化工与化学制药行业EHS与PSM管理

OverviewHSE/PSMforChemicalIndustryMr.GaoBoContact:139-17-242-130Sep.2012I

ObjectiveItisanawarenesstrainingprogram.Thecourseaimstohelpnon-EHSprofessionalstounderstandthebasicEHSconceptinchemicalindustryandestablishbasicknowledgeofEHSmanagement.Thecoursewilllast2hours.Afterthecourse,thelearnerwill•

understandtheimportanceofEHSinchemicalindustry•

gettoknowtheoverviewofEHSmanagementin

chemicalindustryOverviewEHSManagementforChemical

Industry2II

ContentOverviewEHSManagementforChemical

Industry3III

Definition•

AIChE:

AmericanInstituteofChemicalEngineers•

CCPS:

CenterforChemicalProcessSafety•

CSB:

U.S.ChemicalSafetyandHazardInvestigation

Board•

CSR:

CorporateSocialResponsibility•

EHS:

Environment,IndustrialHygieneandSafetyManagement•

FTA:

FaultTreeAnalysis•

GMP:

GoodManufacturingPractice•

Hazop:

HazardandOperabilityAnalysis•

IH:IndustrialHygieneU.S.NationalInstituteofOccupationalSafety&•

NIOSH:Health•

OSHA:

U.S.OccupationalSafetyandHealthAdministration•

PS:

ProductStewardship•

PSM:

ProcessSafetyManagementOverviewEHSManagementforChemical

Industry41Importanceof

EHSOverviewEHSManagementforChemical

Industry51.TheImportanceof

EHSBhopal,India1984DuringthenightofDecember2-3,1984,astoragetankcontainingmethylisocyanate(MIC)attheUnionCarbidepesticideplantleakedgasintothedenselypopulatedcityofBhopal,India.Itwasoneoftheworstindustrialaccidentsinhistory.Estimatesofthedeathtollvarygreatly.Mostsourcessayatleast3,000peoplediedfromimmediateexposuretothegas,whilehigherestimatesgoupto8,000.Inthetwodecadesfollowingthenightofthedisaster,approximately20,000additionalpeoplehavediedfromthedamagetheyreceivedfromthegas.OverviewEHSManagementforChemical

Industry61.TheImportanceof

EHSHebeiKeeperChemicalPlant,Feb.29th201216killed,and43injuredandhospitalizedOverviewEHSManagementforChemical

Industry71.TheImportanceof

EHSHeinrichPyramidOverviewEHSManagementforChemical

Industry81.TheImportanceof

EHSTheRealCostsofaccidentsNotonlytheinsurablecosts•

Reputation•

Productioncontinuity•

Crisis•

Debt•

BankruptIcebergofAccidentOverviewEHSManagementforChemical

Industry92OverviewEHSManagementOverviewEHSManagementforChemical

Industry102.OverviewofEHSManagementTheLogicofEHSManagementActionCheckDoPlanOverviewEHSManagementforChemical

Industry112.OverviewofEHSManagementRiskBasedEHSManagementOverviewEHSManagementforChemical

Industry122.OverviewofEHSManagementEHSManagementCycleOverviewEHSManagementforChemical

Industry132.OverviewofEHSManagementTheBroaderSenseofEHS1.ProcessSafety2.OccupationalSafety&Health3.EnvironmentManagement4.ProductStewardship5.Warehouse&TransportSafety6.CommunityAwareness7.Security8.CorporateSocialResponsibilityOverviewEHSManagementforChemical

Industry142.OverviewofEHSManagementKeyProcedureofEHSManagementOverviewEHSManagementforChemical

Industry152.OverviewofEHSManagementKeyProcedureofEHSManagementOverviewEHSManagementforChemical

Industry162.OverviewofEHSManagementLevel1Level2Level3Localproceduresandpractices(design,maintenance

&operation)AccidentsPreventionControlsMitigationControlsMAPotentialHowEHSManagementWorksOverviewEHSManagementforChemical

Industry17全面损失控制管理EHSR法律法规符合性危害识别与风险评估监管产品工艺安全企业社会责任员工职业健康与安全CSR环境管理C环境企业社会责任CSR管理安防产品监管A工艺安全产品储运安全社区意识3ProcessSafetyManagementOverviewEHSManagementforChemical

Industry193.ProcessSafetyManagementWhatIsChemicalProcessinPSM?OverviewEHSManagementforChemical

