1. Process Safety Management
…. and its Impact on the
Professional Engineering Community
PRESENTATION OVERVIEW
Brian D. Kelly P Eng
BriRisk Consulting Ltd.
Calgary AB T3G 5J6
Sept 14, 2010

2. Process Safety Management is a comprehensive framework of activities for managing the integrity of a hazardous (chemical) operation. Its goal is to eliminate (prevent and mitigate) loss of containment incidents.
Loss of containment events can lead to fire, explosion or toxic effects and may result in large numbers of casualties.

3. Occupational Health and Safety Process Safety
Workplace rules
Worker training
Supervision
Individual behaviors
Safety equipment
Focus on individual well being
Collective commitment
Addresses events over which the individual worker has little or no control
Focus on systems
Broader impact – events that could affect groups of workers or general public

4. Early Development
Process Safety concepts were first adopted by companies that specialized in the production of highly hazardous chemicals (DUPONT, ICI).
1984 Bhopal, India chemical plant incident released toxic gas into local community causing the deaths of 3000 people.
Analysis indicated the accident was preventable through formal management systems.
Industrialized nations formally adopted Process Safety Management.

5. PSM Protocols Several PSM protocols exist worldwide.
OSHA (US) is legislated and requires “designated” operations to comply with provisions of 14 element framework.
Center for Chemical Process Safety (industry alliance) recently developed a 20 element risk based framework that better addresses people, process and equipment issues.
PSM element framework should be tailored to type of operation.

6. Canadian Requirements
No formal PSM regulation per se.
CEPA 1999, section 200 (Environment Canada) mandates the development and implementation of emergency response plans for environmental emergencies in designated high hazard industries.
Bill C-45 (Westray bill) includes amendments to the criminal code of Canada.
Legal duty for all persons directing work to take “reasonable steps” to ensure the safety of workers and the public.
Severe penalties for failing to ensure safety and integrity of operating facilities.

7. PSM Structure Understand Hazards Learn from Experience
Commitment to PSM
Understand Hazards
and Risk
Learn from Experience
Manage Risk

8. Risk Based PSM Framework
Commit to Process Safety
Process Safety Culture
Compliance with Standards
Process Safety Competency
Workforce Involvement
Stakeholder Outreach
Understand Hazards and Risk
Process Safety Information
Hazard Identification and Risk Analysis
Manage Risk
Operating Procedures
Safe Work Practices
Asset Integrity and Reliability
Contractor Management
Training and Performance Assurance
Management of Change
Operational Readiness
Conduct of Operations
Emergency Management
Learn from Experience
Incident Investigation
Measurement and Metrics
Auditing
Management Review and Continuous Improvement

9. PSM Structure
Each of the 20 elements of Risk Based Process Safety is fully described in the CCPS Guidelines book: Guidelines for Risk Based Process Safety, Wiley, 2007, ISBN
A better understanding of process safety may be acquired through a participative workshop with other professionals.

10. Engineering Discipline Involvement
CHEMICAL
Process selection
Operating conditions
Safe operating envelope
Process design
Process control
Safeguards
Monitoring
CIVIL
Site layout
Elevated structures
Grading
Drainage
Buildings
Facility siting
Infrastructure
MECH
Pressure envelope design
Rotating equipment
Codes
Monitoring
ELECTRICAL
Reliable power
Arc flash protection
Area classification
Grounding bonding
GFIs

11. Why Process Safety Management?
PSM framework is essential to avoidance of loss of containment incidents – these can put a company out of business
PSM drives rigor and discipline into an operating organization
An effective PSM framework will also address smaller incidents including those not associated with loss of containment
PSM will improve the bottom line

12. Executive Support
Executive support is required in the following areas to ensure PSM success:
Financial – additional resources (people and money) required for PSI, PHAs, training, maintenance etc.
Production penalty – may need to suspend production if warranted by serious process safety concerns
Hold organization accountable – engage in discussions with operations personnel about process safety issues. Ask questions