1990 BASF, Cincinnati, OH,incident resulting in 2 deaths, and theMay 1991 IMC, Sterlington, LA,incident resulting in 8 deaths and 128 injuries and many more.
In United State:
PSM 29 CFR 1910.119was initiated by the OSHA in 1992 to respond with government oversight of industries using HHCs. Events prior to that date, involving the infrequent release of HHCs had sometimes resulted in catastrophic damage, injuries, and even death. Clearly, unchecked processes added to a volatile situation sometimes making things worse; much worse.
In September 1994, OSHA issued Instruction CPL 02-02-045, PSM of HHCs-Compliance Guidelines and Enforcement Procedures. This instruction ceded that the PQV inspections required great resources and limited the number of inspections that could be accomplished. This was a program that did not have the effect that was desired.
In Canada:
MIACC was active in PSM from 1988 up to its dissolution in 1999. MIACC was a partnership of federal, provincial and municipal governments, industry, labor, emergency response groups, public interest groups and academia. When MIACC was dissolved, it transferred its intellectual property to the CSChE. The CSChE initially maintained the twelve elements that were part of the early CCPS structure and found in PSM Guide 4th edition.
Canada does not have an explicit process safety management regulation comparable to the US OSHA 1910.119, EPA 40 CFR Part 68 or to COMAH in the United Kingdom.
This is where CSA Z767 comes into play. The objective of the CSChE was to develop a national standard, CSA Z767, and have it referenced by provincial jurisdictions.
CAPP conducted a regulatory scan for PSM in 2014. The purpose was to provide an overview of process safety regulations and best practices in Canada and the world.
Process Safety (PS):
Is a disciplined framework for managing the integrity of operating systems and processes handling hazardous substances. It is achieved by applying good design principles, engineering, and operating and maintenance practices. It deals with the prevention and control of events that have the potential to release hazardous materials and energy. Such incidents can result in toxic exposures, fires or explosion, and other releases of hazardous energy that could ultimately result in serious incidents including fatalities, injuries, property or environmental damage, lost production.
Process Safety Management (PSM):
Is an analytical tool focused on preventing releases of any substance defined as an “HHCs" by the EPA or OSHA. PSM refers to a set of interrelated approaches to managing hazards associated with the process industries and is intended to reduce the frequency and severity of incidents resulting from releases of chemicals and other energy sources (US OSHA 1993). These standards are composed of organizational and operational procedures, design guidance, audit programs, and a host of other methods.
Risk-Based Process Safety (RBPS):
Is the Center for Chemical Process Safety’s process safety management system approach that uses risk-based strategies and implementation tactics that are commensurate with the risk-based need for process safety activities, availability of resources, and existing process safety culture to design, correct, and improve process safety management activities.
Elements of PSM:
OSHA Recommended 14 PSM Elements:
With the Occupational Safety and Health Act of 1970, Congress created the Occupational Safety and Health Administration (OSHA) to assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education, and assistance. In 1992, OSHA issued 29 CFR 1910.119 14 elements of PSM as follows:
1.Process Safety Information (PSI)
2.Employee Participation
3.Process Hazard Analysis (PHA)
4.Operating Procedures
5.Management of Change (MOC)
6.Hot Work Permit
7.Mechanical Integrity
8.Emergency Planning & Response
9.Pre-Startup Safety Review (PSSR)
10. Incident Investigation
11. Compliance Audits
12. Contractors
13. Training
14. Trade Secrets
CCPS Recommended Risk-Based 20 PSM Elements:
On March 25, 1985, American Institute of Chemical Engineers (AIChE) formed the Center for Chemical Process Safety with seventeen charter member companies. In 2007 the CCPS definedthe 20 elements of PSM as follows:
The four pillars include:
1.Commit to process safety
2.Understand hazards and risk
3.Manage risk
4.Learn from experience
The 20 CCPS elements are as follow:
CSChE Recommended 12 PSM Elements:
The CSChE Canadian Society of Chemical Engineering initially maintained the twelve elements that were part of the early CCPS structure and found in PSM Guide 4th edition in 2012.The PSM elements as follows:
1.Accountability: Objectives and Goals
2.Process Knowledge & Documentation.
3.Capital Project Review and Design Procedures.
4.Process Risk Management.
5.Management of Change (MOC)
6.Process & Equipment Integrity
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7.Human Factors.
8.Training & Performance
9.Incident Investigation.
10. Company Standards, Codes & Regulations.
11. Audits & Corrective Action
12. Enhancement of Process Safety Knowledge.
ILO Recommended 16 PSM Elements:
The ILO is the United Nations specialized agency devoted to advancing opportunities for women and men to obtain decent and productive work in conditions of freedom, equity, security and human dignity. Created by the Treaty of Versailles in 1919, along with the League of Nations, the ILO traversed the Second World War with its principles, methods and goals not only intact but reiterated and reinforced. The ILO started to establish the guideline of PSM in 2001, then they defined the16 elements of PSM as follows:
Link: https://www.ilo.org/global/topics/safety-and-health-at-work/normative-instruments/lang--en/index.htm
1.Process Safety Information (PSI).
2.Employee Involvement.
3.Process Hazard Analysis (PHA).
4.Management of Change (MOC).
5.Operating Procedures.
6.Safe Work Practices & Permits.
7.Employee Information & Training.
8.Contractor Personnel.
9.Pre-startup Safety Reviews (PSSR).
10. Design Quality Assurance.
11. Maintenance & Mechanical Integrity.
12. Emergency Response.
13. Periodic Safety Audits.
14. Process Incident Investigation.
15. Standards & Regulations.
16. Trade Secrets.
