psm specialty group
TRANSCRIPT
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PSMSpecialtyGroup
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Training Process Safety Management AUDITING
Ujwal Ritwik CRSP, QEP, REM, LA ISO 45001/14001/9001/22000/50001
PSM Expert
KuwaitChapter
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Objectives
Participants will - § Get an overview of Compliance Audit element of OSHA
standard 29 CFR 1910.119 § Get a snapshot Audit element of CCPS RBPS § Get a view of current state of practice of Auditing for Process
Safety Management
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Agenda Overview Session - 1
§ Audit definition § Quick recap of OSHA Process Safety Management Standard 29
CFR 1910.119 § Requirements of Compliance Audit in OSHA PSM § Success factors for auditing § Requirements of PS Audit in CCPS RBPS § Question - answer
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Why I am interested – I remain deeply interested in Process Safety
– Background of Nuclear Industry where public risk perception is critical
– Began career in high hazard chemical industry, encountered several situations and major accident
– Worked at ICI, originator of HAZOP, and met Trevor Kletz
– Part of team to survey Major Hazard Control program in India; experienced several catastrophic accidents closely
– Became passionate about PS and risk management; self appointed ambassador
– Implemented Process Safety Management at KPC and KNPC TrainingonPSMAuditing:UjwalRitwik
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Quick Revisit of Process Safety Management
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Opening question
Wouldyouliketohavebenefitsofcheaperenergy,plastic,fuel,transport,technology,conveniencesoflife?
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Areyoureadytopaytheprice-hurtandkillpeople,poisontheenvironment,losemoneyand
destroyproperty?
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The History of Major Chemical Accidents
• Flixborough,UnitedKingdom,1974• Seveso,Italy,1976• Bhopal,India,1984• PemexLPGTerminal,MéxicoCity,México,1984• PiperAlphaPlatform(Offshore),UKContinentalShelf,1988• TexasCity,Texas,BP2005• BuncefieldOilDepotFire,HertfordshireUK,2005• GulfofMexico,BPMacondo,2010
WhendidPSMstart?
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OnthenightofDecember2-3,1984,asuddenreleaseofabout30metrictonsofmethyliso-cyanate(MIC)occurredattheUnionCarbidepesticideplantatBhopal,India.Theaccidentwasaresultofpoorsafetymanagementpractices,poorearlywarningsystems,andthelackofcommunitypreparedness.Theaccidentledtothedeathofover3,500peoplelivinginthevicinityandcausedrespiratorydamageandeyedamagetoover20,000others.Atleast200,000peoplefledduringtheweekEstimateddamage$350millionto$3billion
Methyl Isocyanate Tank Rupture and Release Bhopal, India – Dec. 2-3, 1984
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Phillips 66 Houston Chemical Complex Pasadena, Texas – Oct. 23, 1989
OnOctober23,1989,anexplosionandfirerippedthroughthePhillips66CompanyHoustonChemicalComplexinPasadena,Texas.Twenty-threeworkerswerekilledandmorethan130wereinjured.Propertydamagewasnearlythree-quartersofabilliondollars.Morethan85,000poundsofhighlyflammablegaseswerereleasedthroughanopenvalve,duringregularmaintenanceoperationsononeoftheplant'spolyethylenereactors.Avaporcloudformedandtraveledrapidlythroughthepolyethyleneplant.Within90to120seconds,thevaporcloudcameintocontactwithanignitionsourceandexplodedwiththeforceof2.4tonsofTNTTrainingonPSMAuditing:UjwalRitwik
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Regulatory Responses – Clean Air Act Amendments of 1990
1. OSHAProcessSafetyManagementregulations–(29CFR1910.119)concernedwithaccidentpreventionintheworkplace(1992)
2. EPARiskManagementProgramRegulations(40CFRPart68)-concernedwithaccidentpreventiontoprotectthepublicandenvironment(1996)
3. TheAmendmentsalsoestablishedtheindependentU.S.ChemicalSafetyandHazardInvestigationBoard(42U.S.C.7412)(CSB,1998)
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29 CFR 1910.119
OSHA’sProcessSafetyManagementStandard
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Elements of PSM Standard
1. EmployeeParticipation2. ProcessSafetyInformation3. ProcessHazardAnalysis4. OperatingProcedures5. Training6. Contractors7. Pre-startupSafetyReview
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8. MechanicalIntegrity9. Hot-workPermits10. ManagementofChange11. IncidentInvestigations12. EmergencyPlanning&Response13. ComplianceAudits14. TradeSecrets
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Quiz
1. Whatpricedowepayforcheaperenergy,chemicalsandplastics?2. WhatpromptedCleanAirActAmendmentBill(USA,1990)?3. WhatyearOSHAPSMstandardregulationwasbroughtinforce?4. WhatisthecompanionregulationbyEPAtoprotectpublicand
environment?5. HowmanyelementsdowehaveinOSHAPSMstandard?
