Process Safety Management Program Development and Implementation
Miscellaneous Clients • Multiple Locations
Solution Overview
Client:
Miscellaneous Clients
Business Challenge:
- Develop and maintain a Process Safety Management (PSM) program that fits industry and site needs while also supporting ongoing production and operational efficiency.
Solution:
- Deep knowledge and expertise in the development and implementation of PSM programs across a wide range of industries and hazards, with cross-disciplinary experience in management systems development and training.
Results:
- Efficient and effective PSM programs tailored to site and employee needs.
Challenge
Performing PSM can be a challenging task for any organization. The main challenge is to ensure the safety of employees and the surrounding community while simultaneously maintaining production levels. This requires a thorough understanding of the various hazards associated with the process and how to mitigate them. Additionally, companies must comply with various regulations and standards to ensure that their PSM system is up to par. Proper training of employees is also crucial in ensuring that they are aware of potential hazards and know how to respond in case of an emergency. Overall, PSM is a complex task that requires careful planning, execution, and monitoring to ensure the safety of all involved.
Solution
Apex has developed PSM programs for the beverage and container industries for sites exceeding threshold quantities of anhydrous ammonia and chlorine. Compilation of Process Safety Information (PSI) for covered processes has included chemical evaluation, process flow design, piping, and instrument diagrams (P&IDs), and the formation of engineered safety systems to minimize incidents. To ensure that equipment used in high hazard process is maintained with the highest mechanical integrity (MI), Apex helps identify and institute requirements that apply to pressure vessels, storage tanks, piping systems, relief devices, emergency shutdown systems, controls, and pumps used in high hazard processes. Apex performs Process Hazard Analyses (PHA’s) using Hazard and Operability Analysis (HAZOP), Fault Tree Analysis, and Failure Modes and Effect Analysis (FMEA) to identify potential causes and consequences of fires, explosions, releases and of toxic chemicals. Major spills are assessed in relation to equipment, instrumentation, utilities, human actions, and external factors that might impact the process.
The PSM program supported by Apex at these facilities has included the development and implementation of written Standard Operating Procedures (SOPs) as required by 29 CFR 1910.119. These include required elements such as initial startup, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown, and startup following an emergency.
Apex develops and delivers training for contractors and employees and has supported the implementation of employee participation programs to ensure all elements of the standard are met. Management of Change (MOC) programs have been developed to ensure that contemplated changes to hazardous processes are thoroughly evaluated to fully assess the potential impact on employee safety and the environment, and to determine what changes may be needed to existing operating procedures. Following any changes or introduction of new hazards, Apex supports the development and creation of a Pre-Startup Safety Review (PSSR) process to verify that construction plans and equipment meet design specifications, that safety, operating, maintenance, and emergency procedures are current and accurate, and that hazard analysis and training have been developed to address changes.
While Apex and the facilities it supports focus on preventing incidents from occurring, it is critical that emergency pre-planning and training procedures are in place and practiced. Apex develops and trains employees on procedures required for handling releases of highly hazardous chemicals. Additionally, Apex develops incident investigation processes to enable the site teams to identify root causes and to implement corrective actions that will prevent reoccurrence of incidents. To ensure all aspects of PSM are implemented, Apex performs compliance audits, required by the standard every three years, to certify the sites are identifying and correcting deficiencies.
Results
Apex’s approach to PSM results in a safer work environment for employees and the surrounding community while also helping to protect our clients from financial and legal challenges that often arise due to uncontrolled hazards. Our knowledge of industry operations, and our cross-disciplinary expertise with management systems and associated training requirements results in increased production efficiency and reduced downtime due to accidents or incidents. We know that properly trained and empowered employees can respond quickly and effectively in case of an emergency, potentially preventing serious injuries or fatalities, and therefore focus on delivering impactful instruction to your teams. Our goal is to help you design and deliver a sound PSM program that will protect lives, property, and the environment while also benefiting your company’s bottom line.