Process safety management presentation.pptx

Process management, the systematic approach to analyzing, optimizing, and controlling business processes, has become an indispensable tool for organizations seeking to improve efficiency, reduce costs, and enhance customer satisfaction. This presentation will delve into the core concepts, methodologies, and best practices of process management, providing a comprehensive overview of how organizations can leverage this discipline to achieve their strategic objectives.

1. Process safety management

2. PSM (process safety management) Process Safety is a disciplined framework for managing the integrity of operating systems and processes handling hazardous substances by applying good design principles, engineering, and operating practices. Process Safety defines PSM as “a management system that is focused on prevention and restoration from catastrophic releases of chemicals or energy from a process associated with a facility”.

3. Personal safety VS Process safety

4. The Alarming Cost of Neglecting PSM Devastating consequences:  Major accidents like explosions, fires, and toxic releases can have catastrophic consequences, leading to: Loss of life and injuries Environmental damage Property destruction Economic losses History has shown that a lack of, an ignorance of, or an improper or inadequate implementation of a suitable PSM program can be disastrous….

5. Related incidents (external) The toxic gas leak at the LG Polymers plant in Andhra Pradesh on 7 May that lead to 11 worker suffocated and killed. Initial reports suggest that maintenance failures, operating errors, and improper storage of the toxic styrene gas, may have led to the tragedy.

6. Related incidents (internal) Sulfonic Area Flame was found on the surface of the underground melter. That was due to improper heating control system, (inadequate temperature sensor). And no clear procedures to decrease the temperature ,action was taken very slowly. Alarm was neglected No automatic prevention for this failure.

7. Related incidents (internal) ACI Caustic Soda Tank (Tank farm) While discharging a caustic soda truck, overflow and material loss from the tank occurred . That was due to inadequate level control system. Human error due to leaving the discharge pump without monitoring the tank level.

8. The Pillars of PSM Commitment and resources :  Establishing a strong foundation with clear management commitment to process safety and allocating necessary resources. Process understanding :  Thoroughly comprehending the process, its potential hazards, and deviations to proactively manage risks. Hazard identification and analysis :  Proactively identifying potential hazards and systematically analyzing their likelihood and severity to implement effective procedures & actions .(HAZOP) Managing change :  Implementing a well-defined process for managing changes to processes, equipment, or procedures to ensure safety is not compromised. Clear operating procedures :  Establishing clear and well-defined procedures for safe operation, including startup, shutdown, and emergency response protocols. Safe work practices :  Implementing safe work practices like permit systems, proper personal protective equipment (PPE) use, and lockout/tagout procedures to minimize risks during activities. Empowering through training :  Providing comprehensive training to employees on process safety, their roles and responsibilities, and emergency procedures. Contractor engagement :  Ensuring contractors working on-site understand safety requirements and adhere to safe work practices. Learning from incidents :  Thoroughly investigating incidents to identify root causes and implement corrective actions to prevent recurrence. Continuous improvement :  Regularly reviewing and auditing PSM programs to identify areas for improvement and ensure their effectiveness.

9. The Tangible Benefits of PSM Reduced risks:  PSM significantly reduces the likelihood of accidents and injuries, protecting the workforce, communities, and the environment. Operational excellence:  By promoting safe operations and minimizing downtime, PSM contributes to improved operational efficiency and reliability. Environmental stewardship:  Effective PSM helps organizations minimize their environmental footprint by preventing accidental releases and pollution. Regulatory compliance:  Implementing a efficient PSM program ensures compliance with relevant regulations set by various countries and industries. Enhanced reputation:  A strong PSM program fosters a positive company reputation and enhances public trust, demonstrating a commitment to safety and responsible operations. Example: SANMAR

10. Process hazards

11. HAZOP HAZOP stands for Hazard and Operability Study. It's a systematic method for identifying potential hazards and operability issues in a process plant design. HAZOP is typically used in industries such as chemical processing, oil and gas, FMCG, and pharmaceuticals to ensure that risks are minimized and that processes are safe and efficient.

12. HAZOP Study To apply applicable HAZOP study we should be aware of the detailed process flow and its outputs and inputs. So the team can identify the Variation and analyze it.

13. Risk assessment Severity × Probability = RISK SEVERITY probability

14. Risk Assessment

15. control measures Eliminate the Hazard Substitute: Use Processes/ Methods with less Risk(Replace Manual by Auto) Isolate/ Segregate/ Moderate Hazard and/ Targets(Guards) Engineered Safeguards: Prevention: Design to Prevent unwanted Event Recovery: Design to Mitigate Consequences Organizational Controls: Training, Competency, Communication Procedural Controls: Operating Procedures, Work Instructions, Permits….. etc Personal Protective Equipment

16. Major Finds. 1- Safety culture need to be implemented Operators and Engineer commitment. Operators should report for any incompliance and understand the consequences that may happen. H azop study be done by team that include mechanical, electrical , Operation….etc. (stakeholders). 2- Implementing SOP. I n some cases Operation team by pass the sob as to prevent more time to be spent, which can lead to gas release, fatal damage or minor incidents. (Sulphonation Incident).

17. Major Finds. 3- PROCESS Signs a nd LABELS. Pipes and lines need signs to identify the direction of the flow and the material. Pumps and tanks need Clear Identifications to represent its number, Capacity and material. 4- Equipment and facility Safety control valves. For assuring not exceeding the max allowable temperature or pressure. periodic check if its already installed and assure its operability. (Tank 16 Incident & Caustic soda Tank) 5- Updated PID Not updated PID (T1 & T2 & Old Sulphonation ).

18. Thank you