Safety Management System guidance

Published on June 2016 | Categories: Types, Instruction manuals | Downloads: 31 | Comments: 0 | Views: 428
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Much attention is on Major Accident Hazard Category industry particularly involving Hydrocarbon/Chemical process, while hazard anywhere is a potential cause for harm.Systems like OHSAS, EMS, PSM, ISRS offer guidance to build a strong edifice for structured SHE Management System.

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Preface
Much attention is on Major Accident Hazard Category industry particularly involving Hydrocarbon/Chemical process, while hazard anywhere is a potential cause for harm. Systems like OHSAS, EMS, PSM, ISRS offer guidance to build a strong edifice for structured Safety Management System. The stress in this PPT is on beneficial application of elements of PSM to suit one¶s own context. This PowerPoint builds on the earlier paper published in SCRIBD on ³Process Safety Management´ under reference to CFR 1910-119 and covered by its print /publication rights.

1

Why Focus on MAHAC Process Industry
Complexity of Reactions Diversity and spread Domino/Cascade effects-Offsite High Inventories, Nature of materials Severity of impact

2

Industry product--Consumer Benefits
Audio Cassettes Bubble gum Cooking Gas Detergents Fertilisers Leather chemicals Masking tapes Oils Paints Perfumes Petrochemicals Pharmaceuticals Plastics Semiconductors Tyres etc

3

Process Safety Management
1.Process Safety Information 2.Process Hazard Analysis 3.Standard Operating Procedures 4.Training 5.Contractor control 6.Pre-start up safety review 7.Mechanical Integrity

4

PSM Contd
8.Non-routine work authorisations 9.Management of Change 10.Investigation of incidents 11.Emergency Preparedness 12.Compliance audit 13.Employee participation

5

Process Safety information:
ChemistryCritical Process Parameters²Runaway, Unstable, NFPA ratings²Health, Reactivity, Flammability and Water reactive Toxic, Corrosive, explosive, Radioactive, carcinogenic data TLV, STEL, PEL, Odour threshold values Incompatibility Matrix, Interlock matrix

6

Hazard Analysis³(AIChE Ref)
Typical Applications Activity Design Detailed Engineering Analysis Construction / Startup Review Pilot Plant Operation / Routine Operation Technique PHA Fault Tree / Event Tree Checklist/Safety

HAZOP

7

Process Hazard Analysis (Contd)
Decommissioning Analysis Expansion Ranking R&D Incident Investigation What±If, Checklist HAZOP/Relative What ± If What± If / FMEA / HRA

8

Operating Procedures
Process parameters, Equipment operation details Normal start-up Emergency Shutdown Contingency shutdown Manual operation safeguards Do¶s and Don¶ts Equipment release/takeover steps Instrumentation controls, MSDS, Specs

9

SOP review need
Typical: Change of Process Change of chemistry Change of Operating parameters. Modifications Equipment changes. Layout changes Lessons Learnt/Operational experience

10

Training
‡ ‡ ‡ ‡

Identification of training need Skill gap analysis Job performance need New Process /Equipment modification need Behavioural, Functional and New Hire need

11

Training contd..
‡ ‡ ‡ ‡ ‡ ‡

Preparation of Training Calendar Identification of Trainers/Faculty Training attendance sheet record Training card fill-up with feedback Re-training if required A Process Map for Employee competency development.

12

Training
Training Subjects: ‡ Pre-start up safety checks ‡ Permits ‡ Familiarity to Legislation ‡ Hazard analysis and Risk assessment ‡ Engineered controls ‡ Industrial hygiene ‡ Audits and inspections ‡ Contractor Safety Management
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Training subjects
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡

Chemical Hazards and Control measures Emergency preparedness Fire & Explosion hazard prevention Electrical Safety Static electricity Storage area safety Chemical Safety Datasheets Vehicle & Fleet Safety Off-the-Job Safety Fire protection systems Incident prevention and investigation

14

Contractor Control
Selection criteria-Track record, Background check Training, I.D, Restricted access familiarity Methods statement:- Work, JSA Tools/ Equipment/Work area checklist-review Joint inspections-Compliance monitoring Performance review Meetings:- Incidents, Audits, Violations Focus items identification/Implementation Permits Insurance cover
15

