Process Safety in Chemical Plants

Vikas Nigam
Assistant General Manager - Risk Services

Cholamandalam MS Risk Services

27th September 2014

 About Chola MS Risk Services
Chola MS Risk is a 50:50 joint Venture between $ 4.4 bn Murugappa Group of
India and Mitsui Sumitomo Insurance of Japan

Offering Comprehensive Risk management & Engineering

solutions in the field of EHS and Insurance Support
Nearly two decades of experience in Safety Consulting
Solutions
Pan Asia presence with multiple offices in India, besides
operating through partner offices in Abu Dhabi, Kuwait
and Singapore
Technical Collaboration with Inter Risk, Japan
Consulting Solutions
Process Safety in Chemical Plants
 Process Safety

Process Safety is a blend of engineering and management skills focused on

preventing catastrophic accidents, particularly explosions, fires, and toxic
releases, associated with the use of chemicals and petroleum products.

Process Safety was born on the banks of the Brandywine River in the early
What is Process Safety?
days of the 19th century at the E. I. du Pont black powder works.

Recognizing that even a small incident could precipitate considerable

damage and loss of life, DuPont directed the works to be built and
operated under very specific safety conditions.

Process Safety evolved as industry progressed through the 19th and 20th
centuries, but really emerged as a industry-wide discipline following a
major industrial accident in Bhopal, India, in which a catastrophic release of
methyl iso cyanate killed more than 3,000 people.
 Process Safety vs Occupational Safety

Process Safety Occupational Safety

 Preventing fires, explosions and toxic  Concerned with protecting the

release incidents in process facilities, safety, health and welfare of people
which can lead to multiple fatalities engaged in work or employment.
and heavy asset, production, Focuses more on work injury
environmental & reputation damage. prevention, occupational health,
driving safety, etc.

 Prevention of high consequence low  Prevention of low consequence and

frequency risks. high frequency risks.
 Some of the major Catastrophic Events

YEAR LOCATION / EVENT CATEGORY DEATHS INJURIES

1974 Flixborough, England VCE 28 ?
1976 Seveso Italy Runaway reaction ? ?
1984 Mexico city, Mexico LPG release 650 ?
1984 Bhopal, India MIC release 3000+ ?
1988 Henderson, NV Explosion 2 350
1989 Pasadena, TX VCE 24 132
1990 Channel view, TX Tank explosion 17 0
1998 Longford, Australia VCE 2 8
2001 Toulouse, France Explosion 31 2400+
2005 Texas city, TX VCE 15 170
2010 Gulf of Mexico VCE 11 17
 Chemical incidents in India after Bhopal

ORIGIN OF
LOCATION YEAR CHEMICAL INVOLVED DEATHS INJURED
INCIDENT

Cochin 1985 Release Hexacyclo pentadiene - 200

Bombay 1988 Fire in refinery Oil 35 16

Nagothane 1990 Leakage Ethane and propane 32 22

Vizag 1997 Refinery fire LPG 60 31

Vellore 2003 Explosion Explosives 25 3

Mohali 2003 Fire Not known 4 25

Jaipur 2009 Fire in Oil depot Petrol 12 200

Vizag 2012 Explosion Oxygen Plant 19 -

 Major Reasons for Process Incident Occurrence

• People often assume the system works as intended,

despite warning signals.

• Only good performances are cited as examples while poor ones

are overlooked or forgotten.

• Human and Organizational factors are ignored in

considering the data for hazard analysis and risk
assessment.

• Integration of intrinsic safety at the conceptualization of an

industry for siting, selection of process and chemicals, selection
of skilled manpower, design of equipment, etc, are normally
not accounted.
 Effective Tool for Prevention

Process Safety Management (PSM) system

 What is PROCESS SAFETY MANAGEMENT ?

PROCESS SAFETY MANAGEMENT is the proactive identification,

evaluation and mitigation or prevention of chemical releases that
could occur as a result of failures in processes, procedures, or
equipment.

PSM is a disciplined framework for managing the integrity of

operating systems and processes that handle hazardous materials.
 Evolution of PSM

Technology and HSE Management Improved Culture

Standards System
12

10

8
RISK

0
0 2
19th Century 41970s 6 8
1990s 10
 Elements of PSM

Employee Participation Mechanical Integrity

Process Safety Information Safe Work Practices

Process Hazard Analysis Management of Change

Operating Procedures Incident Investigations

Training Emergency Planning & Response

Contractor Safety Compliance Audits

Pre-startup Safety Review Trade Secrets

 Loss Prevention / Control Strategies
• Always operate within Safe operating limits, and established operating
procedures. (PSM: Operating procedure & Safe work practices)
• Follow approved procedures for authorizing changes to established
procedures, including thorough risk evaluation. (PSM: Management of
change)
• Asset integrity and reliability should be high priorities to avoid such incidents.
(PSM: Mechanical integrity)
• Recognize “near miss” events to remind you of what could have gone wrong.
(PSM: Incident investigation & Reporting)
• Use incidents which occur in other facilities (LFI’s) , to remind the possibility
of similar problems at your plant.
• Focus on Inherent safer design
• Emphasize on Building Safety Culture
• Allocation of appropriate Safety budget at various stages of Plant Project
lifecycle.
 Process Safety – Present Scenario

• Process Safety studies making inroads to across

various industrial sectors
Power plants
Automobiles
Telecom
High Rise Buildings
• OISD updating standards and making safety studies
mandatory
• Various conclaves on Process Safety
CCPS
• Visible Management commitment, Top down
approach
 Statutory provisions of PSM
In India, PSM is still in developmental stages. The major players providing
guidance include:
 American Petroleum Institute (API)
 Center for Chemical Process Safety (CCPS)
 DuPont
 Occupational Safety & Health Administration, U.S (OSHA)
 Health and Safety Executive , U.K (HSE)

Indian Statutes / Standards addressing PSM elements

Manufacture, Storage and Import of Hazardous Chemical Rules, 1989

Petroleum and Natural Gas Regulatory Board Emergency Response Regulations (2010)

OISD Standards / Guidelines / Recommended Practices

Petroleum Rules, 2002

The Public Liability Insurance Act, 1991

 Process Safety Studies

1.Quantitative Risk Assessment (QRA)

2.Hazard and Operability Study (HAZOP)
3.Hazard Identification (HAZID)
4.Safety and Operability Study (SAFOP - EHAZOP)
4.Safety Integrity Level (SIL) Assessment
5.Layer of Protection Analysis (LOPA)
6.Review of Hazardous Area Classification (HAC)
7.Project Health, Safety and Environment Review (PHSER)
8.What If Analysis
9.Process Safety Management implementation
10.Fire Protection System
11.Comprehensive Safety Audit
12.Disaster Management Planning Study
 Chola MS Risk Offices:
CHOLAMANDALAM MS RISK SERVICES LTD.
Chennai | Mumbai | New Delhi | Gurgaon |
PARRY HOUSE, 4TH FLOOR
Kuwait & Singapore [Partner Offices]
NO.2, NSC BOSE ROAD, PARRYS, CHENNAI – 600 001
inquiry@cholams.murugappa.com
Phone: 044 – 3044 5400 Fax: 044 – 3044 5550
www.cholarisk.com