PROCESS SAFETY

MANAGEMENT (PSM)
PAKISTAN OILFIELDS LIMITED (POL)
HSE DEPARTMENT
PPF, KHAUR
Pakistan Oilfields Limited

CONTENTS
Introduction
Elements of PSM
Process safety information (PSI)
Process hazard analysis (PHA)
Standard operating procedure (SOPs)
Mechanical integrity
LecturePLUS Timberlake 99

CONTENTS
Hot work permit (HWP)
Employees participation
Management of change (MOC)
Pre-start up safety review (PSSR)
Emergency response plan (ERP)
Incident investigation (II)
Training
Audit compliance
Trade secrete
Contractor
Pakistan Oilfields Limited

Introduction
Un-expected release of toxic, reactive or
flammable liquid and gas in process involving
highly hazardous chemicals have been
reported many years.
The major purpose of PSM of highly hazardous
chemicals is to prevent unexpected release of
hazardous chemicals especially in those areas
that could expose employees and others.
Pakistan Oilfields Limited

ELEMENTS OF PSM

Pakistan Oilfields Limited

OSHA STANDARD AGAINST PSM

ELEMENT

Pakistan Oilfields Limited

PROCESS SAFETY
INFORMATION
PSI helps in conducting PHA and to identify
the hazards of hazardous chemicals used or
produced by the process.
Information on the hazards of highly
hazardous chemicals
Information on the technology of the process
Information on the equipments of process

Pakistan Oilfields Limited

PROCESS SAFETY
INFORMATION
Process
safety
information

Informatio
n on the
hazards of
highly
hazardous
chemicals

Informatio
n on the
technology
of process

Pakistan Oilfields Limited

Informatio
n on the
equipment
of process

INFORMATION ON THE HAZARDS OF

HIGHLY HAZARDOUS CHEMICALS
Lower explosive limit (LEL)
Higher explosive limit (HEL)
Toxicity
Reactivity
Pyrophoricity
Acidity
Alkalinity
Corrosivity
Water reactivity
Combustibility
Thermal and chemical stability

Pakistan Oilfields Limited

Information on the technology of

the process
Process flow diagram
Process chemistry
Safe upper and lower limits of (T,P,F &
Composition)

Deviation consequences on health and safety

of the employees exposed in that area
Pakistan Oilfields Limited

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Information on the equipments of

process
P&IDs
MOC
Relief system design
Ventilation system design
Material and energy balance
Electrical classification of equipments
according to HAC
Pakistan Oilfields Limited

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PHA
An organized and systematic effort to identify and
analyze the hazards associated with a processing
or handling of hazardous chemicals.
Analyze the potential causes and consequences
of fires, explosions, release of toxic & flammable
chemicals and major spills of highly hazardous
chemicals
PHA focuses equipments, instrumentation, utilities
and human actions and external factors that might
affect the process.
LecturePLUS Timberlake 99

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METHODS for conducting PHA

What-if
Checklist
What-if/checklist
HAZOP
FMEA
FTA
ETA
Or an appropriate equivalent method
Pakistan Oilfields Limited

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PHA MUST DO
Address the hazards of process
Identify any previous incident
Determining engineering and administrative controls
Identify the consequences of failure of engineering
and administrative controls
Address facility sitting
Address human factor
Conduct a qualitative evaluation of H&S effects of
employees
Pakistan Oilfields Limited

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PHA TEAM MEMEBERS

Operation engineer
Process engineer
Electrical engineer
Instrumentation engineer
Process chemist
HSE engineer
SOP
ERP
Procurement of parts and supplies
Maintenance procedures both routine and non-routine tasks
LecturePLUS Timberlake 99

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PHA PROCESS
Identify
Hazards

Revalida
te
process

Evaluate
Hazards

Act to
address
hazards

Recomme
nd Action

Pakistan Oilfields Limited

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PROCESS HAZARDS
ENERGY TYPES

HAZARDS

Chemical energy

Flammability
Thermal instability
Pyrophoricity
Acidity
Alkalinity
Combustibility
Toxicity
Water reactivity
Thermal and chemical reactivity

Thermal energy

Elevated temperature
Reduced temperature

Electrical energy

Elevated voltage

Electro-magnetic (EM)

Elevated EM radiation level

Pakistan Oilfields Limited

SOPS
Employer must develop written SOPs consistent with PSIs.
SOPs must contain:
Operating Phase

Initial
Startup

Normal
Operation

Temporary
Operation

Pakistan Oilfields Limited

E/N
shutdown

Startup

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SOPS
Employer must develop written SOPs consistent with PSIs.
SOPs must contain:
HSE
Considerations

System
Safety

Quality
Control
Raw
Material

Exposure
Control

Pakistan Oilfields Limited

Properties
of chemical
used and
its effects

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SOPS
Employer must develop written SOPs consistent with PSIs.
SOPs must contain:
Operating
Limits

