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Process Safety Management is an approach to create a safe system for the people that work in the process, and for the surrounding environment. It is designed as a systematic approach to manage physical threats, health and safety regulations and standards, training requirements, and compliance. As this is a new way of managing safety it also creates new challenges for businesses, especially small to medium-sized businesses.

Process Safety Management (PSM) is the set of actions and procedures implemented by the owners, operators, designers, and engineers of an organization or a process in order to safely manage the risks involved in their operations. Process Safety Management consists of the implementation of the policies and rules placed by different organizations on how to operate processes to ensure that the safety guidelines are met. It essentially means keeping people, property, and the environment safe from harm during the process. Process Safety Management or PSM is a set of principles, guidelines, and procedures which work together to identify, prevent and control industrial risks that may cause an explosion, fire, or release of harmful gas. The main purpose of PSM is to ensure the safe operation of existing chemical processes.

Process Safety Management (PSM) is an approach to managing risks in a number of industries, including manufacturing and Chemical Production. Process Safety Management focuses on the safe design, construction, operation, and decommissioning of facilities. An important factor in successful PSM implementation is the use of checklists and program standards. Businesses can achieve multiple benefits from implementing process safety management. These benefits include increased plant and worker safety, improved process performance and better compliance with regulations, such as OSHA.

The management of processes with hazardous materials is essential to keep a safe environment for the people who work in the plant, as well as to protect the environment and save natural resources. Implementing process safety management can benefit businesses by providing an environment focused on safety, which minimizes and prevents incidents, fatalities, and evacuations. Process Safety Management is a key safety system for eliminating process hazards. It is a collection of management practices that together can provide protection to people involved in the former and neighboring processes from fatal harm, injury, and damage. Process safety management also ensures the protection of equipment, environment, and facilities where a process is carried out. It helps in avoiding catastrophic process accidents that can cause serious loss of production capacity, financial loss due to downtime, environmental degradation, and oftentimes loss of life.

THE 14 ELEMENTS YOU SHOULD INCLUDE IN YOUR PSM PROGRAM

EMPLOYEE PARTICIPATION                        

One of the most effective ways to make sure that you are running a safe operation is employee participation. It’s important, in fact, it has become an industry standard to have weekly safety meetings at all levels of the workplace. In many cases, you will see meeting agendas with titles that refer to employee involvement at some level in a second or third bullet point.

PROCESS SAFETY INFORMATION                      

Process Safety Management (PSM) refers to an organization’s ability to manage the risks created by hazardous processes. These risks can lead to incidents, accidents, and even catastrophic events that harm people, destroy assets or impact the environment. When a process poses threats of this magnitude, some type of formal PSM system must be in place to mitigate those changes.

PROCESS HAZARD ANALYSIS                            

Process Hazard Analysis (PHA) is the systematic identification, evaluation, and control of the hazards of a particular process. Its primary purpose is to identify hazards that cause injuries or deaths within a facility, during product processing operations.

OPERATING PROCEDURES                                  

Operating procedures are the step-by-step details that guide operators and others involved in managing a process. Operating procedures can be formal or informal, depending on the industry and company. A formal operation procedure typically is part of a written manual for operating a process. An informal operating procedure may just be an unwritten policy and procedure that employees follow to manage processes.

TRAINING            

Safety Training is a critical part of the operator’s role in managing risks associated with operating the process. In this role, you are an integral part of the team that develops, implements, and communicates the process safety management plan. Process Safety Management training can be an important aspect of plant safety. It may be required to complete during job interviews or it may be just a must-have for your resume. Regardless, an individual with knowledge of this subject will see immediate growth in the industry.

CONTRACTORS

Contractors have a direct impact on process safety and health management programs (PSH & PHM). Successful contractors are those who understand not only the work they perform but the connection to overall PSH & PHM program strategies.  Contractors who understand their role, as well as when to take action, communicate with site employees, and know where to find information can improve safety for all.

PRE-STARTUP SAFETY REVIEW

Pre-Startup Safety Review, the review of a process to be started up. This is usually performed by a Process Safety Management (PSM) consultant or contractor or by an employee operating under the supervision of a PSM competent person. The Pre-Startup Safety Review is required to be conducted before feed streams are placed in the unit for the first time and is also required at significant modification to the unit.

