1

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)

2

3

• 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.

4

• 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.

5

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?

6

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?

7

Risk Management is a methodology that helps managers make best use

of their available resources

What is Risk Management?

8

• 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

9

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.

10

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).

11

Process safety management refers to the

general management systems in place to

address major accident hazards

12

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.

13

• 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.

14

• 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.

15

• 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

16

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.

17

CCPS

Process Safety Management

Elements

18

There are 12 Elements

1 ACCOUNTABILITY2 PROCESS KNOWLEDGE AND

DOCUMENTATION3 CAPITAL PROJECT REVIEW AND

DESIGN PROCEDURES4 PROCESS RISK MANAGEMENT5 MANAGEMENT OF CHANGE

19

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

20

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.

21

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.

22

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

23

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

24

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:

25

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:

26

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

27

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

28

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.

29

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.

30

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.

31

32

What is a disaster?

An occurrence inflicting widespread destruction and distress

DISASTERHazardVulnerability

33

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.”

34

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)

35

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

36

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

37

Major post-Bhopal developments

Major Hazard remained an unknown concept

in India till the Bhopal disaster

38

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

39

APELL Process

INTEGRATEDCOMMUNITYEMERGENCY

RESPONSEPLAN

INTEGRATEDCOMMUNITYEMERGENCY

RESPONSEPLAN

APELLPROCESS

APELLPROCESS

Local GovernmentLocal Government

IndustryIndustry

CommunityCommunity

40

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)

41

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

42

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

43

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

44

THE PHASES OF A DISASTER

EVENT!Response

Recovery

Development

Prevention/ Mitigation

Preparedness

45

PREVENTION

Measures aimed at impeding occurrence

of a disaster event and/or averting such

an occurrence having harmful effects on

community

46

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.

47

PREPAREDNESS

• Measures to enable to respond rapidly and

effectively to disaster situations

48

DISASTER IMPACT

• Point at which a disaster event occurs

• It has varying degrees of consequences

49

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

50

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

51

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

52

INTER-RELATIONSHIP

BETWEEN

PROCESS SAFETY MANAGEMENT

&

DISASTER MANAGEMENT

53

THANK YOU

54

THE PHASES OF A DISASTER

EVENT!Response

Recovery

Development

Prevention/ Mitigation

Preparedness

55

PREVENTION

Measures aimed at impeding occurrence

of a disaster event and/or averting such

an occurrence having harmful effects on

community

56

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.

57

PREPAREDNESS

• Measures to enable to respond rapidly and

effectively to disaster situations

58

DISASTER IMPACT

• Point at which a disaster event occurs

• It has varying degrees of consequences

59

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

60

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