Steps to avoid deviations

and mitigation of
consequences

Consequences of
deviations

Pakistan Oilfields Limited

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MECHANICAL INTEGRITY
OSHA focuses on the MI of critical process equipments to ensure that, they are
designed and installed correctly and working properly.
MI is applicable on the following process equipments:

MI Application

Pressure vessel
Storage tanks
ESD system
PSVs & PRVs devices
Piping system involving flanges
and valves
Pumps

Pakistan Oilfields Limited

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HOT WORK PERMIT

Any hot job activity at process plant must be conducted
by proper implementation of PTW system in order to
avoid fire prevention and fire protection measures:

WORK PERMIT SAMPLE is provided at the next slide

Pakistan Oilfields Limited

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HOT WORK PERMIT

Permit No.
Work specification
Equipment to be used
Hazards identified by the area authority
Precautions to be taken by the performing
authority
PPEs used
Pre-cautions to be taken by the area authority
Supplementary certificates
Approval of area authority
Gas test performed by HSE representative
Permit issued by area authority
Permit accepted by the area authority
Pakistan Oilfields Limited

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EMPLOYEES PARTICIPATION
Employer must develop written plan for employees participation in:

Employees
Participation

Developing PHA

Developing other
elements of PSM

Pakistan Oilfields Limited

Access provided for the

employees to PHA and PSIs

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PSSR
PSSR is performed when :
Highly hazardous chemical introduced in process
New facility build
Modification in existing facility
That pertaining significant changes in PSIs.
PSSR must confirm the following:

Construction of equipments in accordance of design specifications

PHA conducted
Operating, maintenance and safety manual must be in place
Training of the employees
Pakistan Oilfields Limited

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MOC
MOC is also called a written procedure to manage changes
to the process chemical, equipments, technology and
procedures, and determine its effect on employees H&S.
MOC contain:
Technical basis of proposed changes
Impede on employees H&S
Modification to SOPs.
Necessary time period for changes

Pakistan Oilfields Limited

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INCIDENT INVESTIGATION
Crucial part of PSM, incident must be investigated thoroughly to
identify the chain of events and causes so that corrective action
can be developed and implemented.
Incident investigation report must include:

Date of incident
Date investigation begins
Description of incident
RCA of incident
Recommendations results from incident

Pakistan Oilfields Limited

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ERP
ERP must be developed according to the emergency situations that can be
happened at the process plant like
H2S release
Fire and explosion
Oil spillage
ERP consists of the following:
Objectives
Handling procedures
Responsibilities of concerning authorities
Authorization for declaring Emergency
Authorization for terminating emergency/Crisis
Command and Control Levels
Communication flow during emergency
General Responsibilities during Emergency
Pakistan Oilfields Limited

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AUDIT COMPLIANCE
The employer must certify that they have evaluated compliance with PSM
provision every 3 years, to ensure that procedures and practices
develop under standard are adequate.
AUDIT
COMPLIANCE

To identify gaps and

defficiences

To identify high risk

areas

Pakistan Oilfields Limited

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TRAINING
An employee involving in a process or newly assigned must be trained in
the following aspects in initial training.
Initial
training

H&S hazards of
the process

SOPS

Pakistan Oilfields Limited

ERPS

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REFRESHER TRAINING
At least every 3 years or whenever it is necessary refresher training must be conducted for
the employees involving in process to ensure that the employees know everything
mentioned in first slide know and training record must be maintained having following
information.

Refresher
Training

Employees name
and its ID No.

Training date
and time

Pakistan Oilfields Limited

Training module
and trainer name

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CONTRACTOR
PSM is applicable to the contractor performing following activities:
Maintenance work
Repair work
ATA
Major renovation
Other specialty work that may affect the covered process.
Not applicable to the following:
Providing incidental services
Janitorial staff
Food and drink
Laundry
Other delivery services
That do not influence the process safety.
Pakistan Oilfields Limited

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EMPLOYER
RESPONSIBILITIES
Employer responsibilities are following:
Evaluate the contract employer safety
performance and program
Inform about fire and explosion and toxic gas
release hazards
Inform contract employer about ERP
Enforce the contract employer to implement
the safe work practices

Pakistan Oilfields Limited

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CONTRACT EMPLOYER
RESPONSIBILITIES
Hire trained, well educated and experienced
staff
Ensure that contract employees know about
the fire and explosion and toxic gas release
hazards
Ensure the training of the contract employees
Ensure the contract employees performs safe
work practices and follow strictly safety rules
and regulation of the respected organization
Pakistan Oilfields Limited

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TRADE SECRETE
Employer must provide all the necessary
information to those performing the following
jobs and not make it secrete

Compile process safety information

Developing process hazard analysis
Developing SOPs and ERPs
Performing incident investigation

Pakistan Oilfields Limited

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