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Overview of Process Safety & Industrial Disaster Management and
their Inter-relationship
R. P. BhanushaliAdviser (Tech),
NSC
National Workshop on
PROCESS SAFETY & DISASTER MANAGEMENT
Jaipur (29-31 July, 2009)
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• There are Unexpected releases of toxic, reactive, or flammable chemicals in processes involving highly hazardous chemicals.
• there is a potential for an accidental release any time they are not properly controlled, creating the possibility of disaster.
• An effective Process Safety Management program can help prevent releases and prepare for emergency response in the event of a chemical release.
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• A process is an activity or combination of activities including any use, storage, manufacturing, handling or the on-site movement of Highly Hazardous Chemicals.
• Process Safety Management is intended to prevent an incident finally leading to a Disaster.
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Good management practice
Process steps that enable improvement in decision making
A logical and systematic approach
Identifying opportunities
Avoiding or minimising losses
What is Risk Management?What is Risk Management?
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Risk Management is the logical and
systematic method to identify, analyse, treat and monitor the risks involved in any activity or process.
What is Risk Management?
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Risk Management is a methodology that helps managers make best use
of their available resources
What is Risk Management?
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• It is the complete process of understanding risk, risk assessment, and decision making
to ensure effective risk controls are in place and implemented.
• Risk management begins with identifying possible hazards leading to ongoing mgt of those risks deemed to be acceptable.
management of those risks deemed to be acceptable.
Risk ManagementRisk Management
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Risk Management analyze risk (for probability and
consequences), so the risk (with respect to acceptability) can be assessed, and ultimately managed
it is simply not possible to commence this cycle without first effectively identifying the hazards of concern.
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Process safety is a blend of engineering and
management skills focused on preventing
catastrophic accidents, particularly explosions,
fires, toxic releases (associated with the use of
chemicals and petroleum products).
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Process safety management refers to the
general management systems in place to
address major accident hazards
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Process Safety Management have
a positive effect on safety of employees
offer potential benefits to employers, such as increased productivity,
smaller businesses with limited resources might consider alternative avenues of decreasing risks associated with highly hazardous chemicals at their workplaces.
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• One method is reducing inventory. The reduction in inventory results in reducing the risk or potential for a catastrophic incident. Employers can establish more efficient inventory control by reducing, to below the established threshold, the quantities of highly hazardous chemicals onsite.
• When reduced inventory is not feasible, disperse inventory to several locations onsite so that a release in one location will not affect another location. This is also a practical way to reduce the risk or potential for catastrophic incidents.
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• Various lines of defense that have been incorporated into the design and operation of the process to prevent or mitigate the release of hazardous chemicals need to be evaluated and strengthened to ensure their effectiveness at each level.
• 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.
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• To control these types of hazards, employers need to develop necessary expertise, experience, judgment, and initiative within their work force to properly implement and maintain an effective process safety management program
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Process Safety Management (PSM) is the application of management principles and systems to identification, understanding and control of process
hazards to prevent process-related injuries and accidents.
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CCPS
Process Safety Management
Elements
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There are 12 Elements
1 ACCOUNTABILITY2 PROCESS KNOWLEDGE AND
DOCUMENTATION3 CAPITAL PROJECT REVIEW AND
DESIGN PROCEDURES4 PROCESS RISK MANAGEMENT5 MANAGEMENT OF CHANGE
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6 PROCESS AND EQUIPMENT INTEGRITY7 HUMAN FACTORS8 TRAINING AND PERFORMANCE9 INCIDENT INVESTIGATION10 COMPANY STANDARDS, CODES AND
REGULATIONS11 AUDITS AND CORRECTIVE ACTIONS12 ENHANCEMENT OF PROCESS SAFETY
KNOWLEDGE
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1 ACCOUNTABILITY: OBJECTIVES & GOALS• Management commitment at all levels is
necessary for PSM to be effective. • objectives for establishing accountability
are to demonstrate the status of process safety compared to other business objectives (e.g. production and cost), to set objectives for safe process operation and to set specific process safety goals.
• These objectives should be internally consistent, i.e., supported by appropriate resources.
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2. PROCESS KNOWLEDGE & DOCUMENTATION
Information necessary for the safe design,
operation and maintenance of any facility
should be written, reliable, current and
easily accessible by people who need to
use it.
