Process Safety Management checklist

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Requirements:

• Clearly defined, well-explained and precisely documented program which expounds safety roles and responsibilities, risks, prevention and mitigation techniques, etc;
• Presentation including the process definition, process flow diagram, design criteria, risks & hazards, technical assumptions, references, and safety statements (for example safe upper and lower limits for temperatures, pressures, flows, compositions, etc);
• Evaluation and research on the possible negative effects, including those on health and safety, quality of the process’s products and results, and the environment (inside and outside of the working premises), if operating beyond of these safe limits;
• A set of different established safety-keeping methodologies appropriate to the complexity of the controlled process, and expounded in definite instructions for operators and supporters;
• A team of working personnel who are appropriately skilful and possess expertise in engineering (at least basically) and process operations (as appropriate for their positions and duties);
• A team of supportive personnel who possess sufficient experience and knowledge to maintain the hazard analysis methodology being used, and to service the process as appropriate;
• Appropriate industrial Standards and government regulations have been implemented, introduced, and got working;
• Strongly promoted and continually developed process safety culture;
• Properly designed, established, regulated, and maintained system which either prevent or mitigate accidents, with elements such as critical alarms and interlocks, pressure relief and venting systems, fire detection, alarming & protection equipment, emergency isolation valves and doors, etc;
• Effective manuals studied and understood by everyone who directly participates in the process, and everyone who concerns the process, as appropriate;
• Effective Emergency Management system (emergency management strategies, action plans such as emergency evacuation and shutdown plans, specific instructions and requirements are at hands of appropriate staff members);

Elements:

• Employee participation;
• Process safety information (PSI);
• Process hazard analysis (PHA);
• Operating procedures;
• Training;
• Contractor safety;
• Pre-startup safety review (PSSR);
• Mechanical integrity;
• Non-routine work authorizations (hot work permits);
• Management of change (MOC);
• Incident investigation;
• Emergency planning and response;
• Compliance audit;
• Trade secrets;

Guidelines:

• The main tools include the following components to maintain and work at:
  • Appropriate staff awareness, knowledge and training;
  • Continuous developing of process safety culture;
  • Systematic anticipating and prevention of hazardous situations;
  • Understanding & modeling hazards and their interrelationships;
  • Ensuring that process and equipment design matches the safety management requirements;
• Assign responsibility for maintaining the process safety documentation to a competent clerk(s), establish effective procedures for accessing, managing and changing documents, make sure that all standards and instructions to be followed are properly identified and expounded;
• Manage process risks strategically through implementing safe work practices, safety-oriented proceduring and controlling of the process performance operations on every critical step, providing regular trainings to personnel and managers, and conducting regular safety audits;
• Improving engineering and administrative controls to develop their better outreach for safety management needs;
• Manage technical integrity and reliability of assets to keep their operational readiness;
• Conduct regular audits of working facilities,...

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