Industry203.ProcessSafetyManagementExampleofaSimplifiedProcessFlowDiagramOverviewEHSManagementforChemical

Industry213.ProcessSafetyManagementWhatIsProcessSafetyManagement?ProcessSafetyManagementistheapplicationofmanagementprinciplesandsystemsto

theidentification,understanding,andcontrolofprocesshazardstoprotectemployees,facilityassetsandtheenvironment.OverviewEHSManagementforChemical

Industry223.ProcessSafetyManagementWhyProcessSafetyManagementIsVital?•

ProcessSafetyManagementcontainsrequirementsforpreventingorminimizingtheconsequencesofcatastrophicreleasesofchemicalsthatare:•Toxic•

Reactive•

Flammable•

Explosive•

Thesereleasesmayresultintoxic,fireorexplosionhazards•

Anumberofcatastrophicaccidentshaveoccurredresultinginlossoflifeandgreatpropertydamage.OverviewEHSManagementforChemical

Industry233.ProcessSafetyManagementProcessAccidentLeadstoDisasterBhopal,India(1984)•

2,000deathsIsocyanatereleasePasadena,TX(1989)•

23deaths,132injuriesPetroleumexplosionCincinnati,OH(1990)•

2deathsExplosionSterlington,LA(1991)•

8deaths,128injuriesChemicalreleaseOverviewEHSManagementforChemical

Industry243.ProcessSafetyManagementCausesoftheProcessAccidentFlixborough1974•

Managementofmodificationfailure•

Inadequateexperience•

OverstretchedresourcesPiperAlpha1988•

Failuresinshifthandover•

Permittowork•

Training•

Communications•

AuditingOverviewEHSManagementforChemical

Industry253.ProcessSafetyManagement光气及光气化工艺Phosgenationprocess重氮化工艺Diazotizationprocess123456789电解工艺（氯碱）chlor-alkaliproduction氧化工艺Oxidationprocess101112131415氯化工艺Chlorinationprocess过氧化工艺Peroxidationprocess硝化工艺Nitrificationprocess胺基化工艺Aminationprocess合成氨工艺Ammoniacalsynthesisprocess磺化工艺Sulfonationprocess裂解（裂化）工艺Crackingprocess聚合工艺PolymerizationProcess氟化工艺Fluorinationprocess烷基化工艺AlkylationProcess加氢工艺HydrogenationprocessChinaRegulated

HighRiskProcessOverviewEHSManagementforChemical

Industry263.ProcessSafetyManagement14ElementsofPSM01.ProcessSafetyInformation02.ProcessHazardAnalysis03.OperatingProcedures04.EmployeeParticipation05.Training06.Contractors07.Pre-StartupSafetyReview08.

MechanicalIntegrity09.HotWorkPermit10.

ManagementofChange11.

Incident

Investigation12.EmergencyPlanningandResponse13.ComplianceAudits14.TradeSecretsAdobe

AcrobatDocumentOSHA3132OverviewEHSManagementforChemical

Industry273.ProcessSafetyManagementPSMStructureOverviewEHSManagementforChemical

Industry283.ProcessSafetyManagement3.1ProcessSafetyInformation•

MaterialSafetyDataSheets(MSDS)•

Pipingandinstrumentationdiagrams(P&IDs)•

Blockflowdiagrams•

Materialandenergybalancecalculations•

Relevantconsensusstandards•

Materialsofconstruction•

AvailabletoallaffectedP&IDSampleemployees•

AvailableforProcessHazardAnalysisandrevalidationsOverviewEHSManagementforChemical

Industry293.ProcessSafetyManagement3.2ProcessHazardAnalysis•

ArguablytheMostDifficultPartofPerformingtheStandard•

PHAprocessisdynamicandsubjecttorevisionwheneverchangesaremade•

PerformedbyYourPSMTeam•

TakesSignificantTime&Effort•

PHA’sareNeverEnding•

What-if•

Hazop•

FTA•

PHASoftwarePHAWorks5.0OverviewEHSManagementforChemical

Industry303.ProcessSafetyManagement3.3OperatingProcedures•

StandardOperatingProcedures•

DointandemwithJobHazardAnalysis(JHAs)•

Meshwithtrainingprogram•

PartnerwithQualityTeam(ISO9001)tocreatetrainingmatrixandmanageddocumentsOverviewEHSManagementforChemical

Industry313.ProcessSafetyManagement3.4EmployeeParticipation•

Employeesarerequiredtobeanactivepartoftheprocessandyourwrittenprogramsneedtodocumentwhatrolesemployeesplay,theirinvolvementinthedevelopmentoftheprograms,andcontinuingparticipationintheprocess.•

Participationwithtrainingandsupervisiontodeterminethefrequencyandcontentofinitialandrefreshertraining.•

Participationtodevelopandreviewoperatingandmaintenanceprocedures.•

Participationinincidentinvestigationsregardingthecoveredprocess.OverviewEHSManagementforChemical

Industry323.ProcessSafetyManagement3.5Training•

Theemployershallpreparearecord:a.

