Process Safety Management. Morley Brownstein. Canadian Society for Chemical Engineering

Transcription

1 Process Safety Management Morley Brownstein Canadian Society for Chemical Engineering

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3 Process Safety Management Standard CSA Z767-17

4 Process Safety focuses on the prevention of releases of hazardous material or energy, with an emphasis on low frequency, high consequence events

5 Process safety management (PSM) The application of management principles and systems for the identification, understanding, avoidance, and control of process hazards to prevent, mitigate, prepare for, respond to, and recover from process-related incidents. These principles and techniques may be applied across industry sectors

6 Standard broadly applicable across industry sectors and organization sizes. Eg. organizations using PSM are known in the chemical, food, mining, nuclear, petroleum, pulp and paper, transportation, and utilities sectors

7 applicable to large, integrated manufacturing sites, as well as to small businesses or retail sites. may also be applied to municipalities that can have hazardous scenarios, such as loss of containment in water treatment, arenas, or swimming pool facilities

8 Why is PSM applicable to water/wastewater treatment facilities and operations?

9 Chlorine tonners on site potential for release

10 chlorine exposure at related municipal infrastructure eg exposure at municipal pools. There have been numerous incidents of serious chlorine exposure requiring hospitalization at swimming facilities.

11 Guadalajara sewer explosion April km of street exploded gasoline leaked into sewer system 215 known dead, missing, 13 km of streets, 1500 homes destroyed

12 Louisville sewer explosion February 1981 hexane from soybean processing plant leaked into sewer 13 miles of sewer destroyed, no deaths Company was fined $62,500, agreed to pay Sewer District more than $18 million in damages, and more than $8.9 million to 16,000 plaintiffs and government agencies. It admitted that it released hexane into the sewers, but denied negligence

13 PSM standard developed by Canadian Society for Chemical Engineering published and made freely available 2012 Joined a number of resource documents on CSChE PSM Division website

14 To bring to wider audience, CSChE PSM standard was provided to CSA as a seed document to form the basis for a CSA standard a balanced committee including representatives from chemical, pipeline, mining industry, regulators, workers and public interest representatives, the CSA Z published in February 2017 Currently in translation into French

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16 Minimum lifecycle requirements Standard applies throughout the lifecycle of a facility or worksite, including

17 conceptual design facility siting preliminary and process design detailed engineering design construction commissioning and start-up

18 operations/maintenance revamps/modifications decommissioning site closure

19 Z767 identifies the various policies, practices, and procedures that may be used to implement a PSM system

20 It is not the intent of Z767 to define prescriptive solutions that will meet the needs of every organization. Each facility or worksite is unique and the user of the Standard will find that a particular policy, practice, or procedure that is effective at one site might need to be modified or rewritten for it to be effective at another site. An organization may include these minimum requirements in an integrated health, safety, environmental, and risk management program or in a stand-alone PSM program in preventing incidents at facilities that manufacture, store, handle, or otherwise use potentially hazardous materials. An organization may also use this Standard as an audit tool of their Process Safety Management

21 There are four foundational pillars for PSM: a) process safety leadership; b) understanding hazards and risks; c) risk management; and d) review and improvement.

22 Each of the pillars contains a number of elements. Users of this Standard may enumerate these elements under these pillars.

23 The system of elements as organized in CSA Z Process safety leadership Understanding hazards and risks Risk management Review and improvement Accountability Process knowledge and documentation Training and competency Investigation Regulations, codes, and standards Project review and design MOC Audits Process Process safety culture Process risk assessment and risk reduction Process and Equipment integrity Enhancement of process safety knowledge Conduct of operations senior management responsibility Human factors Emergency management planning Key performance indicators

24 General principles and considerations The facility operator shall be responsible for ensuring that the requirements of this Standard are met.

25 Standard defines the minimum requirements that shall be in place for a process safety management system (PSM) throughout the life cycle of a facility

26 The management system shall follow the Plan-Do-Check-Act continual improvement model

27 The organization shall include all PSM pillars and respective requirements as outlined in the Standard

28 The depth, breadth, and detail involved in any element or component should be relative to the hazardous scenarios and the magnitudes of the risks; minimal implementation of certain elements of the Standard shall be supported by documented justification

29 In developing a PSM program, organizations should ensure that their policies, practices, and procedures strive to align with the principles of inherent safety, which can result in a reduction in the number, complexity, and severity of hazards that need to be managed, without transferring the risk elsewhere

30 Process Safety Pillars Process safety leadership Understanding hazards and risks Risk management Review and improvement Accountability Process knowledge and documentation Training and competency Investigation Regulations, codes, and standards Project review and design MOC Audits Process Process safety culture Process risk assessment and risk reduction Process and Equipment integrity Enhancement of process safety knowledge Conduct of operations senior management responsibility Human factors Emergency management planning Key performance indicators

31 Process safety leadership Senior management shall be accountable for the PSM system

32 Senior management shall a) set expected performance requirements by establishing process safety goals and objectives, and by making resources available to meet the process safety goals; b) make process safety goals that address worker, public, and environmental risks visible to and understood by relevant stakeholders; c) provide direction to those responsible for design to consider inherently safer options; d) require adherence to safe operating conditions (e.g., procedures) through appropriate conduct of operations; and e) ensure that both PSM and the integrity of the equipment and processes are addressed through completing risk assessment and risk reduction throughout the lifecycle of the facility.

33 A management system shall be in place to identify, and ensure conformance with, regulations, relevant external standards, and codes. The management system shall guide the development of internal standards and guidelines

34 Process safety leadership and competency shall be the core values of every manager from the CEO to the front line supervisors

35 Helpful Links Process Safety Management Division - Canadian Society for Chemical Engineering (CSChE) CSA Z Process Safety Management free PSM Publications including CSChE PSM standard Environmental Emergency Regulations (CEPA 1999) Process Safety Management - Chlorine Hazards in Water / Wastewater Treatment Processes RITY_SUMMIT_-_JUNE_4_2013_2_428293_7.pdf Water/wastewater related incidents Bethune Point waste water treatment plant, Daytona Beach, FL, Jan 11, (explosion - methanol for tertiary treatment - nutrient removal) Guadalajara sewer explosions Wastewater plant workers overcome by hydrogen sulfide

36 Chlorine swimming pool incidents selected examples St. Catherines Ontario merritton-pool-accident/ California Ottawa