Process

Safety Management
(PSM)
 Government Regula8ons
2 Regula)ons most applicable to chemical plants:
•  Occupa)onal Safety and Health Administra)on (OSHA)
à Process Safety Management of Highly Hazardous
Chemicals
•  Environmental Protec)on Agency (EPA) à Risk
Management Plan (RMP)
OSHA
•  O S H A : O c c u p a ) o n a l S a f e t y a n d H e a l t h
Adminsitra)on
•  Force of law with respect to on-site workplace
hazards/accidents. Jurisdic)on is only on the plant
site, not off site
•  PSM developed aNer Bhopal accident (1984) à
prevent similar accidents à excellent regula)on to
reduce number & magnitude accidents
PSM Standard : 14 Major Sec8ons
1.  Employee par)cipa)on
2.  Process safety informa)on
3.  Process hazard analysis
4.  Opera)ng procedures
5.  Training
6.  Contractors
7.  Pre-startup safety review
8.  Mechanical integrity
9.  Hot work permits
10.  Management of change
11.  Incident invees)ga)ons
12.  Emergency planning & response
13.  Audits
14.  Trade secrets
PSM – Employee Par8cipa8on

•  Requires ac)ve employee par)cipa)on in all

major elements PSM
•  Employers à develop & document a plan of
ac)on to specify this par)cipa)on
PSM – Process Safety Informa8on (PSI)
•  PSI à Compiled & made available to all employees to
facilitate the understanding & iden)fica)on hazards
•  The informa)on includes:
–  Process flow diagram
–  Process chemistry
–  Process limita)on: temperature, pressure, flow, &
composi)on
–  Consequences of process devia)ons
•  PSI needed à before training, process hazard
analysis, management of change & accident
inves)ga)on
PSM – Process Hazard Analysis (PHA)
•  Performed by: team experts, including engineers,
chemists, operators, industrial hygienists & other
appropriate & experienced specialists
•  Needs to include:
–  A method that fits the complexity process
–  A hazard & operability study (HAZOP) study for complex,
less complex, & rigorous process such as what-if scenarios,
checklists, failure mode & effect analysis or fault trees
process

