UNIT 3 I

SAFETY MANAGEMENT SYSTEM

( Element of PSM ( Process Safety
Management System)

 Highly flammable material

High Temperature/Pressure
Modern Technologies use Hydrogen extensively
Chemicals/Solvents/Catalysts used in the Process
Corrosivity/Reactivity
Self Ignition on Leakage from System
Uncontrolled Process Reactions
Loss of Containment/Accidental Releases

Importance of safety
Safety = freedom from accidents
Safety today is more important, since we are
developing our industry rapidly.
Due to rapid development in information
technology & communication, Safety awareness
has grown so much that, to day with out safety
very existence and growth in industry not
imaginable
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Importance of safety

Protection of personnel
Protection of plant &property
Production uninterrupted
Legal requirements
Welfare of community
Good reputation
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OUTCOMES OF ACCIDENTS

NEGATIVE ASPECTS

INJURY TO PERSONS
LOSS to organization
DAMAGE TO EQUIPMENT &
PROPERTY
LITIGATION COSTS
LOST PRODUCTIVITY

Injury to the person

Suffering and pain

Worry
Absences
Incapability to perform
Loss of wage
Medical expense
Loss of limb or life
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Organization loss

Good man is lost

New person for the job to be trained
More supervision
Loss of out put
Medical expenses
Loss of morale
Loss of prestige
7

Economical loss
Past two slides shows some loss on this
account

DAMAGE TO EQUIPMENT & PROPERTY

Major accident may stop production

Legal

LITIGATION
Factory act
Police cases
Worker compensation act
Public liability act
Consumer protection act

Reputation
Very important today for organization
Also for individual

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Safety Management
In the early stage of industrialization safety was
managed through training and following safe
procedures, compliance with rules and regulations,
etc.
Next stage witnessed enhanced safety feature through
technological upgradation - safe processes, safety
features in built in design and prescriptive statutory
rules.
Finally safety is managed through systems approach.
The Cullen Report, 1990 on Piper Alpha Disaster
stressed the need for formal safety management system.
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Management Commitment &

Leadership
Corporate safety policy
Allocation of resources
Development of systems & guidelines
Performance of systems & guidelines
Nurturing positive safety culture
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Management Commitment &

Leadership
Rewarding outstanding performance
Occupational Health
Compliance with Regulations
Environmental Protection
Community Awareness

13

Safety management
The 3 Ps of safety management
Safety Policy - Specifying how safety will be
achieved
Procedures - What management wants people
to do to execute the policy
Practices - What really happens on the job .

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Why safety management is needed

Manufacturing Storage & Import of
Hazardous Chemicals (Amended in Jan
1999) rules ,specifies in schedule 8,9,10,12
Factory Act revised in 1988 in section
41/B/C/D/E/F/G/H
Public Liability Act 1991 as amended in
1992
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Standard of safety management practices

DNV Safety management system;ISRS
(Det Norske Veritas) DNV is a global provider of
services for managing risk, helping customers to
safely and responsibly improve their business
performance. An independent ...
Training - Careers - Certification - Company profile
OSHA Rules, Process Safety Management of
Highly Hazardous Chemicals 29 CFR Part
1910
IS 14489: code of practices for occupational
safety & health
16 ;
OISD std (206) Safety Management System

(System Approach)Safety Management

Safety Policy
System based on OISD STD 206 & ISRS
Safety Committees
(PSM- Process Safety Management System)
Employees Participation
Process Safety Information
Process Hazard Analysis
Operating Procedures
Training
Contractors
Pre-startup Safety Review
Mechanical Integrity
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Safety Management System based on

OISD STD 206 & ISRS
Work Permit/safety rules
Management of Plant Change
Incident Investigation and Analysis
Emergency Planning and Response
Audit/inspections
Occupational Health
General safety promotion
Customers and Products
Off-the job Safety
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1.0 Safety Policy

Safety policy duly approved by the Board of
Directors of the organization.
It contain intentions and commitment . Safety target
and objectives for each position in the organization
it is published
It is made available to all employees in a language
easily understood.
It is displayed at various locations in the
organization web sites/ LAN net works
- Safety tour by executives
- Annual loss control objectives
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2. Safety Committees
The Committees encourage employees participation.
Deliberations of safety reports, audits, and incident
enquiries should be a part of agenda of safety meetings.
At HPCL MR Every two years safety committee members
are changed and a new booklet with new members names
and their functions are published.
The names of members are also displayed in units
Committee members are also included in the internal
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safety audit team

3.Employees Participation
Some ways by which participation is encourage at HPCL
are as follows
Employees involved in Internal Safety Audits and Job Safety
Analysis.
Sunday safety talks in control rooms(Group communication
Element16)
Spot trained on the for use (PPE)/permit procedures
MSDS are displayed in local control rooms.
Employees are involved in management of change related to
process & equipment. they part of pre commissioning safety
audits teams
Safety quiz / suggestion schemes / competitions etc. are also
conducted to enhance participation of employees.