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3. CAPITAL PROJECT REVIEW & DESIGN PROCEDURES
Appropriation request procedures Risk assessment for investment
purposes Hazards review Siting (relative to risk management) Plot plan Process design & review procedures Project management procedures
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4 PROCESS RISK MANAGEMENT Hazards identification Risk assessment of existing operations Reduction of risk Residual risk management (in-plant
emergency response and mitigation) Process management during emergencies Encouraging client & supplier companies
to adopt similar risk management practices Selection of business with acceptable
risks
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5. MANAGEMENT OF CHANGE
Clear definition of change (scope of application); Description & technical basis for the proposed change; Potential impact of proposed change on H,S & E Authorization requirements to make the change; Training requirements of change for people at work; Updating of documentation including; process safety
information, operating & maintenance procedures, alarm and interlock settings, fire protection systems, etc.; and
contingencies for "emergency" changes.
A system to manage change is critical to the operation of any facility. A written procedure should be required for all changes except replacement in kind. system should address:
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6 PROCESS AND EQUIPMENT INTEGRITY
Pressure vessels and storage tanks; Piping, instrument and electrical systems; Process control software; Relief and vent systems and devices; Emergency and fire protection systems; Controls including monitoring devices and sensors, alarms and
interlocks; and Rotating equipment.A documented file should be maintained for each equipment.
Procedures for fabricating, inspecting and maintaining equipment vital to process safety. Written procedures should be used to maintain ongoing integrity of process equipment such as:
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Human factors are a significant contributor to many process accidents. Three key areas are operator – process/equipment interface, administrative controls and human error assessment.
7 HUMAN FACTORS
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8. TRAINING AND PERFORMANCEPeople to be trained in the skills & to have ongoing retraining to maintain these skills.
9 INCIDENT INVESTIGATION• Major incidents• Near-miss reporting• Follow-up & resolution• Communication• Incident recording• Third-party participation as needed
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10. CO. STANDARDS, CODES & REGULATIONS
A management system is needed to ensure that the various internal and external published guidelines, standards and regulations are current, disseminated to appropriate people and departments, and applied throughout the plant.
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11 AUDITS AND CORRECTIVE ACTIONS
The purpose of safety audits is to determine the
status and effectiveness of safety management
efforts versus goals and also the progress toward
those goals.
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12. ENHANCEMENT OF PROCESS SAFETY KNOWLEDGE
A management system for process safety should be
designed for continuous improvement. Safety
requirements are becoming more stringent, while
knowledge of systems and technology is growing.
Safe operation of a process plant calls for personnel
to stay abreast of current develop-ments, & for
safety information to be accessible.
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What is a disaster?
An occurrence inflicting widespread destruction and distress
DISASTERHazardVulnerability
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What is a disaster?
“A sudden calamitous event bringing great damage, loss or destruction.”
“What happens only if you are not prepared for it.”
“An event the timing of which is unexpected and the consequences seriously destructive.”
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What is Disaster?A catastrophe, mishap, calamity or grave occurrence in any area, arising from natural or man- made causes, leading to accident, and resulting in substantial loss of life or human suffering or damage to, and destruction of property, or damage to, or degradation of environment, and is of such a nature and/or magnitude as to be beyond the coping capacity of the community of the affected area. (Source: DM Act, 2005)
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Factors contributing to industrial disasters Storage of flammable, explosive, or toxic
chemicals, including radioactive materials Uncontrolled release of un-reacted
chemicals, chemical reaction products, or energy from a chemical reaction
The presence of people in the proximity to result in exposure
Exposure sufficient to cause serious injury or death
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Bhopal Disaster -3 Dec., 1984–A Turning Point
Methyl isocyanate (MIC) released resulting in over 2 500 dead and 100 000 injuredBrought home the unprecedented scale of disaster potential of a hazchem incident in terms of loss of life, health and injury and evacuation needed and created a compelling evidence to apply a holistic Disaster Management approach to chemical safety A new era of restructuring and inducting new HAZCHEM control systems & procedures started
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Major post-Bhopal developments
Major Hazard remained an unknown concept
in India till the Bhopal disaster