Identityofemployeeb.

Dateoftrainingc.

Meanstoverifythatemployeeunderstoodtraining•

Ataminimum,refreshertrainingshallbeprovidedatleasteverythreeyearsandmoreoftenifnecessarytoeachemployeeinvolvedinoperatingaprocess.OverviewEHSManagementforChemical

Industry333.ProcessSafetyManagement3.6Contractors•

EmployerDocumentation:•

Contractemployeeinjuryandillnesslogsrelatedtoworkincoveredprocessareas.•

ContractEmployerDocumentation:•

Recordsshowingemployeesreceivedtraininginandunderstandssafeworkpracticesrelatedtotheprocessonornearwheretheywillbeworkingsotheyperformtheirjobssafely.OverviewEHSManagementforChemical

Industry343.ProcessSafetyManagement3.7Pre-StartupSafetyReview•

Check,doublecheck,andreviewanychanges,modifications,additionsmadeinaPSMcoveredarea–beforeyoufliptheswitch.OverviewEHSManagementforChemical

Industry353.ProcessSafetyManagement3.8MechanicalIntegrityTheemployershalldevelopandmaintainamasterlistofallequipmentspecificallycoveredbythestandard,andequipmentthatisimportanttosafetyof

theprocessandconductpreventivemaintenance.•Pressurevesselsandstoragetanks•Pipingsystemsincludingvalvesandotherpipingcomponents•Reliefandventsystemsanddevices•Emergencyshutdownsystems•Controls(includingmonitoringdevicesandsensors,alarms,andinterlocks)•Pumps•Rotatingequipment•Heatexchangeequipment•Electricalgenerationanddistributionequipment•Un-interruptablepowersupplies•Emergencypower

supplyequipment•FireprotectionequipmentOverviewEHSManagementforChemical

Industry363.ProcessSafetyManagement3.9HotWorkPermit•

Welding,cutting,braising–makesureonlytrainedpersonnelperformthesefunctions•

Havetrainedfirewatchers(alignwithfireextinguisher/fireresponsetraining)OverviewEHSManagementforChemical

Industry373.ProcessSafetyManagement3.10ManagementofChangeRelatedto:•

PSI•

MechanicalIntegrity•

P&IDs•

HotWork•

ContractorSafety•

EmployeeTraining•

PSSRCreateformalizedsystemtoreviewallchangestoprocessareasincluding:•

Rawmaterialchanges/substitutions•

Personnelchanges•

OperatingProcedures•

Processparameters•

Facilitychanges(HVAC/roof/fireprotection/ꢀꢀ..)OverviewEHSManagementforChemical

Industry383.ProcessSafetyManagement3.11IncidentInvestigationInvestigateIncidents&Beginwithin48-hoursNear-MissesIncidentInvestigationTeamwithProcessKnowledgeReatainReports5-yearsFollow-upSystemforRecommendationsReportwithConclusions&RecommendatonsOverviewEHSManagementforChemical

Industry393.ProcessSafetyManagement3.12EmergencyPlanningandResponseCallinallresourcesandmakeplancomprehensive:•

InformationTechnology(IT)DisasterRecoveryPlan•

BusinessContinuity•

Security•

Communications/PublicRelations•

EmployeeAssistanceOverviewEHSManagementforChemical

Industry403.ProcessSafetyManagement3.13ComplianceAudits•

ToensurethatPSMiseffective,employersmustcertifyevery3yearsthattheyhaveevaluatedcompliancewiththestandard•

Mustbecompletedbyatleastonpersonknowledgeableintheprocess•

Reportmustbedevelopedanddocumented•

Deficiencycorrectionsmustbedocumented•

LasttwocomplianceauditsmustbekeptonfileOverviewEHSManagementforChemical

Industry413.ProcessSafetyManagement3.14TradeSecrets•

EmployersmustmakeallnecessaryinformationrequiredtocomplywithPSM,regardlessoftradesecrets,availabletopersonsinvolvedindevelopingorcreating:a.

