20120315 management of process safety r1.pptx

8/12/2019 20120315 Management of Process Safety R1.pptx

1/14

API RP-750


2/14

Objective of Process Hazard/Safety Management(PSM) is prevention of catastrophic release through :1) Process Safety Information (PSI)2) Process Hazard Analysis3) Management of Change (MOC)4) Operating Procedures5) Safe Work Practices6) Training7) Assurance of quality and mechanical integrity of critical

equipment8) Pre-Start-Up Safety Review (PSSR)9) Emergency Response and Control10) Investigation of process-related incidents11) Audit of PSM systems


3/14

Principle of This Recommended Practice (RP) PSM is an integral part of the design, construction,maintenance and operation of facility

The RP is intended for facility that use, produce,

process or store following substance: Flammable or explosive substance quantity andcondition that a sudden cause catastrophic release

Toxic substance that have Substance Hazard Index(SHI) greater than 5000 and present in amount above

treshold quantity


4/14

This RP is developed for refineries, petrochemicaloperation and major processing facilities, except: Distribution, retail and jobber operations (contractor)

LNG facilities, pipeline and transportation by US DOT

Oil & Gas well drilling, services and production covered by

US Mineral Management Services (MMS) Storage of flammable or combustible nonreactive, bulk

liquid at atmospheric pressure without benefit of chilling orrefrigerant

Storage of hydrocarbon fuel solely for on-site consumption

Natural Gas processing excluded process with extractionprocess of LPG


5/14

PSIelement : Process Design Information

PFD, process chemistry, maximum intended inventory,acceptable upper and lower limit i.e. temperature,pressure, flow

Process Design information could be developed inconjuction with Process Hazard Analysis

Mechanical Design Information

material of construction, P&ID, Electrical Are Classification,design and basis of relief system, design of ventilatingsystem, description of shutdown and interlock

Mechanical design information could be developed fromavailable equipment and inspection records
http://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-010-OPS%20Process%20Safety%20Information%20-%20English.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-010-OPS%20Process%20Safety%20Information%20-%20English.pdf


6/14

Purpose of PHA Minimize likelihood of occurance and consequences

Methodology General

Identification

Assessment

Alternative

Initial Analysis : existing and new facilities

Periodic Analysis : 3-10 years Analysis Team

Knowlegeabele person in engineering, process, prod.
http://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-004-TS%20Process%20Hazard%20Analysis%20Procedure.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-004-TS%20Process%20Hazard%20Analysis%20Procedure.pdf


7/14

Type of Change Change in Technology, i.e.

Bypass connection, change operating procedure

Change in Facilities, i.e. Temporary connection, replacement of equip.different

from original Procedureshould consider :

Process and mech.design basis for proposed change Analysis of HSE consideration, incl.PHA Necessary modification of operating procedures Communication of proposed change and consequence Required authorization Duration of change
http://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-003-TS-PSM%20%20Management%20of%20Change%20A7.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-003-TS-PSM%20%20Management%20of%20Change%20A7.pdf


8/14

Written Procedureshould incl : R&R of facilities operating area

Clear instruction ~ PSI

Operating Condition and steps of operation

Initial S/U, normal op.,S/D, emergency, S/U during T/A

Operating limit where consideration are present

Steps required to avoid deviations, function of safety system

OHS Consideration, i.e. MSDS explanation

Operation procedure before start up

Review periodically : 3 5 years
http://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/Procedure%20List.xlsxhttp://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/Procedure%20List.xlsx


9/14

SWPfor Operation, maintenance, and modificationactivities Opening Equipment, LOTO, Confined Space

Control of Material

Specification and inventories critical to process safety QC procedure should be established to ensure all

materials received and used meet the specifications
http://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/Procedure%20List.xlsxhttp://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/Procedure%20List.xlsx


10/14

Initial Training Required knowledge and skill for all personnel to carry out

duty and responsibility, incl. S/U and S/D

Communication of Change To all operating personnel before operate the facility

Periodically, at least per 3 year Procedure to ensure adequate retention of required

knowledge and skills

Qualified Instructor Documented


11/14

Critical equipment: designed, fabricated, installed and

maintained in a manner

Written QC procedure during Fabrication

Checks and Inspection before start up (installation)

Ensure Mechanical Integrity in Maint.System: Maintenance procedure and work practice (API 2007)

Training of maintenance team prior procedure application

QC procedure to ensure maintenance material and spareequipment and part as per design

Procedure to ensure maintenance employee andcontractors are qualified

Procedure to ensure change are review & implemented


12/14

PSSR performed for new and modified facility

PSSRelement : Construction is in accordance w/ specification

Safety, Operating, Maintenance and Emergency Procedureare in place, as appropriate

PHA recommendation already considered and completed

Training of operating personnel has been completed
http://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-005-TS-PSM%20%20Procedure%20for%20Pre-Startup%20Safety%20Review%20A7.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/OP-005-TS-PSM%20%20Procedure%20for%20Pre-Startup%20Safety%20Review%20A7.pdf


13/14

Emergency Action Plan following OSHA 1910.38(a) Employee Emergency Plan and fire prevention

plans OSHA 1910.120 Hazardous Waste Operation and Emergency

Response If Fire Brigade established, OSHS 1910.156 Fire Brigade

Emergency Control Center, equipped w/: Plant Layout and Community Plan Utility drawing, included fire-water system Emergency Lighting Emergency Communication Reference : plan, MSDS, phone number List of emergency equipment (location), mutual aid info Access to meteorogical
http://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/G-002-TS-HSE%20%20Emergency%20Response.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_9/PSM/G-002-TS-HSE%20%20Emergency%20Response.pdf


14/14

Finding of investigation should be kept by facilityfor possible use in next PHA update

Management system to determine anddocument finding f/u

To ensure effectiveness of performance 1-10

Audit interval 3-5 years

Audit team : knowleageable in process andspecialist deemed necessary

f/u Report to Management

20120315 management of process safety r1.pptx

Documents