MECHANICAL INTEGRITY

Mechanical Integrity (MI) is the state of being intact and able to perform its required functions. It is a primary focus for metal structures, groups of components, and piping systems in industrial plants that handle major process hazard fluids like hydrocarbons, polymers, caustics, or flammable liquids due to their critical role in plant operations.

HOT WORK PERMIT

A hot work permit is a document that outlines the specific grades of steel or other materials that can be worked on. This permit needs to be documented, signed, and filed offsite or brought into the facility. There are a number of locations where personnel may document the hot work permit. The document must remain with the facility but can be stored anywhere on-site.

MANAGEMENT OF CHANGE

The management of change is a long-established process safety concept and framework that has recently been the focus of greater attention in the chemical industry because of increased regulatory emphasis on human factors issues. It was originally applied to major shutdowns for plant modification, but it is now used more broadly to address any change in plant equipment, procedures, or processes. Management of change (MOC) involves systematic evaluation of hazards associated with a proposed change, identification, and analysis of risks, an assessment of implementation options to minimize hazards and risks, and preparation for safely implementing changes.

INCIDENT INVESTIGATION

Incident investigations are critical to the health and safety of any facility that could have an on-site release of a toxic or hazardous chemical. The investigation is designed to determine the causes of the incident. The primary purpose of this investigation is to make recommendations to prevent future incidents. The facility then must implement changes that will make the whole system safer.

EMERGENCY PLANNING AND RESPONSE

Emergency planning and response (EPR) is a focused effort, principally driven by facility management, to mitigate the potential for significant injury or death as a result of unexpected events. An unexpected event is an unplanned consequence of the normal and expected use of a chemical process, which requires immediate attention because it causes harm to some individuals or threatens public health and safety.

COMPLIANCE AUDITS

A compliance audit is a formal assessment of the organization's compliance with the safety and health requirements as defined by a regulatory agency. The objective of a compliance audit is to determine if an organization has met required standards. This includes reviewing the contents of the management program, assessments, inspections, training documentation, access authorization procedures, incident investigations, and any other records related to the safety program.

TRADE SECRETS

The most important aspects of Process Safety and Risk Management are often protected as trade secrets for competitive reasons. Trade Secrets - The key to identifying areas of improvement, when a company puts aside competition and trades it for cooperation, the company can exploit the knowledge that individuals cannot see because it is hidden in the process.

HOW WE CAN HELP

•             Online/Onsite Training

•             Audit and Documentation          

•             Process Safety Management Analysis

Hazard identification and risk analysis are an integral part of the occupational health and safety (OHS) management process. The absence of these requirements could result in a serious injury or fatality, which in turn can lead to serious financial implications for employers, employees, and also the wider public. The preventive measures implemented can also prevent human suffering and loss and livelihoods. The process of identifying hazards followed by the identification of the ways in which these hazards can be controlled or eliminated is known as hazard identification and risk analysis. Hazards are the conditions that cause injuries or damages at the workplace. In order to control the occurrence of these hazardous situations, it is necessary to properly identify them. By understanding the risks associated with the job site and the potential hazards faced while at work, preventive measures can be taken.

Hazard identification and risk analysis is an important area of safety management as it helps to minimize the risk of an accident occurring. The hazards of an enterprise are analyzed first, and the risks associated with these hazards are identified next. Hazard identification is the first step in formulating a safety program. This is the stage where management should decide what hazards to be included in the risk analysis. The objective of hazard identification is to identify all foreseeable hazards and their consequences. Once identified, you can monitor these hazards and ensure their control, thus protecting your equipment, workers, and company’s reputation. In our modern world, industries and companies with adequate security and safety measures are more and more valued. Security systems play a significant role in providing the safety of personnel, facilities, and assets. Unsafe conditions can easily lead to accidents or even loss of life, which is extremely dangerous to any organization. These days almost every company needs a reliable security system or services.