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Components of OSHA - PSM Compliance Audit Element
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Audit is a feedback mechanism that provides management with the status and measurement of effectiveness of the various efforts and leads to the appropriate control over these efforts A site audit program consists of
- separating the PSM program into its component parts - auditing each part to determine actual versus intended effectiveness - formulating corrective action to improve performance - reporting / documenting findings - follow up controls
In addition to PSM improvement often audits point to improvements in operations, maintenance, and engineering aspects Compliance Audit: Evaluation of compliance with the provisions of law
What is Process Safety Management Audit
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29 CFR 1910.119, OSHA Process Safety Management of Highly Hazardous Chemicals (o) Compliance Audits
(1) Employers shall certify that they have evaluated compliance with the provisions of this section at least every three years to verify that the procedures and practices developed under the standard are adequate and are being followed
(2) The compliance audit shall be conducted by at least one person knowledgeable in the process
(3) A report of the findings of the audit shall be developed
(4) The employer shall promptly determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected
(5) Employers shall retain the two (2) most recent compliance audit reports
OSHA PSM Compliance Audit Text
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Compliance Audits - Requirements
• ComplianceauditsofPSMProgramevery3years• Auditsconductedbyperson(s)knowledgeableintheprocess• Auditteamsizewillvary• Trainedauditteamleader• Writtenreportofcorrectiveactionandfollow-up• Last2complianceauditreportsonfile• Createdocumentationofsafeandunsafepractices
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Compliance Audits – Recommendations
• TrainedauditteamsortrainedsingleauditorsshouldconductPSMaudits
• PSMauditsshouldconsistofPSMprocessdocumentreviews,recordsreviews,employeeinterviewsandonsiteobservations
• Trackingsystemsshouldbeusedtomanageauditrecommendations/correctiveactions
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Compliance Audits – Recommendations
• Thirdparty(outside)auditorswhileimpartialarenotmandated• However,U.S.OSHAsays,"Theauditshouldbeconductedorledbyapersonknowledgeableinaudittechniqueswhoisimpartialtowardsthefacilityorareabeingaudited."(emphasisadded)
• Certificationofauditrequiredbyresponsibleperson-shouldincludesignatureanddate
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Compliance Audits – Recommendations
• PSM“StatusAssessments”,“ReadinessReviews”,etc.canbecountedasauditsiftheyweredonetocomplywithAuditProtocols
• Recommendationsdonothavetobedevelopedaspartoftheaudititselfbutcanbeaddedlater
• ResolvingAuditRecommendations:• notexpectingeverythingtobecompletedin2-3months• everythingshouldbecompletedin6months,unlessjustificationiswarrantedforlongerperiod(e.g..leadtimeonmaterial)
• keywillbewhatinterimstepshavebeentakentoassureemployeesafetyNote:Thesecommentsmayapplytootherelements
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Compliance Audits – Recommendations
• ResolvingAuditRecommendations:• Facilitiescannottakethe3yearsuntilthenextaudittocorrectfindings-correctiveactionsshouldstartimmediately
• Standardauditprotocol/checklistorreportformatisrecommended• Thetriennialrequirementforthenextauditshouldbemeasuredfromthecertificationdateofthepreviousaudit
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Compliance Audits – Best Practices • Useauditteammembersfromotheroperatingdepartmentsatsite• Useauditteammembersfromothersites• Conductauditsonasmallerscopebutmorefrequentbasis
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Auditing Audit Program • Haveyouestablishedaformalauditprogramtoreviewtheprocesssafetyofyourfacility?
• Doestheprogramcallforre-evaluationauditsatleasteverythreeyears?
• Doyouhavearecommendationstrackingsysteminplacethatassuresthatdeficienciesaredocumented,assignedtoaresponsiblepartyforcorrectiveaction,anddocumentedwhencomplete?
• AreyourauditsconductedbyanindividualorteamthatisknowledgeableofthePSMprogramandrequirements?
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Compliance Audit Checklist
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Quiz
1. WhatisthenameofthePSMelementonaudit?2. Whoissupposedtodotheaudit?3. Howoftentheauditisrequired?4. Whomustbepartofauditteam?5. Whatmustbedocumentedbytheemployerafterreceivingan
auditreport?6. Howmanycomplianceauditreportstheemployerisrequiredto
retain?
