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PROCESS SAFETY MANAGEMENT FRAMEWORK …

PROCESS SAFETY MANAGEMENT FRAMEWORK guidance document AIGA 099/17 Asia Industrial Gases Association 52 Jurong Gateway Road,JEM, #15-02, Singapore 608550 Tel : +65 6276 0160 Fax : +65 6274 9379 Internet : AIGA 099/17 Reproduced with permission from European Industrial Gases Association. All rights reserved. ASIA INDUSTRIAL GASES ASSOCIATION 52 Jurong Gateway Road,JEM, #15-02, Singapore 608550 Tel: +65 62760160 Fax: +65 62749379 Internet: AIGA 099/17 PROCESS SAFETY MANAGEMENT FRAMEWORK guidance document Disclaimer All publications of AIGA or bearing AIGA s name contain information, including Codes of Practice, SAFETY procedures and other technical information that were obtained from sources believed by AIGA to be reliable and/ or based on technical information and experience currently available from members of AIGA and others at the date of the publication.

PROCESS SAFETY MANAGEMENT FRAMEWORK GUIDANCE DOCUMENT AIGA 099/17 Asia Industrial Gases Association 52 Jurong Gateway Road,JEM, #15-02, Singapore 608550

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Transcription of PROCESS SAFETY MANAGEMENT FRAMEWORK …

1 PROCESS SAFETY MANAGEMENT FRAMEWORK guidance document AIGA 099/17 Asia Industrial Gases Association 52 Jurong Gateway Road,JEM, #15-02, Singapore 608550 Tel : +65 6276 0160 Fax : +65 6274 9379 Internet : AIGA 099/17 Reproduced with permission from European Industrial Gases Association. All rights reserved. ASIA INDUSTRIAL GASES ASSOCIATION 52 Jurong Gateway Road,JEM, #15-02, Singapore 608550 Tel: +65 62760160 Fax: +65 62749379 Internet: AIGA 099/17 PROCESS SAFETY MANAGEMENT FRAMEWORK guidance document Disclaimer All publications of AIGA or bearing AIGA s name contain information, including Codes of Practice, SAFETY procedures and other technical information that were obtained from sources believed by AIGA to be reliable and/ or based on technical information and experience currently available from members of AIGA and others at the date of the publication.

2 As such, we do not make any representation or warranty nor accept any liability as to the accuracy, completeness or correctness of the information contained in these publications. While AIGA recommends that its members refer to or use its publications, such reference to or use thereof by its members or third parties is purely voluntary and not binding. AIGA or its members make no guarantee of the results and assume no liability or responsibility in connection with the reference to or use of information or suggestions contained in AIGA s publications. AIGA has no control whatsoever as regards, performance or non performance, misinterpretation, proper or improper use of any information or suggestions contained in AIGA s publications by any person or entity (including AIGA members) and AIGA expressly disclaims any liability in connection thereto. AIGA s publications are subject to periodic review and users are cautioned to obtain the latest edition.

3 AIGA AIGA 099/17 Table of Contents 1 Introduction .. 1 2 Scope of document .. 1 3 Purpose .. 1 4 Definitions .. 2 5 Overview of PSM elements .. 3 PROCESS SAFETY leadership .. 3 Risk identification and assessment .. 3 Risk MANAGEMENT .. 3 Review and Improvement .. 4 6 PSM Elements .. 5 Element 1: Leadership, commitment & responsibility .. 5 Overview .. 5 Requirements .. 5 Element 2: Compliance with legislation and industry standards .. 6 Overview .. 6 Requirements .. 6 Element 3: Employee selection, training and competency .. 7 Overview .. 7 Requirements .. 7 Element 4: Workforce involvement .. 8 Overview .. 8 Requirements .. 8 Element 5: Communication with stakeholders .. 9 Overview .. 9 Requirements .. 9 Element 6: Hazard identification and risk assessment .. 10 Overview .. 10 Requirements .. 10 Element 7: Documentation, records and knowledge MANAGEMENT .

4 11 Overview .. 11 Requirements .. 11 Element 8: PROCESS and operational status monitoring, and handover .. 12 Overview .. 12 Requirements .. 12 Element 9: Operating procedures .. 13 Overview .. 13 Requirements .. 13 Element 10: MANAGEMENT of operational interfaces .. 14 Overview .. 14 Requirements .. 14 Element 11: Standards and practices .. 15 Overview .. 15 Requirements .. 15 Element 12: MANAGEMENT of change .. 16 Overview .. 16 Requirements .. 16 Element 13: Operational readiness and PROCESS start-up .. 18 Overview .. 18 Requirements .. 18 Element 14: Emergency MANAGEMENT .. 19 Overview .. 19 Requirements .. 19 Element 15: Inspection and maintenance .. 20 AIGA AIGA 099/17 Overview .. 20 Requirements .. 20 Element 16: MANAGEMENT of SAFETY critical 21 Overview .. 21 Requirements .. 21 Element 17: Work control, permit-to-work and task risk MANAGEMENT .