Hazard identification is the initiation of the risk process. It is the first step and should be done even for small projects to make sure you have the people needed to start conducting the risk analysis. The key to identifying hazards is to look at everything that could possibly go wrong during a project. You can identify hazards from your stakeholder interviews, brainstorming, and other activities. When you're in a highly dangerous area, you want to know which risks are the most lethal. The threat of falling garbage or even drowning might not even come close to the threat of high prison escape. Any powers that do hazard identification and risk analysis can identify the highest threats so they can take appropriate steps and precautions. Hazard identification and risk analysis is a technique used in risk management. The aim is to identify, assess and prioritize potential hazards (events that could cause harm) in an organization's processes, products, services, or activities and to compare with the controls already in place to reduce the likelihood of the hazards occurring.

The purpose of hazard identification and risk analysis is to describe and evaluate the safety risks of a system. It is important because it can provide information that will enable the design personnel to make appropriate safety improvements to the existing system. A well-conducted Hazop study can also allow policymakers to make informed decisions about what steps should be taken to ensure public safety in general and how certain risks need to be handled specifically.

TheSafetyMaster is a leading top safety consultant provider of a variety of programs and services for helping employers identify hazards, preventing workers from injury as well as in conducting safety inspections and work-site assessments. The company provides expert assistance to improve the safety record, employee morale, and also financial health of the business. TheSafetyMaster is a leading company providing an extensive range of Chemical Safety Assessment, Safety Analysis Testing, and mitigation services to a large number of industries the world over. TheSafetyMaster has an extensive worldwide network of offices which provides our customers wide choice for their services. TheSafetyMaster is one the best company provide a complete range of safety services that include Accident Investigation Services, Accident Investigations and Analysis, Hazard Identification, Hazardous Materials Transportation, International Shipping and Ship Survey and inspection, and Industrial Hygiene Inspection.

HIRA is a process of identification of Chemicals, which are present in the work area and the number of chemicals stored. It is not mandatory to follow the HIRA procedure for all industries. But most often than not, it is required by law. The primary aim of the HIRA technique is to be able to recognize who are inherently exposed to hazardous chemicals and also to prevent any kind of health hazards that may arise due to such exposure. The SafetyMaster, an accredited company has provided a practical solution for effectively and efficiently conduct HIRA analysis without incurring a huge expense on it.

The Safety Master provides health and safety services that deal with issues in the workplace, this includes consulting, auditing and training services, risk management services as well as the provision of personal protective equipment for workers. Due to the complexity of these issues and the overwhelming wealth of information and regulations governing it, TheSafetyMaster has built an extensive library of resources. The Safety Master is India’s leading and most experienced provider of auditing services to the construction industry. We put our extensive knowledge and expertise to work for you, to ensure your projects are safe and compliant.

The Safety Master knows how important the safety of your family and employees. Safety Professionals can spend a lifetime learning the basics of all the hazards around the workplace. Our safety specialists are fully trained and do not need to learn any new equipment when they arrive on site. Our goal is to provide a complete solution for safety management that will help your business to improve compliance. The Safety Master is one of the most reputed and professional industry specialists. We are an experienced team of qualified engineers, well trained in all kinds of manufacturing industries, we can provide Hazop study on any kind of process. Request a quote for your Hazop study today from an expert in the industrial field. We aim at delivering qualitative products, services, and solutions to our clients which guarantees healthy growth in their business.

HOW WE CAN HELP                                                                                                          

·        Onsite/Online Training

·        Audit and Documentation

Behavior-Based Safety (BBS) principles can be employed to prevent hazards and create safe work environments. BBS has grown from an idea in the Industrial Age that is beginning to emerge in the Connected Workplace as a way of managing people in order to steer them toward safe behaviors that benefit them, their teams, their company, and the society at large. Employing BBS, employers can create workplaces where employees are inspired to find innovative ways to solve problems and produce great results.

Behavior-Based Safety is an approach to working on a project that originated in manufacturing with the goal of creating a safer workplace. The idea behind Behavior-Based Safety is that there is a direct correlation between job stress, frustration, and the number of incidents that occur. Behavior-based safety (BBS) is an approach to workplace safety that relies on analyzing patterns of safe and unsafe behavior. This approach differs radically from other ideas about the nature of workplace accidents, such as human error or system failures, which focus primarily on mistakes people make or equipment failures.

