NEXUS NNPC FSTP

Process Safety
Management

Nexus Alliance Ltd

 Session Elements

1. Introduction

2. What is Process Safety Management

3. Process Safety Elements

4. What can you do?

 INTRODUCTION

Not all hazards are the same or can cause equal

consequences

Personal or occupational safety hazards such as slips,
falls, cuts, and vehicle accidents usually affect one
individual worker

Process safety hazards may cause major accidents
involving release of potentially dangerous materials. Fire
and explosions or both!

Process safety incidents can have catastrophic effects
and can result in multiple injuries and fatalities, as well
as substantial economic, property and environmental
damage

3
 What is Process Safety Management

Process Safety Management is the

application of management principles and
systems to the identification,
understanding, and control of process
hazards to protect employees, facility
assets and the environment.

4
Process Safety Management

5
 What is Process Safety Management

Process Safety Elements:

Design and
Process Safety
Engineering of Information
facilities
Operating and

Hazard assessments maintenance
procedures

Incident Investigation

Inspection, testing

Management of
and maintenance of
Change
equipment

Employee

Personnel Training
participation

Emergency planning
and response 6
 Design and Engineering of
Facilities
Compliance with appropriate technical codes and
standards

Requires a documented system for managing
technical codes and standards

Provides procedures for managing exceptions
for projects and modifications to existing facilities
and operations

Includes verifications that designs for new
projects and modifications to existing facilities
are consistent with the facility approved
technical codes and standards
 Hazard Assessments

Process Hazard Analysis (PHA)

It’
It’s a comprehensive look at all aspects of
the process – what has happened, what
could happen, and suggestions
(recommendations) for preventing disaster
from happening.

Don
Don’’t start until all information has been
gathered
 Hazard Assessments

What-
What-if, checklist, Hazard and Operability
Study (HAZOP), Failure Mode and effects
analysis (FMEA), Fault Tree, or an
appropriate equivalent.

Information needed: P&IDS, Incidents,
Process drawings.

“Catastrophic release means a major
uncontrolled emission, fire, or explosion
involving one or more highly hazardous
chemicals, that presents serious danger to
employees in the workplace.”
workplace.” - OSHA
Process Safety
Management
 Incident Investigation

In v e s t ig a t e
In c id e n t s B e g in w ith in
& 4 8 -h o u r s
N e a r -M is s e s

R e a ta in In c id e n t Team
w it h P r o c e s s
R e p o r t s 5 -y e a r s
In v e s t ig a t io n K n o w le d g e

F o llo w - u p R e p o r t w ith
S y s te m f o r C o n c lu s io n s &
R e c o m m e n d a tio n s R e c o m m e n d a to n s
 Management of Change

Create formalized system to review all

changes to process areas including:

 Raw material changes / substitutions

 Personnel changes
 Process parameters
 Facility changes (HVAC / roof / fire protection
/ ……..)
 Management of Change

PSI

Mechanical Integrity

PINDs

Hot Work

Contractor Safety

Employee Training

PSSR

Operating Procedures
 Employee Participation

Employees are required to be an active

part of the process and your written
programs need to document what roles
employees play, their involvement in the
development of the programs, and
continuing participation in the process.

Front line workers – those that live and
breathe the process – are critical to an
effective program.
 Employee Participation
 Consultation / participation with training
and supervision to determine the
frequency and content of initial and
refresher training.
 Consultation / participation to develop

and review operating and maintenance

procedures.
 Consultation / participation in incident

investigations regarding the covered

process.
 Process Safety Information

Material Safety Data Sheets (MSDS)

Piping and instrumentation diagrams
(P&IDs)

Block flow diagrams

Material and energy balance calculations

Relevant consensus standards

Materials of construction
 Operating & Mtce
Procedures

Standard Operating Procedures

Do in tandem with Job Hazard Analysis
(JHAs)

Mesh with training program - OJL

Partner with Quality Team (ISO 9001) to
create training matrix and managed
documents
 Inspection, Testing & Mtce

The employer shall develop and maintain a
master list of all equipment specifically covered
by the standard, and equipment that is important
to safety of the process.

Pressure vessels and storage tanks.

Piping systems including valves and other

piping components.

Relief and vent systems and devices.

Emergency shutdown systems.

Controls (including monitoring devices and

sensors, alarms, and interlocks).

 Inspection, Testing & Mtce

Pumps.

Rotating equipment.

Heat exchange equipment.

Electrical generation and distribution

equipment.

Un-
Un-interruptable power supplies.

Emergency power supply equipment.

Fire protection equipment.

 PSSR

Check, double check, and review any

changes, modifications, additions made in
a PSM covered area – before you flip the
switch.
 Personnel Training

The employer shall prepare a record:
 Identity of employee.
 Date of training.
 Means to verify that employee understood
training

At a minimum, refresher training shall be

provided at least every three years and
more often if necessary to each employee
involved in operating a process.
proc
 Emergency Planning &
Response

Call in all resources and make plan
comprehensive:

Information Technology (IT) Disaster
Recovery Plan

Business Continuity Plan

Security

Communications / Public Relations

Trained ER personnel
 What can you do?

Understand specific hazards of the materials in
your facility and your responsibility in the safe
handling of these materials

Understand the specific hazards of the
manufacturing, storage, transport, repackaging
or other process operations conducted at your
facility

Understand your role in process safety activities
including process hazard analysis, management
of change, incident reporting and investigation,
maintenance and testing and following safe work
practices and procedures.
Any Questions?