Employers must ensure that recommendations from PHA acted on in

a timely manner. Every PSM process needs an updated PHA at least
every 5 years after the initial analysis completed
PSM – Opera8ng Procedures
•  SOP à safe opera)on plat must be documented
•  Instruc)on à clearly wricen & cinsistent with process safety
informa)on
•  Coverage: ini)al start up, normal opera)ons, temporary
opera)ons, emergency shutdown, emergency opera)on,
normal shut down, startup aNer normal & emergency shut
down, opera)ng limit & consequences of devia)ons, safety &
health considera)ons, hazardous proper)es of chemicals,
exposure precau)on, engineering & administra)ve control,
quality control specifica)on all chemicals, special or unique
hazards, & safety control system & func)on
•  Safe work prac)ces: hot work, lockout/tagout & confined
space
•  SOP à updated frequently
PSM – An Effec8ve Training
•  Help employees understand the hazard
•  Maintenance & opera)on personnel receive
ini)al training & refresher training
•  Operators à understand hazard associated
with every task, including emergency shut
down, start up, & normal opera)on
•  Refresher training à every 3 years & more
oNen is necessary
PSM – Contractors
•  Trained à to perform their task safely to the
same extent as employees
•  Selec)ng contractor à consider the
contractors’ safety performance in addi)on
to their skills
PSM – A Pre-startup Safety Review
•  Special safety review conducted aNer
modifica)on process or opera)ng condi)on
& before startup
•  Team of reviewers must ensures:
1.  System constructed in accordance with the
design specifica)on
2.  Safety, maintenance, opera)ng & emergency
procedures à in place
3.  Appropriate training completed
4.  Recommenda)ons from PHA implemented/
resolved
PSM – Mechanical Integrity
•  Ensures equipment, piping, relief system,
control, alarm are mechanically sound &
opera)onal
•  Requirement include:
1.  Wricen procedures to maintain func)oning
system
2.  Training regarding preven)ve maintenance
3.  Periodic inspec)ons & tes)ng based on vendor
recommenda)on
4.  A process to correct deficiencies
5.  A process to ensure that all equipment & spare
parts are suitable
PSM – Management of Change
•  PSM standar employees reuired to develop
& implement documented procedures to
manage in the process chemistry, process
equipment & SOP
•  Before a change occur à reviewed to
ascertain that it will not affect opera)on
safety
•  ANer the change has been made à all
affected employees trained & pre-startup
review in conducted
PSM – Incident Inves8ga8ons
•  Employers must inves)gate all incidents that
have or could have resulted a major release
or accident within 48 hours of the event
•  Inves)ga)on team: people, including
operators who are knowledgeable about the
system
•  ANer inves)ga)on à the employers are
required to appropriately use the
inves)ga)on recommenda)ons
PSM – Emergency Planning & Response
•  Respond effec)vely to the release highly
hazardous chemicals
•  Regula)on à applied for companies more
than 10 employees
•  Should be a part of program that handle
hazardous chemicals
PSM – Audits
•  Cer)fy that employers have evaluated their
compliance with the standard at least every
three years
•  The recommenda)ons from the audit must
be followed
•  The audit report need to be retained as long
as the process exist
PSM – Trade Secrets
•  PSM standard ensures: all contractors given
all informa)on relevant to opera)ng in the
plant safely
•  Some personnel may need to sign secrecy
agreements before they receive this
informa)on
Process Safety/Risk Management
•  Management Systems •  Pre-Startup Safety Reviews
•  Employee Par)cipa)on •  Mechanical Integrity
•  Process Safety Informa)on •  Safe Work Prac)ces
•  Process Hazard Analysis •  Management of Change
•  Opera)ng Procedures •  Emergency Planning and
•  Training Response
•  Contractor Safety •  Incident Inves)ga)on
•  Compliance Audits
EPA
•  EPA – Environmental Protec)on Agency
•  Handles releases outside the plant site
•  Decreasing the number & magnitude of accidental
releases of toxic & flammable substances
RMP
Elements of Risk Management Plan:
•  Hazard assessment
•  Preven)on program
•  Emergency response program
•  Documenta)on à maintained on the side &
submiced to federal, state & local authori)es à
shared with local community
Industrial Hygiene
•  Concerns condi)ons related to workplace injury & sickness
e.g.: exposures to toxic vapors, dust, noise, heat, cold,
radia)on, physical factors, etc

ANTICIPATION - Expecta)on of hazard existence

IDENTIFICATION - Presence of workplace exposure

EVALUATION - Magnitude of exposure

CONTROL - Reduc)on to acceptable levels

•  Chemical plants & labs à requires co-opera)on from

industrial hygiene, safety & plant opera)on people
 Iden8fica8on
CHEMICAL PROCESS •  Process design
•  Opera)ng instruc)ons
OPERATING CONDITIONS •  Safety reviews
•  Equipment descrip)on
OPERATING PROCEDURES •  Chemical proper)es MSDS

POTENTIAL HAZARDS HAZARD DATA

•  Physical state / vapor pressure
•  Liquids
•  Vapors •  TLV’s
•  Dusts •  Temperature sensi)vity
•  Noise •  Rate & heat of reac)on
•  Radia)on •  By product
•  Temperature •  Reac)vity with other chemicals
•  Mechanical •  Explosion limits

RISK ASSESMENT: poten)al for hazard to result in an accident

Group Discussion
A survey of a laboratory is made & the following
chemical species are iden)fied:
•  Sodium chloride
•  Toluene
•  Hydrochloric acid
•  Phenol
•  Sodium hydroxide
•  Benzene
•  Ether
Iden)fy the poten)al hazards in the laboratory à
provide descrip)on & poten)al hazard

Chemical Descrip8on & poten8al hazard
Sodium chloride Common table salt. No hazard.
Toluene Clear, colorless liquid with a slight fire hazard & moderate
explosion hazard. Entry into the body is mostly by vapor
inhala)on. Acute & chronic exposures occur with
concentra)on greater than 200ppm. Irritant to skin & eyes.