Creating an effective Behavior-Based Safety (BBS) Program

Depending upon which efforts one cites, BBS programs have been in existence for as long as thirty to forty years. Many of these attempts, however, resulted in little or no measurable benefit. Frequently these projects failed because BBS was considered a stand-alone program, rather than an integral component of the overall safety management process. In addition, the lack of a standard methodology has limited its success. This has produced a great deal of confusion about what really constitutes a Behavior-Based Safety Program (BBS).

Most companies today are focused on creating a culture of respect and safety in the workplace. Having a Culture of Safety is an absolute necessity to achieve success in today’s business climate. It is just as important to have effective Behavior-Based Safety Programs in order for your core values to actually be materialized throughout the company.

Need of  Behavior-Based Safety (BBS)          

Safety is a necessary consideration for both employers and employees. The former ensures that the latter can work in safe and healthy conditions, while the latter ensures that it can be done without undue risks to life and limb. This makes safety an important quality in the workplace. Some may think that common sense should be enough to keep employees safe but there are several cases to prove that it is not always possible to exercise your senses all the time.

Safety is a very broad term that encompasses several different areas and serves different purposes. Safety has always been of paramount importance especially in the industrial sector. It encompasses any action or activity that prevents injury of workers or compromise their health without compromising on the organization’s efforts to achieve its goals.

Behavior-Based Safety (BBS) is a reason that it's becoming increasingly important for all industries globally to take note of like the old style of running an organization with complete focus on improving operational performance while forgetting to take care of its people, is slowly changing into one that focuses on such aspects as an increase in employee engagement and loyalty, better job satisfaction, teamwork, culture change initiatives, etc. The business environment today has seen the emergence of diversified dimensions in the manufacturing business particularly due to the infinite presence of social media and technological advancements.

Advantages of Behavior-Based Safety (BBS)

In the Occupational work environment, behavior-based safety (BBS) is used as a method in which employees involved in their work activities. Behavior-based safety basically describes the behavior of employees on the job. It is looking at when accidents happen and what causes them to happen. BBS also concerned with the modification and improvement of unsafe behaviors of employees. So, in order to minimize or reduce injuries, it would be great if all employees at the workplace will behave properly according to instructions, etc. In a word, behavior-based can be described as how people act on the job and what causes them to act that way.

Human behavior in the workplace is important to understand because it can determine how safe or unsafe the environment is. Behavior-based safety focuses on individuals’ actions that affect the workplace. BBS has numerous advantages over other safety techniques. BBS contributes to a safe environment by reducing injuries and rework, improving company image, increasing production, and creating an organizational culture of personal responsibility.

Behavior-based safety implementation              

Safety has been one of the most talked-about topics in the past few years. With all the different stories we hear about each year, it’s no wonder people are scared of their jobs. There have been many reports on how important safety is to an organization’s success but it’s not too often that they tell you how to implement behavior-based safety. So here is how to build a behavior-based safety system.

Behavior-based safety (BBS) implementation is imperative if one wants to achieve a successful plan for their workplace. A BBS can help improve organizational communication and increase productivity. Companies that implement a BBS have been shown to reduce recordable work-related injuries by 20%. It is very important to not only install the equipment but to enforce the safety policy that was created with the help of a BBS consultant or safety expert. It is also crucial to hire a strong BBS advisor who has experience implementing behavior-based safety programs. This will ensure that employees are encouraged to report hazards and unsafe behaviors, thus making them more comfortable talking about problems and solutions on the job.

Behavior-based safety implementation is the foundation for creating a safe workplace. Effective behavior-based safety implementation takes careful planning, investigation, and attention to detail. This starts with management and needs the buy-in of everyone. A common theme in a SAFETY program is the active participation of everyone from top to bottom. This includes leadership down to every level of your business. The people closest to an actual task are most impacted by unsafe work behaviors. They are also best suited to help ensure behaviors stay safe.

How we can help                                                          

·        Online/Onsite Behavior-Based Safety Training

·        Safety Culture Survey

·        Audit and Documentation

·        Implementation