Process Safety Management elements

AlChE/CCPS Process Safety Management Elements... 

FIGURE 3-4. Occupational Safety and Health Administration (OSHA) Process Safety Management Elements... 

The American Petroleum Institute s Recommended Practice 750 describes process safety management elements recommended for operations in the oil and gas industry. 

One of the six elements of Responsible Care is the Codes of Management Practice, and one of the codes is the Process Safety Code of Management Practices (34). This code emphasi2es management commitment and accountabiUty, information sharing, and community relations, but also includes 11 of the 14 specific elements of the legislated process safety management standards developed later. 

It is incumbent upon the toller to develop and follow internal management systems as appropriate to support business needs, production needs, process safety, environmental responsibility, and worker health. The selection process should have considered whether or not satisfactory systems are in place. Nevertheless, the contract or auxiliary documents may be the vehicle used to help ensure that the system reviewed is the system actually used for completing the toll in question. Within the process safety management system, the management of change and training elements are essential subsystems. 

Process Safety Management (PSM) A program or activity involving the application of management principles and analytical techniques to ensure the safety of chemical process facilities. Sometimes called process hazard management. Each principle is often termed an element or component of process safety. 

In 1989, CCPS published the Guidelines for Technical Management of Ghemical Process Safety, which presented a model for Process Safety Management characterized by twelve distinct, essential, and interrelated elements. The Foreword to that book stated ... 

Employers shall develop a written action plan that implements employee participation in developing and conducting process hazards analyses and other elements of process safety. management. 

CCPS has identified 12 elements that together make up process safety management. [List 12 elements.]... 

The CCPS model describes process safety management systems in terms of 12 elements and 68 components. The elements and components appear as Table 1.1 on pages 2 and 3 of this book. 

The Chemical Manufacturers Association s Code of Management Practice for Process Safety is oriented toward the chemical industry, and describes the elements of a process safety management program as part of CMA s Responsible Care program. 

To expand process safety management to these activities, you should first identify how each PSM element relates to the new activity, as shown in Figure 9-1. You can then determine how the existing PSM systems must be modified. For example, you may find that most elements of PSM should be installed in R D, so that pilot plant activities employ the same safety management systems as production. 

These publications contain information on twelve key elements of chemical process safety management. In this section, seven of those elements that can be significantly impacted by paying careful attention to human factors principles are addressed. These are ... 

Accountability is the obligation to answer for one s performance with respect to expectations, goals, and objectives. It is an important element of an effective process safety management system. To improve safety, the risk associated with human errors must be reduced. The work situation is the predominant cause of human errors and management has control over the work situation. 

The "Capital Projects Design Review Procedures" element of process safety management assures that the design, the equipment and the construction are properly reviewed for all new projects. Process safety review procedures should be involved with the project from its inception. One method of illustrating the various phases of a project is shown in Figure 8.1 (Figure 5-1 from CCPS, 1989a). 

Exhibit 2-4. Comparison of Different Process Safety Management Programs and Elements... 

There are numerous other CCPS publications that may be helpful in your integration effort. In particular, the selection of measures to monitor the effectiveness of your integration effort and identify continuous improvement opportunities can be enhanced through the use of the results of a CCPS research and development effort to develop performance measures for CCPS s 12 process safety elements. These results will be described in the CCPS Guidelines for Developing Performance Measures for Continuous Improvement of Process Safety Management (scheduled for publication in... 

One of the most important elements of the PSM Rule is the process hazard analysis (PrHA). It requires the systematic identification of hazards and related accident scenarios. The PSM Rule allows the use of different analysis methods, but the selected method must be based on the process being analyzed. The PSM Rule specifies that PrHAs must be completed as soon as possible within a 5-year period. However, one-fourth of the PrHAs must have been completed by May 26, 1994, with an additional one-fourth completed each succeeding year. The highest risk processes were to be done first. A schedule for PrHAs must be established at the outset of a process safety management (PSM) program to give priority to the highest risk processes. PrHAs must be reviewed and updated at least every 5 years. 

Identified hazards can either be reduced at the root (e.g., reduction of inventory) or by introduction of protective systems (e.g., automatic emergency shutdown). The increased understanding of the chemistry and the process that is obtained from hazard evaluation procedures provides guidance for many other elements of process safety management as well (e.g., procedural instructions, emergency strategies, personnel training, and preventive maintenance). 

The Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers (AIChE) has identified twelve elements that must be part of any chemical process safety management program [5]. Application of these elements specifically to plant operations has also been defined [6]. Because of the critical importance of these twelve elements, they are listed here as follows for reference ... 

Process security and process safety have many parallels and use many common programs and systems for achieving their ends. Process security management requires a systems approach to develop a comprehensive security program, which shares many common elements with process safety management. 

Inadequate process safety management practices are often cited as the cause of reactive incidents, as discussed in Section 3.0 (Table 4). Incident data underscore the critical importance of successfully implementing the following key elements throughout the life cycle48 of a manufacturing process ... 

On the other hand, there are a number of elements of fire prevention that overlap with elements of other programs. For example. Incident Investigation, Management of Change (MOC), Process Safety Information (PSI), and Process Hazard Analysis (PHA) input required for fire prevention can be derived from these same elements of the Process Safety Management (PSM) program. 

Overall plant-wide maintenance is an element of fire prevention. It is shared with the business need to maintain the production process, as well as with Process Safety Management and other health, safety, and environmental programs. 

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