PSM

Quick 4-Step Review of Process Safety ManagementOmesh Garga, Business Manager, DuPont Safety Resources, India, recently presented a paper on “Integrating Process Safety Management Efforts in Pursuit of Safety Excellence” at a Process Safety Management forum organized by the Indian Chemical Council. The following content summarizes this paper, which was co-authored by Ranga Shingte, Senior Consultant, DuPont Safety Resources, India. At DuPont we believe world-class safety performance is often a competitive differentiator for a company. Understanding the business value of safety management systems and methodologies has made our workplaces, which include operations at more than 300 facilities and employing more than 60,000 people in 70 countries, up to ten times safer than that of other industries. Achieving a competitive edge also requires a system that drives continuous improvement and protects people, the environment and your business. We believe that sustainable safety performance requires, in addition to occupational/behavioral safety management system, a robust Process Safety Management (PSM) system driven by operational discipline. Process Safety Management or PSM is the application of management systems and controls (programs, procedures, audits, evaluations) to a manufacturing or chemical process in a way that process hazards are identified, understood, and controlled, so that process-related injuries and incidents are prevented. While a comprehensive program is essential for achieving excellent results in preventing process incidents, it is only one of four key steps required to establish and maintain an effective PSM effort. with each of the 14 elements. No matter how comprehensive and well-designed PSM programs may be. and Mechanical Integrity. supports establishing safety systems where safety priorities are recognized. creating a strong overall safety culture. including higher productivity. it is the day-to-day ability of everyone to practice operational discipline that successfully changes safety systems from concept to reality. but rather as inherently necessary for completing any task the right way. as shown in the figure below. PSM requirements are defined by a series of corporate process safety standards that both reflect and extend federal and state regulations. PSM efforts are doomed to conflicting priorities. du Pont de Nemours and Company. Personnel.dupont. and Facilities. as shown in the figure above. A good starting point for developing a strong PSM program is existing regulations. Incident Investigation. The principles and essential features of the PSM program are described by 14 elements grouped by Technology. Personnel. and lower costs. and environmental issues. Over the last 25 years. DuPont Process Safety Management Model Auditing Emergency Planning and Response Management of Personnel Change Incident Investigation Contractors Training and Performance Process Safety Information Process Hazards Analysis Operating Procedures and Safe Practices Operating Excel ving len hie ce c A PERSON N EL TECH N Y OG OL Management Leadership and Commitment FA C ILI T I E S Management of Technology Change Th rou g Management of “Subtle Changes” ne ipli h Operational Disc Prestart-Up Safety Reviews Quality Assurance Mechanical Integrity Step 2—Providing Management Leadership and Commitment: Management leadership and commitment which is visible throughout the organization is required for continued excellence in PSM. All rights reserved. representing minimum essential levels of practice. is shown at the center of the PSM Wheel. and Personnel Training and Performance. the actions of all levels of management must support and reinforce strong PSM programs and accountability. Process Hazards Analysis.safety. and day-to-day decision-making. Management leadership and commitment. A strong safety culture. and site personnel. arranged around the spokes of the wheel. the PSM program at DuPont has been continuously upgraded and extended due to the leadership of corporate and business management.com Copyright © 2010 E. The principles and essential features of the PSM program are described by 14 elements grouped by Technology.I. please contact us at 1-800-532-SAFE (7233) or visit us at www. This figure is typically called the PSM Wheel. though. Today. but also contributes to excellent business performance through increased operating excellence. If an organization has a weak safety culture. Step 4—Achieving Excellence through Operational Discipline: Operational discipline is the deeply rooted dedication and commitment by every member of an organization to carry out each task the right way each time. such as the OSHA PSM Rule and the EPA Risk Management Program in the United States.Quick 4-Step Review of Process Safety Management Step 1—Establishing the Safety Culture: A PSM program will only be as effective as the underlying safety culture permits. DuPont™ and The miracles of science™ are trademarks or registered trademarks of DuPont. higher quality. Step 3—Implementing a Comprehensive PSM Program: A comprehensive PSM program includes integrated managing systems for various elements of process safety such as. DuPont’s fundamental policy on safety was established by our company founder and has remained a core value for over 200 years. connecting all of the elements and translating the required managing systems into real results for preventing injuries and incidents.extend federal and state regulations. Operating Procedures and Safe Work Practices. Additional requirements should be considered that go beyond regulations and better meet corporate needs for process safety. health. reduced waste. PSM professionals. such as Process Hazards Analysis. and implemented in dayto-day decisions that provide resources and establish high priority for safety-related activities. Operational discipline is shown as the rim of the PSM Wheel. continuing with policies that set high expectations for excellent safety performance. DuPont oval logo. and Facilities. necessary for implementing and maintaining strong PSM programs. For more insights on PSM and operational discipline. Beginning with the formation and fostering of a strong safety culture. such as production needs or lowering costs. and as evidenced by organizational policies. based on a commitment to core values on safety. Regulations should generally be considered the starting point only. . goals. not as conflicting with other priorities. metrics. Operational discipline not only helps prevent serious injuries and incidents.