5 22 Overview .. 22 Requirements .. 22 Element 18: Contractors and suppliers - selection and MANAGEMENT .. 23 Overview .. 23 Requirements .. 23 Element 19: Incident investigation .. 24 Overview .. 24 Requirements .. 24 Element 20: Audit, MANAGEMENT review and intervention .. 25 Overview .. 25 Requirements .. 25 Element 21: Measures and metrics .. 26 Overview: .. 26 Requirements* .. 26 Appendix A: Related AIGA & EIGA Documents and Publications .. 27 AIGA AIGA 099/17 1 1 Introduction PROCESS SAFETY MANAGEMENT (PSM) is of interest to many organisations looking to adopt a holistic and systematic approach to assuring the integrity of their operations. As the starting point, AIGA has decided to adopt EIGA s PSM FRAMEWORK Doc 186 because it was found to be the most complete and relevant to the industrial gases industry.

6 Acknowledgement and thanks are hereby given to EIGA for permission granted for the use of their document . The AIGA PSM FRAMEWORK document is a modified version of the High level FRAMEWORK for PROCESS SAFETY MANAGEMENT published by the Energy Institute to make the document more specific to the industrial gases industry. At the highest level this document is essentially the same as the Energy Institute (EI) PROCESS SAFETY FRAMEWORK document (PSM FRAMEWORK ). The layout of this document and substantial sections of the text are based on the Energy Institute (EI) document with the EI s permission. Changes to the EI PSM FRAMEWORK were only considered and incorporated where there was a unique aspect of the industrial gases industry operating in Asia with its diverse languages and legislative requirements that needed to be accommodated or addressed.

7 AIGA members may choose to follow other PSM systems such as the one developed by the American Institute of Chemical Engineers (AIChE) Centre for Chemical PROCESS SAFETY (CCPS). 2 Scope of document The AIGA PSM FRAMEWORK is applicable to all processes within the industrial and medical gases industry. It is designed to address PROCESS SAFETY hazards and be equally suitable for most of the processes that are found in the industry including: ASU production facilities Hydrogen and carbon monoxide (HYCO) production facilities including electrolysis facilities Acetylene production facilities Nitrous oxide production facilities Carbon dioxide production facilities Cylinder and container filling facilities Speciality gas production, package filling and storage facilities Distribution depots Pipelines Transportation Customer installations A facility may include not just the main production plant but all other ancillary equipment that has PROCESS hazards.

8 The decision to apply various PSM elements to a given PROCESS needs to be made by evaluating the tolerability of risk and agreeing the MANAGEMENT approach. For example, transportation risks may be managed by applying national and international codes which may not necessarily require all the elements of the AIGA PSM FRAMEWORK to be applied. In some countries, there can be existing regulatory requirements for PROCESS SAFETY MANAGEMENT systems. This FRAMEWORK is not intended to replace these requirements but may be used to supplement them. 3 Purpose The AIGA PSM FRAMEWORK is intended to provide a design basis for the development of a PROCESS SAFETY MANAGEMENT system where an organisation does not have one. It also may be used as a common basis for benchmarking existing PROCESS SAFETY MANAGEMENT systems.

9 AIGA AIGA 099/17 2 Where an organisation has a PROCESS SAFETY MANAGEMENT system or an integrated MANAGEMENT system incorporating health, SAFETY and environmental and PROCESS SAFETY MANAGEMENT they should carry out a gap assessment versus the requirements of each element in order to identify any aspects of the system that need to be enhanced. When the initial assessment has been completed, the significance of the gaps should be determined and a prioritised plan developed to address the identified issues. In some cases there can be a significant programme of work required to upgrade the MANAGEMENT system to meet the requirements of the AIGA PSM FRAMEWORK . In these cases it should be recognised that this upgrade work can take many years to complete effectively. Of the elements listed in this document the following are the minimum elements that form the basis of a robust PROCESS SAFETY MANAGEMENT system.

10 Leadership, commitment and responsibility (Element 1) Compliance with legislation and industry standards (Element 2) Employee selection, training and competency (Element 3) Workforce involvement (Element 4) Hazard identification and risk assessment (Element 6) Documentation, records and knowledge MANAGEMENT (Element 7) Operating procedures (Element 9) MANAGEMENT of change (Element 12) Operational readiness and PROCESS start-up (Element 13) Emergency MANAGEMENT (Element 14) Inspection and maintenance (Element 15) Work control, permit-to-work and task risk MANAGEMENT (Element 17) Contractors and suppliers selection and MANAGEMENT (Element 18) Incident investigation (Element 19) Audit, MANAGEMENT review and intervention (Element 20) The remaining elements (5,8,10,11,16 and 21) will also need to be implemented to provide a complete PROCESS SAFETY MANAGEMENT system.


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