Pre-commission checks
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡

Physical Check up Construction/ Modification debris pull out Punch List Job Completion certification P & ID Validation Internal cleaning- De-dusting and by Utilities Degreasing, Acidising, Passivating, Pressure testing Inerting/Box-up Blinds List
16

PCC- Contd..
‡ ‡ ‡ ‡ ‡ ‡

Check up of Machinery /Equipment Check of Vents/Drains, Traps Check all Utility connections Labeling and ID Flow direction markers Valves functionality including Remote control

17

PCC--Documents
‡

‡

‡ ‡ ‡ ‡

Check of Field and Panel Instrumentation, Zero checks and calibration, Alarms/Trips checks Field Electrical gear checks²Swtichgear, Transformers, Capacitors, MCC, FLP appliances. SOP availability Check of Communication systems O & M Manuals Catalogues & Specifications

18

Mechanical Integrity:
Visual Inspection Leak testing Hydrotest NDT MP Wet fluorescent magnetic particle DP

19

MI- Methods
X-Ray Eddy Current Acoustic emission Thermal imaging/Infrared Vibration analysis

20

MI Aids-Contd
Boroscopy Defectology (Destructive testing) Dimensional inspection Residual/Remnant Life Analysis Plant Life Extension Studies Reliability Engineering studies Corrosion monitoring

21

Attention spots
During fabrication Weld/Post weld Heat treatment²Local treatment, Furnace treatment, Temperature control, Rate of heating/Cooling Casting Forging

22

Focus spots
Elbows Bends Pipe supports Spring hangers Vents/Drains Nozzles Shells/Heads

23

Heat treatment in MI
Annealing Normalising Quenching Hardening Tempering

24

Non-routine work practices
Cold Work Hot Work, Confined Space entry, Line breaking, Clearing Jams Excavation, Electrical Line clearance, Lock out/Tag out , Work at heights, Bye-pass authorisations

25

Checklists
Typical: (Entry to Confined space) Isolating, Pump out, Emptying, Blinding, Tagging, Depressuring, Cooling, Removal of sludge/sediments, Gas freeing, Evacuating, Ventilating, Gas testing, Permit preparation/ Issue, Head count, Inspectionpre-entry, Protection of Personnel/ neighbourhood equipment, Rescue, Evacuation, (Buddy/Lifelines), First aid/Fire fighting appliances, Certified Tools/ELCB, Permits display, Name board, Compliance monitoring, Renewal conditions- Gas test frequency, STOP WORK Conditions etc

26

Restoration
Verification of Job Approval/acceptance Surrender and closure sign off of permit File record, Retention, Disposal (Doc Control)

27

Change Management
Reasons:
‡ ‡ ‡ ‡ ‡ ‡ ‡

SHE Productivity, Throughput increase Change of Equipment Change of Procedure Change of Process Chemistry & Technology Facility Change General Modifications & Changes

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Change Mgt -Pre-requisite.
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡

Nature of Change-Temp/Perm PHA/HAZOP Authorisation required Checklist,Approval forms SOP Training & Certification PDCA Validation Timetable Payout projection

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Change Mgt-- Considerations
‡ ‡ ‡ ‡ ‡ ‡

Design Codes/Standards Relief systems, Pipe supports, Expansion Loops, Insulation, Valves Fabrication Standards Material of Construction Engineered controls:Fail Safe Instrumentation, Detectors, Alarms and Trips, Earthing, Bonding,etc

30

Change Management--Docs
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡

Section Block diagram P & ID, Utilities Matrix Isometric drawing Elevation/Plan Change identification External approvals as needed Lighting, Ventilation and Noise factors OEM Catalogues and Specifications

31

Incident investigation
Involve Inspect Inquire Implement Integrate Information share

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Analysis
Fact Finding Root Cause Analysis:- QC, Ishikawa, 5 Why concept, Corrective action plan Preventive Action Plan Problem statement, Data collection, Evaluation, Review discussion, PDCA, Implementation

33

Incident--What it Means
Property Damage /Personnel harm Plant Start-up Delays Restricted Output Downtime Repairs Cost Insurance Costs Public Reaction Societal impact Economic Impact
34

On Site Emergency Plan
KEY ELEMENTS²ON-SITE EMERGENCY PLAN ‡ Basic Objectives ‡ Essential Elements ‡ Definition of Emergency ‡ ERT (Emergency Response Team) Organisation ‡ Communication Aids/Means ‡ Response ‡ Guidelines for Response Team ‡ Duties of Team Members ‡ Roles of Non-ERT Personnel and visitors
35

