1. Process Safety Management Overview General
Charles Williams
Process Safety Program Manager

2. Process Safety Management (PSM)
Objectives
Define what is Process Safety Management
Review the key elements
Regulatory requirements
Proposed Penn State elements
Discuss benefits of a Process Safety Management Program

3. Process Safety Management (PSM)
Bhopal India – Union Carbide Plant (Dec. 3, 1984)
> 2,000 people killed in 40 ton chemical
release
Piper Alpha (July 6, 1988)
167 men killed in explosion and fire
Formosa Plastics (April 23, 2004)
5 workers killed in explosion and fire
BP, Texas City (March 23, 2005)
15 deaths and more than 170
others injured

4. Process Safety Management (PSM)
Major disasters involving highly hazardous chemicals draw national attention, however, there have been numerous less notable releases. Hazardous chemical releases continue to pose a significant threat to employees, contractors and the public
Several key regulations have been developed to address the unexpected releases of toxic, reactive or flammable liquids and gases including OSHA’s Process Safety Management (29CFR ) standard and EPA’s Chemical Accident Prevention (40CFR 68) program
Even well designed, constructed and operated unit operations can still pose the potential for an unexpected release of a highly hazardous chemical

5. Process Safety Management (PSM)
State University of NY – Potsdam, HazMat Team response on August 13, 2013 after an employee noticed an ammonia leak in the college’s athletic facilities
WATERTOWN DAILY TIMES - Hazardous materials teams from several agencies suit up Tuesday to investigate and clean up an ammonia leak in Maxcy Hall on SUNY Potsdam’s campus
“Minor Ammonia Leak Closes Rink at Cottage Grove Ice Arena, South Washington Bulletin, MN (Jan. 2014)
“What we’ve found is that the piping was supposed to be in a vault and it wasn’t” – City Administrator
Cottage Grove Ice Arena – Park High School boys and girls hockey clubs.

6. Process Safety Management (PSM)
Penn State has acknowledged the need to develop and implement a Process Safety Management Program with initial focus on ammonia refrigeration units (e.g. Pegula, Food Science - Berkey Creamery)
PSM is an analytical method focused on managing processes to prevent releases of any highly hazardous chemical and subsequent catastrophic events – fires, explosions, or toxic releases

7. What is Process Safety Occupational Safety Process Safety
Protecting against personal injuries
Slips, trips, falls, falling from height, chemical contact
Process Safety
Protecting against catastrophic incidents
Fires, explosions, toxic releases resulting in significant loss of life, property or environmental impact

8. However, these efforts will not reduce the number of plane crashes!
What is Process Safety
The airline industry experiences many back and muscle strains to baggage handlers from lifting and carry luggage
Significant effort is spent trying to prevent these types of injuries
However, these efforts will not reduce the number of plane crashes!

9. What is Process Safety Occupational Safety Examples:
Measures to prevent workplace illnesses, accidents, and injuries
Examples:
Selection and use of PPE
Industrial hygiene monitoring
Shoring requirements for excavation projects

10. What is Process Safety Process Safety Examples:
Identifying the hazards that could lead to fires, explosions, or toxic releases: catastrophic events
Examples:
Inspecting and maintaining equipment
to prevent loss of containment
Using formal assessment program to review
proposed changes to equipment or procedures
Conducting hazard studies to identify the hazards
and appropriate safeguards for each process

11. Process Safety Management (PSM)
After reviewing the basic causes of major Process Safety incidents, OSHA concluded that often there is a serious lack of knowledge either in the organization or at the operations level on basic Process Safety Information
OSHA considers 14 key elements of a PSM Program, however, our proposed program contains 17 key elements

12. Process Safety Management (PSM)
Management System
Process Safety Information
Process Hazard Analysis
Operating Procedures
Training & Assessment
Contractor Mgmt.
Mechanical Integrity
Mgmt. System to Address Action Items
Management of Change
Incident Investigation
Compliance Audits
Trade Secrets
Employee Participation
Pre-startup Safety Review
Emergency Preparedness
Process Hazard Analysis Review
Maintenance Systems

13. PSM Key Elements Management System Process Safety Information
Senior Leadership Commitment
Written Program
Responsibilities Defined
Metrics & Continuous Improvement
Process Safety Information
Process Technology
Chemical Data
Equipment Data

14. PSM Key Elements Process Hazard Analysis
Defined methodology to assess potential releases from process
Management System to Address Action Items
Prioritization process based on risk ranking
Transparent system to assign responsibility and timeframe to accomplish recommendations
Tracking completion

15. PSM Key Elements Process Hazard Analysis Review Employee Participation
Defined process & frequency to review the process hazard analysis and response systems
Employee Participation
Development of PSM program
Process Hazard Analysis
Incident Investigation
Other elements

16. PSM Key Elements Operating Procedures Emergency Preparedness
Steps for each operating phase during initial start-up, normal operations, temporary operations, emergency shutdown and start-up after emergency shutdown
Emergency Preparedness
Defined actions by individuals when a release occurs and other emergency scenarios

17. PSM Key Elements Training & Assessment Contractor Management
Program outlining training requirements for Technicians, Contractors and other individuals that can impact covered processes
Contractor Management
Qualification program that factors in EHS performance
Communicate access and safe work practices for covered areas

18. PSM Key Elements Mechanical Integrity Maintenance Systems
Defined procedures to maintain the on-going integrity of process equipment
Inspection and Testing requirements
Maintenance Systems
Safe Work Permit program
Hot Work Permit
Program associated with non-routine activities

19. PSM Key Elements Management of Change (MOC)
Change management program that encompasses proposing changes to affected Departments prior implementation
Authorization required before implementing change
Pre-Startup Safety Review (PSSR)
Program to conduct pre-startup assessments for new or modified facilities/equipment

20. PSM Key Elements Incident Investigation Compliance Audits
Incidents that resulted or could reasonably have resulted in a catastrophic release
Team approach started within 48 hours
Compliance Audits
PSM Program evaluated by 3rd Party every 3 yrs.
Trade Secrets
Mechanism to maintain confidentiality with individuals/group requiring Process Safety Information

21. Penn State Process Safety Model
Regulations
Standards
Best Practices
Incidents & Accidents
Industry Guidelines
Technology
Equipment
Process Hazard Analysis
(Risk Evaluation)
Process
Personnel
Risk Management – Reduction/Control
17 Management System Elements

22. Process Safety Management (PSM)
Various Functions within our PSM Program:
Ammonia Refrigeration Technicians
Area Supervisors
Safety Officers
Facility/Building Managers
Coaches
EHS Department
HazMat Team
Contractors
Police Services
Interns/Students
Event Staff

23. Process Safety Management (PSM)
Program Benefits
Formal management system to enhance and preserve University’s critical equipment
Platform to assist with improving operational effectiveness
Mechanism to engage and solicit input from various stakeholders
Empower employees to be an active program participant with development and on-going sustainability

24. Why PSM at Penn State?
Contractor started working on system while production was on-going
Standard procedure not followed – refrigeration being re-applied to tank considered “not normal”
Employee operating equipment advised that he was fatigued at work due to being shorthanded and overworked
Maintenance employee identified a problem (post-accident) with valves in system not functioning as designed – was not identified previously since “no preventive maintenance program existed on that equipment

25. Why PSM at Penn State? The results of numerous system failures:
Employee Injuries and Equipment Damage

26. Why PSM at Penn State? Borland Explosion – March 1, 1982
Are our systems robust enough to prevent a similar event today?

27. Questions