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Auditing Success Factors
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Effectiveness of PSM Audits
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D.JonesSurvey(2000)figuresuggestedthat• ProcessSafetyManagement(PSM)complianceauditsarespecificand
comprehensive,focusingon14elementsofOSHA’sPSMStandards• Awell-plannedandorganizedauditprocess—includingcross-trainedpersonnel,
auditchecklistsandself-audits—canhelpensureasuccessfuloutcome• ThePSMauditshavebroughtthenumberofaccidentsdownverysharply• PSMsystemsauditsaskedthetopcorporatemanagementtounderstandits
importanceandallocatesufficientresourcesforitsongoingsuccess
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Top 7 PSM Audit Violations and How to Avoid Them - 1
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1.OutdatedProcessSafetyInformation
e.g.Safetyreliefsystem,inventory,ventilationcalculations,“Fieldverified”pipingandinstrumentationdrawings(P&IDs);Manytimes,facilitieshavemadechangestotheprocesssystemwithoutupdatingthisdocumentation.
2.PreviousProcessHazardAnalysis(PHA)Issues
OutstandingPHArecommendationsthathavenotbeenaddressedorproperlyclosedout.
3.VagueStandardOperatingProcedures(SOPs)
Thosethataregenericinnature,notequipmentspecificandhavenotbeenreviewed/certifiedannuallyasrequiredbytheOSHAStandard.
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Top 7 PSM Audit Violations and How to Avoid Them - 2
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4.ImproperManagementofChange(MOC)Documentation
Toooften,aMOCiscompletedaftertheequipmenthasbeeninstalledandisoperational.EnsurethatMOCsarefullycompletedandsignedoffbytheauthorizingpersonnelbeforestartupoftheequipment.Similarly,MOCsaremanytimesforgottenwhencompletingchangestooperatingprocedures,Elements,etc.MOCsarerequiredforanychangeaffectinghowyoudosomething(i.e.,addingstepstothestart-upprocessofapieceofequipment).
5.LackofProperPSMTraining
PSMrequiresthatpersonnelinvolvedwiththeoperationandmaintenanceoftheammoniasystemreceiveinitialtrainingandrefreshertrainingeverythreeyears.
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Top 7 PSM Audit Violations and How to Avoid Them - 3
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6.GapsinAuditFrequency
ThisreferstoauditsthathavenotbeenconductedeverythreeyearsasrequiredbythePSMStandardortheactionitemsthatweregeneratedfromthepreviousauditthathavenotbeenclosedoutintimeforthenextauditcycle.
7.ImproperorUnorganizedDocumentation
Inpreparationfortheaudit,ensureallofyourwrittendocumentationisuptodateandfiledinaformatthatiseasilyaccessibletotheauditor.Theauditorwillneedtoreadandreviewalargeamountofwrittenproceduresandguidelines.It’sbesttoplacethesedocumentsinanofficeorconferenceroomfortheauditortoworkfrom.Thiswillalsoprovideanareawheretheauditorcanworkprivatelyandconductemployeeinterviews.
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Incidents that underline Ineffective Auditing
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§ Reviewofseveralcatastrophicaccidentshaverevealedineffectiveandinappropriateauditingpracticesprevalentpriortotheincidents
§ PiperAlphaoilrigfire1988–auditingdonebutnomanagementoversight,recommendationsnotactedupon
§ TexasCityRefineryexplosion2005–PSMauditsdonejustforcompletingtheritual,tofulfillpaperwork
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6 July 1988: A series of explosions destroyed the Piper Alpha oil platform in the North Sea. One hundred and sixty seven men died in the world's worst offshore oil disaster.