OSEP--Contd
Control and Protection Measures: Forward Control Centre Emergency Control Centre Assembly Points Escape Routes

36

OSEP--Contd
Reference Information: Risk Scenarios and Impact Distances Built-in Safeguards List of Fire & Safety Equipment²Quantity and Spread Fire Protection System Layout drawing

37

OSEP--Contd
List of Firsts Aid and Personal Protective Equipment²Quantity and Spread Other ER Equipment Quantity and Spread Ambient Air Quality Monitoring equipment List of Antidotes Drawing of Drains MSDS

38

OSEP--Contd
Layout/Plot Plans Wind Direction Details List of Key Contact Persons Key Notification Telephone Numbers Neighbourhood Charts/Maps List of Contractors

39

OSEP--Contd
Operational Emergency Handling Procedures Spill Response Chart Incompatible Chemicals Chart IED/Malicious damage emergency response checklist Storm/Earthquake other natural perils response checklist Civil defence plan guidance notes

40

OSEP--Contd
Off-Site Emergency Services² Contact Particulars:- List of
‡ ‡

‡ ‡

Hospitals and Medicare Points Subject Matter Specialists, Medicare Specialists Pharmacies/Medical Stores Neighbourhood Industries, NGOs, Voluntary Organisations, District Crisis Group Response Authorities
41

Compliance Audits
Self-Internal, Corporate, Statutory Industry Specific--OISD External-3rd Party BIS 14489 5-Star PSM (USA CFR) OHSAS/EMS ISRS Loss Prevention/Risk Management Specialists
42

Good Audits
Clarity in Scope definition Standards referenced Audit methodology²LPRM Specialist- Core competency,No rigid formats, No boundaries, Out of the Box approach, Bare all/ Tell all Partners/ Benchmark Facilitators-Reputation driven. Pre-audit survey/information input Physical visit²Opening meeting, Site co-ordinators, Physical tour, Interaction, Documents review, Audit notes, Draft sum-up, Closing meeting, Focus area identification, Action plan Roadmap, Final report
43

Employee Participation
Emphasis during advertisement/interview During Class/Hands-on/Refresher training SOP write-up O & M review Area audits/pep talks/permits preparation Site safety committees As internal faculty to train fresher Planning/Organising promotional activities Off-the ±Job/Externally Continual improvement Implementation
44

What to do
View First-aid events as Fatality Train/Train/Train/Audit/Audit/Audit RCA/CAP/PAP Fact find not fault find Implement not ignore Share & Learn CARE

45

Where it leads to
Reputation Management Global Outlook International Standards Track record protection Accountability for Quality/Impact Engineered Controls Administrative Measures PPE Partnership Approach
46

Summary-Where to start
LEVERAGE FROM LESSONS LEARNT-DOCUMENT INTERNAL EXPERIENCES GROUP INFORMATION SHARE NETWORKING APPLY: SYSTEM DRIVEN APPROACH SELF-REGULATORY CONCEPT EVERYONE¶S RESPONSIBILITY
47

List of abbreviations
BIS CAP CARE DP EMS ERT FLP FMEA HAZOP HRA ID IED ISO ISRS JSA Bureau of Indian Standards Corrective action plan Constant accident reduction (removal) efforts Dye penetrant Environment management system Emergency response team Flameproof Failure mode effects analysis Hazard operability Human ranking analysis Identity Improvised explosive device International organization for standardization International safety rating system Job safety analysis
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Contd
LPRM MAHAC MCC MI MP MSDS NDT NGO O&M OEM OHSAS OISD P &ID PAP PDCA PEL PHA PPE PSM Loss prevention and risk management Major accident hazard category Motor control centre Mechanical integrity Magnetic particle Material safety data sheet Non destructive testing Non governmental organisations Operation & Manual Original equipment manufacturer Occupational health & safety assessment series Oil industry safety directorate Piping & instrumentation diagram Preventive action plan Plan, develop, check and accept Permissible exposure limit Process hazard analysis Personal protective equipment Process safety management

49

Contd
QC RCA SHE SOP STEL TLV Quality circle Root cause analysis Safety, Health & Environment Standard operating procedure Short term exposure limit Threshold limit value

Acknowledgments--Preface

50

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