Compilingprocesssafetyinformationb.

PHAsc.

SOPsd.

Incidentinvestigationse.

Emergencyplanningandresponsef.

Complianceaudits•

ConfidentialityagreementsareallowedOverviewEHSManagementforChemical

Industry424OccupationalSafetyandHealthOverviewEHSManagementforChemical

Industry434.OccupationalSafetyandHealth01.OccupationalSafety&HealthElementsofOccupationalSafety&HealthLegislationManagement02.HazardIdentificationandAssessment03.JobSafetyAnalysis04.HazardCommunication05.IndustrialHygiene&Ergonomics06.ChemicalManagement07.PersonalProtectiveEquipment(PPE)08.Lockout/Tagout09.PermittoWork(PTW)10.FirstAidOverviewEHSManagementforChemical

Industry444.OccupationalSafetyandHealth4.1OccupationalSafety&HealthLegislationManagementOverviewEHSManagementforChemical

Industry454.OccupationalSafetyandHealth4.2HazardIdentificationandAssessmentThebasicapproachofhazardidentification:•Jobhazardanalysis•FEMA•BrainStormOverviewEHSManagementforChemical

Industry464.OccupationalSafetyandHealth4.3JobSafetyAnalysisOverviewEHSManagementforChemical

Industry474.OccupationalSafetyandHealth4.4HazardCommunication•

Hazardwarningtag•

PPEalertingtag•

MSDS•

Labelonchemicalcontainer•

Periodicaltraining/meetingonsafetyOverviewEHSManagementforChemical

Industry484.OccupationalSafetyandHealth4.5

IndustrialHygiene&ErgonomicsAcute

Result

——

OccupationalSafetyChronicResult——

OccupationalHealth•

Legalrequirements•

RegulatedIHhazard•

IHhazardidentification•

ExposuremonitoringandcomparewithOEL/STEL•

ExposureControl•

Periodicalcontroleffectassessment•

Periodicalpersonneloccupationalhealthexam•

PeriodicaltrainingOverviewEHSManagementforChemical

Industry494.OccupationalSafetyandHealth4.6ChemicalManagement•

Chemicalprocurement•

ChemicallistandMSDS•

Labelonchemicalcontainer•

Chemicaltransportation•

Chemicalloading/unloading•

Chemicalstorage:warehouse/tankfarm•

Thesafetyduringuseofchemicals•

Wastechemicalmanagement•

FirstAidofchemicalburning•

Emergencyresponseonspill,leakage,fire,explosionOverviewEHSManagementforChemical

Industry504.OccupationalSafetyandHealth4.7PersonalProtectiveEquipment(PPE)•

Relatedtoriskassessment•

PPEdemandidentification•

RiskbasedPPEselection•

PPEMatrix•

PPEprocurement•

PPEdistributedtoemployees•

TrainingonuseofPPE•

ThemaintenanceofPPE•

ThePPEeffectivenesstesting•

RefresherofPPEOverviewEHSManagementforChemical

Industry514.OccupationalSafetyandHealth4.8Lockout/Tagout6stepsforthecontrolofdangerousenergyduringmaintenance/repairing/testing•

Preparationforshutdown•

Shutdowntheequipment•

Isolatetheequipment•

Applylockout/tagoutdevices•

Controlstoredenergy•

VerifyisolationofequipmentOverviewEHSManagementforChemical

Industry524.OccupationalSafetyandHealth4.9PermittoWork(PTW)Forhighrisktasks,PTWsystemisimplemented.•

Hotwork•

Workatheight•

Enteringconfinedspace•

Excavation•

Temporaryelectricity•

OtherdefinedhighrisktasksOverviewEHSManagementforChemical

Industry534.OccupationalSafetyandHealth4.10FirstAid•

FirstAidkit•

Firstaidfacilities•

On-sitedoctor/nurse•

Firstaidtraining•

FirstaiddrillFirstaidcannotreplacehospitalmedicaltreatmentOverviewEHSManagementforChemical

Industry545EnvironmentManagementOverviewEHSManagementforChemical

Industry555.EnvironmentManagement01.WasteWaterManagement02.SolidWasteManagement03.Off-gasManagement04.NoiseonBoundaryofSiteManagement05.