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PSM Systems Audit
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Management System
§ OSHA29CFR1910.119isaregulatorystandard,1992§ Itisanobjectivestandardformanagingprocesssafety(PSM),andnotadetailedprescriptivestandard
§ Itisnotamanagementsystem§ Center for Chemical Safety (CCPS) in 2007 cameoutwith a ProcessSafetyManagementSystem–RiskBasedProcessSafetyManagementSystem(RBPS)
§ RBPShasfourfoundationalblocks,20elements
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PSM System Audit Vs. PS Audit
§ Process Safety ManagementSystemsAuditinclude
• Policiesandprocedures• Managementorganization• Planningprocess• R i s k a s s e s s m e n t a n dmanagement
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§ ProcessSafetyAudit• Moredetailedandspecific• Provide increased assurance thatu n i t s a r e o p e r a t e d a n dmaintained people, plant andenvironmentareprotected
• Sometime combine hazardevaluations
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CCPS - RBPS 3Pillar(FoundationalBlock)–ManageRisk3.1Element–OperatingProcedures3.2Element–SafeWorkPractices3.3Element–AssetIntegrityandReliability3.4Element–ContractorManagement3.5Element–TrainingandPerformanceAssurance3.6Element–ManagementofChange3.7Element–OperationalReadiness3.8Element–ConductofOperations3.9Element–EmergencyManagement4Pillar(FoundationalBlock)–LearnfromExperience4.1Element–IncidentInvestigation4.2Element–MeasurementsandMetrics4.3Element–Auditing4.4Element–ManagementReviewandContinuousImprovement
1Pillar(FoundationalBlock)-CommitmenttoProcessSafety1.1Element–ProcessSafetyCulture1.2Element–CompliancewithStandards1.3Element–ProcessSafetyCompetency1.4Element–WorkforceInvolvement1.5Element–StakeholdersOutreach2Pillar(FoundationalBlock)–UnderstandingHazardsandRisks2.1Element–ProcessKnowledgeManagement2.2Element–HazardIdentificationandRiskAnalysis
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CCPS - RBPS
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RBPS Audit Element - Overview
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§ CriticalevaluationoftheRBPSmanagementsystemisoneoffourelementsintheLearningfromExperiencePillar(FoundationalBlock).
§ Theauditselementisintendedtoevaluatewhethermanagementsystemsareperformingasintended.
§ ItcomplementsotherRBPScontrolandmonitoringactivitiesinelementssuchasmanagementreview,metrics,andinspectionworkactivitiesthatarepartoftheassetintegrityandconductofoperationselements.
§ Theauditselementcomprisesasystemforscheduling,staffing,effectivelyperforming,anddocumentingperiodicevaluationsofallRBPSelements,aswellasprovidingsystemsformanagingtheresolutionoffindingsandcorrectiveactionsgeneratedbytheaudits.
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RBPS Audit Element – Key Principles 1
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Thefollowingkeyprinciplesshouldbeaddressedwhendeveloping,evaluating,orimprovinganymanagementsystemfortheauditselement:§ MaintainaDependablePractice
• Whenacompanyidentifiesordefinesanactivitytobeundertaken,thatcompanylikelywantstheactivitytobeperformedcorrectlyandconsistentlyoverthelifeofthefacility.
• Theauditselementshouldbedocumentedtoanappropriatelevelofdetailinaprocedureorawrittenprogramaddressingthegeneralmanagementsystemaspectspreviously.
oEnsureconsistentimplementation.oIdentifywhenauditsareneeded.
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RBPS Audit Element – Key Principles 2
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§ ConductElementWorkActivitiesNote:Thisnarrativeassumesthata2ndor3rdpartyauditteamisconductinganauditofthefullRBPSmanagementsystem.Manyofthesesameactivitieswouldberequiredfora1stpartyaudit;however,someofthelogisticalissuesandpreparatorytaskswouldbesimpler,ornonexistent,forateamself-auditingitsownfacility.
oPreparefortheaudit.oDeterminetheauditscopeandschedule.oAssembletheteam.oAssignresponsibilities.oGatheradvancedinformation.oPlanonsiteactivities.oConducttheaudit.oDocumenttheaudit.oAddressauditfindingsandrecommendations.
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RBPS Audit Element– Key Principles 3
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§ UseAuditstoEnhanceRBPSEffectiveness
oMonitorRBPSmaturationovertimeforeachfacility.oSharebestpractices.
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Quiz
1. WhatisthedifferencebetweenPSMSystemsauditandProcessSafetyaudit?
2. IsCCPSRiskBasedProcessSafetyManagementSystemaregulation?
3. HowmanyfoundingpillarsandelementsRBPShas?4. HowmanykeyAuditingprinciplesRBPShas?5. Whataretheprinciples?
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What did we do?
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1. OSHA PSM 2. Compliance audit – a vital element of PSM standard 3. Minimum requirements of the Compliance Audit program 4. Audit checklist 5. PSM System Audit Vs. PS Audit 6. CCPS RBPS Auditing
Post session exercise – review the OSHA PSM Audit Checklist https://www.osha.gov/sites/default/files/2019-03/08_PSM_Auditing_Checklist.pdf
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Next session
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1. Current status of PSM auditing 2. Best practices 3. How to improve auditing 4. Revision 5. Question answer 6. Conclusion
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Thank you for being with us
Stay Home stay Safe
• SecondsessiononPSMAuditingwilltakeplaceonSunday,April5,202019:30pmKuwaittime(12:30pmET)
• Pleaseregisterinadvanceandlogin15minutesbeforethestartofsession
Forfeedbackandsupport–[email protected]