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4 .Process Safety Information

PSI( Process Safety information) include information on

hazards of highly dangerous chemicals used in or
produced by the process , information on the technology
process, and information of the equipments used.
Knowledge of chemicals
, process and plants is one of the prime asset.
So located that it is be easily available at the time of
need for all employees
HPCL has taken a lead in Computerization of the
information. Many of manuals are made available on
local network for easy accessibility to all concerned.
HPCL has process safety cell.
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 PSI include :

1. Inventories of raw material, product and byprodcut used.

2. Important process parameter i.e pressure, temperature, levels.
3. Process Flow Diagram (PFDs)
4. Piping and Instrumentation diagram
5. Electrical Drawing and classification of hazardous areas
6. Record of relief system data, ventilation system design
For this purpose MSDs can be used which include :
1. Toxicity, 2. Permissible Exposure limit
3. Physical Data, 4. Reactivity Data
5. Corrosivity Data, 6. Thermal and Chemical Stability Data

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5. Process Hazard Analysis (PHA)

Process hazard analysis is systematic management tool to identify
the hazards associated with every aspects of industrial process and
operation which involve use of hazardous cehmical.
Techniques for PHA
1. Cehcklist appraoch
2. Hazard and Operability Studies (HAZOP)
3. Failure mode and Effects Analysis
The PHA for a new process or facility or modification in existing
facility is completed before start-up.
The PHA of existing facilities every 5 years it covers fire,
hydrocarbon, chemical hazards
Special analysis for Electrical hazard,vehicle movement,
environment hazard ,down stream pipelines etc
Other Hazard assessment survey are conducted in plant by internal
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audits teams

6.Operating Procedures
For all process plants for safe operation procedures (SOP)
are available.
Entire operations units Hazop study is done to ensure all
operating procedure are there in placethis study has helped
us in developing
Specific instructions on Startup - emergency shutdowns.
Pocket books for process emergencies handling
For any new equipment or modification procedure are
developed and training is given as per change management
procedures
Planed personal communications(job instructions/training)
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7.Training
Training on HSE should be given to all employees 1. New,
those already working
2. Contractor 3. Third Parties
4. Visitors
Two Type
1. Refresher Training
( Those who are working should receive periodic training to
keep them updated with any change or development )
2. Initial training : include comprehensive training
( Training received by new employees and Contractor is called
initial training)
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Training
Employees, contractors, security personnel, Truck
drivers/khalasis
Core Safety training
Skill training
Refresher training
Use of modern training aids - simulators
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8.Contractors
Assign workers only to employment for which they are
suited by their age, physique, state of health and skill.
Proper safety training to contract employees should be
imparted.
Maintaining a site injury and illness log for contractors is
another method employers must use to track and maintain
current knowledge of activities involving contract employees
working on or adjacent to processes covered by PSM.
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Contractors
Constitute large proportion of work-force
Engaged in construction, repair and maintenance jobs in
hazardous areas
Trained for safe operation
Personal Protective Equipment (PPE)
Information about potential fire, explosion and toxic
release hazards
Contractors are responsible for organising their work and
maintain tools/tackles in such a manner that risk of
accident is minimised.
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9.Pre-startup Safety Review

Perform a pre startup safety audit for new facilities,
modified facilities
For new facilities, Process Hazard Analysis (PHA)
is performed and recommendations have been
resolved or implemented before start up and
modified facilities meet the requirements contained
in management of change

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10. Mechanical Integrity

Mechanical integrity program include, Following
aspects
Equipment Data /Inspection and Testing norms
Work Authorization/Maintenance Procedures
Criteria for Accepting Equipment after
Maintenance/Documentation
Critical task analysis/task observations
Quality Assurance
MAXIMO soft ware effectively handles these
requirements

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Mechanical Integrity
The objective is to ensure

Reliable and safe operation

Higher equipment life
Higher on-stream factor

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Mechanical Integrity
Condition Monitoring
Preventive /Predictive Maintenance
Residual Life Assessment
Periodic Testing of Relief Valves, Interlocks, Alarms,
shut down systems etc.
Documentation of monitored data to guide corrective
actions

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Mechanical Integrity of Equipment