Clear, colorless liquid with no fire or explosion hazard. It is a
moderate irritant to skin, eyes & mucuos membranes & by
Hydrochloric acid inges)on & inhala)on. Throat irrita)on occurs with
concentra)on 35ppm. Highly reac)ve with a wide variety of
substances.
A white crystalline mass that is most frequently found in
Phenol solu)on form. It is a moderate fire hazard. Emits toxic fumes
when heated. Absorbed readily through the skin. Exposures
to skin areas as small as 64in2 have resulted in death in less
than 1 hour.
A skin & eye irritant. Corrosive ac)on on all body )ssues.
Sodium hydroxide Reacts violently with a number of substances


Chemical Descrip8on & poten8al hazard
Benzene Clear, colorless liquid with a dangerous fire hazard & a
moderate explosion hazard. It is a possible carcinogen.
Entry into the body is mostly by inhala)on but is also
absorbed through the skin. High concentra)ons produce a
narco)c effect.
A wide variety of organic compounds that are mostly
Ether narco)c in effect. Large doses can cause death. Most
ethers are dangerously flammable & explosive.

Evalua8ng Vola8les
Monitoring air concentrations Variation in time & place

Time Weighted Average (TWA)

t
1w
Continuous: TWA = ∫ C (t )dt
80
C(t) = concentration (ppm atau mg/m3) chemical in the air
tw = worker shift time in hours
Evalua8ng Vola8les
Evalua8ng Vola8les
n
Ci
additive effect multipletoxicants = ∑
i =1 (TLV − TWA )i

n = total number of toxicants

Ci = concentration of chemical i respect to other toxicants
(TLV-TWA)i = TLV – TWA chemical species i

•  If the value >1 à worker overexposed

•  Problem: The presence of an addi)onal chemical reduces the
exposure concentra)ons.if you are not aware of the presence of an
addi)onal chemical then you might be overexposed when you think
you are OK!
Evalua8ng Vola8les
•  The mixture TLV-TWA:
n

∑C
i =1
i
(TLV − TWA)mix = n
Ci
∑
i =1 (TLV − TWA )i

if ∑C > (TLV − TWA)

i mix → wor ker s over exp osure
⎯⎯
Example 1:
•  Determine the 8-hr TWA worker exposure if the worker is
exposed to toluene vapors as follows:
Dura)on of exposure (hr) Measured concentra)on (ppm)

2 110
2 330
4 90
Example 2:
Es8ma8ng Vola8les
Es8ma8ng Vola8les
Let:
•  C = concentra)on of vola)le vapor in the enclosure (mass/volume)
•  V = volume enclosure (volume)
•  Qv = ven)la)on rate (volume/)me)
•  k = non-ideal mixing factor (unitless)
•  Qm = evolu)on rate vola)le material (mass/)me)

Total mass volatile in volume = VC
d (VC ) dC
Accumulation mass volatile = =V
dt dt
Mass rate volatile material resulting from evolution = Qm
Mass rate volatile material out = kQvC
Es8ma8ng Vola8les
Accumula)on = mass in - mass out:
dC
V = Qm − kQvC
dt
Steady state à acc = 0:
Qm
C=
kQv
Gas ideal:

m = mass, ρ = density
v = volatile, b = bulk gas species
Es8ma8ng Vola8les
Hence:
Vv 6 ⎛ mv / ρv ⎞ 6 ⎛ mv ⎞⎛ RgT ⎞ 6
C ppm = x10 = ⎜ ⎟ x10 = ⎜ ⎟⎜ ⎟ x10
Vb ⎝ Vb ⎠ ⎝ Vb ⎠ ⎝ PM ⎠
Rg = ideal gas cons tan t
T = absolute ambient temperature
P = absolute pressure
M = molecular weight volatile species

mv / Vb ⎯⎯
→ concentration of volatile

Qm RgT 6
C ppm = x10
kQv PM
Example:
Alternate Control Methods