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Major post-Bhopal developments
BROADER FOCUS
The focus of protection was made more
comprehensive to include property,
environment and community instead of the
earlier narrow focus only on employees
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APELL Process
INTEGRATEDCOMMUNITYEMERGENCY
RESPONSEPLAN
INTEGRATEDCOMMUNITYEMERGENCY
RESPONSEPLAN
APELLPROCESS
APELLPROCESS
Local GovernmentLocal Government
IndustryIndustry
CommunityCommunity
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MAJOR POST-BHOPAL DEVELOPMENTS…
NSC-ADPC 2-week Asia Region Training Course on `Technological Risk Mitigation in Cities’ (Mumbai, 1998 with 20 participants from 8 Asian countries)
Signing of MOU between NIDM & NSC (2005) MOU with Lokmanya Medical Foundation for
Strengthening EMS for road accidents (July, 2006)
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PRESENT STATUS Well developed MAHC System
Legislation, organisation, technical competence, enforcement
APELL Process institutionalized Set up Crisis Groups with participation from
authorities, emergency response services, industry and community
Identified hazard-prone industrial pockets with > 5 MAH units
Established inventory of 1,666 MAH units in 24 States & UTs and 347 Isolated storages
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PRESENT STATUS… Enactment of Public Liability Insurance Act, ’91 On-site emergency plans (1 628) and
Off-site plans (166) prepared Mutual Aid Response Groups developed Institutional framework (NAC NSC, NIDM,DMI) Indian Standards -14489:1998, 15656:2006 MOEF Guidelines- MSIHC Rules
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PARADIGM SHIFT IN DISASTER MGT Disaster Management Act, 2005 National Disaster Management Authority Development of National Disaster
Management Guidelines on- chemical disasters, earthquakes etc
Institutional Mechanisms Approach at National, State and Local levels
Focus on- Prevention, Mitigation & Preparedness
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THE PHASES OF A DISASTER
EVENT!Response
Recovery
Development
Prevention/ Mitigation
Preparedness
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PREVENTION
Measures aimed at impeding occurrence
of a disaster event and/or averting such
an occurrence having harmful effects on
community
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MITIGATION
• Measures aimed at reducing the impact of a disaster
• There is a very thin line of separation between Prevention and Mitigation. Hence the combined term “Prevention/Mitigation” is used.
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PREPAREDNESS
• Measures to enable to respond rapidly and
effectively to disaster situations
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DISASTER IMPACT
• Point at which a disaster event occurs
• It has varying degrees of consequences
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RESPONSE
• Measures taken immediately prior to and following disaster impact
• Measures directed towards saving life, protecting property and to dealing with immediate disruption, damage, and other effects caused by a disaster
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RECOVERY• Process by which communities and the
affected entities are assisted in returning to their proper level of functioning following a disaster
• Activities include Restoration Rehabilitation Reconstruction
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Looking Ahead Strengthening District and Local Crisis Groups Strengthening capacities of fire brigades, police, etc Developing Model off-site plans Annual testing and updating of off-site plans Community awareness responsibility by crisis groups Enforcement Authorities’ role , activities and contribution in the
new National approach on DM Developing good medical response system Post disaster reviews Publishing case studies Developing MAH database Designating institutions on technological DM and developing
package of training courses
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INTER-RELATIONSHIP
BETWEEN
PROCESS SAFETY MANAGEMENT
&
DISASTER MANAGEMENT
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THANK YOU
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THE PHASES OF A DISASTER
EVENT!Response
Recovery
Development
Prevention/ Mitigation
Preparedness
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PREVENTION
Measures aimed at impeding occurrence
of a disaster event and/or averting such
an occurrence having harmful effects on
community
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MITIGATION
• Measures aimed at reducing the impact of a disaster
• There is a very thin line of separation between Prevention and Mitigation. Hence the combined term “Prevention/Mitigation” is used.
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PREPAREDNESS
• Measures to enable to respond rapidly and
effectively to disaster situations
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DISASTER IMPACT
• Point at which a disaster event occurs
• It has varying degrees of consequences
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RESPONSE
• Measures taken immediately prior to and following disaster impact
• Measures directed towards saving life, protecting property and to dealing with immediate disruption, damage, and other effects caused by a disaster
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RECOVERY• Process by which communities and the
affected entities are assisted in returning to their proper level of functioning following a disaster
• Activities include Restoration Rehabilitation Reconstruction