Every petroleum installation must review its maintenance programmes and
schedules to see if there are areas where "breakdown" maintenance is used rather
than the more preferable ongoing mechanical integrity programme.
Equipment used to process, store or handle highly hazardous chemicals has to be
designed, constructed, installed, and maintained to minimize the risk of releases of
such chemicals.
This requires that a mechanical integrity programme be in place to ensure the
continued integrity of the plant.
Elements of a mechanical integrity programme include
identifying and categorizing equipment and instrumentation;
inspections and tests and their frequency; maintenance procedures;
training of maintenance personnel;
criteria for acceptable test results; documentation of test and inspection results;
documentation of manufacturers'

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11.Work Permit/safety rules

Refer OISD-STD-105 on Work Permit System for
details.
Monitoring of hot work permit by F&S LAN usage
Return of permits to close work orders with
operations dept clearance
Over lapping area counter signatures
Standby for hot work/supervision
General safety rules
Use of safety signs etc
PPE enforcement
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12. Management of Change (MOC)

Unauthorized change and inability to communicate the changes to the
operating and maintenance personnel caused several accidents of
catastrophic consequences seen in Piper Alpha Incidents. There fore
changes are managed through well lay down procedures known to all.
Every organization therefore should prepare written procedure for this
process.
The procedure is established Management of Change
Hazop is done , documented for implementing a change ,covering all
changes at all the stages like commissioning, operation, inspection,
maintenance, is developed.
OISD-GDN-178 "Guidelines for Management of Changeis also
followed.
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 MOC Include :

1. Technical Aspects of Change

2. Safety Health, Impact of Change
3. Modification in Operating procedure
4. Duration of Changes ( Temporary and Permanent)
5. Details PHA for Change
6. PSI (Process Safety Information) requirement
7. Training of employees and Contractors
8. Authorization of Change

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13. Incident Investigation and Analysis

incorporated which covers

The Objectives/Who Should Investigate

Review of the Initial Investigation
The Role of the Safety Professional
Hi-Po incidents
Investigation by the Committee
Analysis of the Incident
Post Investigation Actions/ Communication
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14. Emergency Planning and Response

The basis for the Emergency Preparedness Plan is
derived from the hazard analysis.
Plan contain the following key elements:
Early warning/alarm system
Procedures Immediate response
Manpower / Organogram(an organizational chart)
and their responsibilities
Emergency valves/ Control Room identification
internal/external Resource Mobilization Plan
Mutual Aid
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Emergency Planning and Response

Evacuation procedures / Assembly Points

List of Attachments, lay out telephone numbers etc
Drills and Updating of the On-site plan
Off site plans
Information to public
Element public communication in events of major
emergencies the mode now specified
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Emergency response
Regular running of equipment & tests on facilities
Emergency Management Plans
- on site
- off site
On site drills once in 6 months
Off site drill with Dist. Administration once in a year
Mutual
aid
Agreements
with
industries/District Fire Services.

Neighbouring

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Emergency response
Dedicated Fire fighting facilities
Fire tenders/Nursers/Hydrant
Storage/Pumps/Alarms etc.

system/Fire

Water

Detectors for Early Warning

Well trained fire crew round the clock
Mock drill every month

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15.Safety Audits/inspections

Audit are the periodic examination of the Systems in place.

Internal Safety Audit
External Safety Audit
Safety Management System Audit is new element in,
ISRS system /ILO practices/loss control assessment
(perception survey)
General plant inspection
Preventive maintenance
Pre use inspection
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16 . Occupational Health
A structured Occupational Health Monitoring exitsto have a
scientific basis for decisions aimed at protection of human
health from any possible adverse consequences of exposure
to the hazards in the occupational environment.
Work environment monitoring system
Hygiene monitoring
First aid
Pre-employment Medical Examination
OISD-GDN-166 "Guidelines for Occupational Health
Monitoring in Oil and Gas Industrynorms are also
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followed

17. General safety promotion

General safety Promotion through Posters & News

Letters
Special Safety Campaigns
Group award and Recognition

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18./ 19.Customers and Products handling

Primary objective of the management is to make
available their customer the intended product
without causing any harm to human and the
environment. This involves three elements
Safe transport product
Education of consumer for safe handling
Product is disposed off safely
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20. Off-the job Safety

Off-the-job safety is a worthy goal in its own right
Safety quiz, contests and competitions are being
organized for the family members of employees to
motivate them towards off-the-job safety
The company is developing a policy to encourage
covering off-the-job safety of the employees.
The reporting and analysis of the off-the-job injuries
to employees and their families willbe encouraged.
Findings of the analysis of the off-the-job injuries
will be made known to all the employees through
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news letters / bulletins