化工与化学制药行业EHS与PSM管理

Overview HSE/PSM for Chemical IndustryMr. Gao Bo Contact: 139-17-242-130 Sep. 2012IObjectiveIt is an awareness training program.The course aims to help non-EHS professionals to understand the basic EHS concept in chemical industry and establish basic knowledge of EHS management. The course will last 2 hours. After the course, the learner will • understand the importance of EHS in chemical industry • get to know the overview of EHS management in chemical industryOverview EHS Management for Chemical Industry2IIContentOverview EHS Management for Chemical Industry3III• • • • • • • • • •DefinitionAIChE: American Institute of Chemical Engineers CCPS: Center for Chemical Process Safety CSB: U.S. Chemical Safety and Hazard Investigation Board CSR: Corporate Social Responsibility EHS: Environment, Industrial Hygiene and Safety Management FTA: Fault Tree Analysis GMP: Good Manufacturing Practice Hazop: Hazard and Operability Analysis IH: Industrial Hygiene NIOSH: U.S. National Institute of Occupational Safety & Health • OSHA: U.S. Occupational Safety and Health Administration • PS: Product Stewardship • PSM: Process Safety ManagementOverview EHS Management for Chemical Industry41Importance of EHSOverview EHS Management for Chemical Industry51. The Importance of EHSBhopal, India 1984 During the night of December 2-3, 1984, a storage tank containing methyl isocyanate (MIC) at the Union Carbide pesticide plant leaked gas into the densely populated city of Bhopal, India. It was one of the worst industrial accidents in history. Estimates of the death toll vary greatly. Most sources say at least 3,000 people died from immediate exposure to the gas, while higher estimates go up to 8,000. In the two decades following the night of the disaster, approximately 20,000 additional people have died from the damage they received from the gas.Overview EHS Management for Chemical Industry61. The Importance of EHSHebei Keeper Chemical Plant, Feb. 29th 2012 16 killed, and 43 injured and hospitalizedOverview EHS Management for Chemical Industry71. The Importance of EHSHeinrich PyramidOverview EHS Management for Chemical Industry81. The Importance of EHSThe Real Costs of accidentsNot only the insurable costs • Reputation • Production continuity • Crisis • Debt • BankruptIceberg of AccidentOverview EHS Management for Chemical Industry 92Overview EHS ManagementOverview EHS Management for Chemical Industry 102. Overview of EHS ManagementThe Logic of EHS ManagementAction Check Do PlanOverview EHS Management for Chemical Industry112. Overview of EHS ManagementRisk Based EHS ManagementOverview EHS Management for Chemical Industry122. Overview of EHS ManagementEHS Management CycleOverview EHS Management for Chemical Industry132. Overview of EHS ManagementThe Broader Sense of EHS 1. Process Safety 2. Occupational Safety & Health 3. Environment Management 4. Product Stewardship 5. Warehouse & Transport Safety 6. Community Awareness 7. Security 8. Corporate Social ResponsibilityOverview EHS Management for Chemical Industry142. Overview of EHS ManagementKey Procedure of EHS ManagementOverview EHS Management for Chemical Industry 152. Overview of EHS ManagementKey Procedure of EHS ManagementOverview EHS Management for Chemical Industry 162. Overview of EHS ManagementLevel 1Level 2Local procedures and practices (design, maintenance & operation)Level 3CausesAccidentsPrevention ControlsMitigation ControlsMA PotentialHow EHS Management WorksOverview EHS Management for Chemical Industry 17ConsequencesHazards全面损失控制管理产品监 管EHSR EHSR 法律法规符合性 法律法规符合性危害识别 危害识别 与风险评估 与风险评估社 区 意 识工艺安全 工艺安全防 预 断 中 务 业 与 理 管 机 危企业 社会 责 CS R 任D 安防C 环境 管理储 品 产 安 运 全员工职业 员工职业 健康与安全 健康与安全环境管理 环境管理企业社会责任 企业社会责任 CSR CSR保险 财产员工职业 B 健康 与 安全安防 安防产品监管 产品监管 A 工艺安全 产品储运安全 产品储运安全社区意识 社区意识3Process Safety ManagementOverview EHS Management for Chemical Industry 193. Process Safety ManagementWhat Is Chemical Process in PSM?Overview EHS Management for Chemical Industry203. Process Safety ManagementOverview EHS Management for Chemical IndustryExample of a Simplified Process Flow Diagram213. Process Safety ManagementWhat Is Process Safety Management?Process Safety Management is the application of management principles and systems to the identification, understanding, and control of process hazards to protect employees, facility assets and the environment.Overview EHS Management for Chemical Industry223. Process Safety ManagementWhy Process Safety Management Is Vital?• Process Safety Management contains requirements for preventing or minimizing the consequences of catastrophic releases of chemicals that are: • Toxic • Reactive • Flammable • Explosive • These releases may result in toxic, fire or toxic explosion hazards • A number of catastrophic accidents have occurred resulting in loss of life and great property damage.Overview EHS Management for Chemical Industry233. Process Safety ManagementProcess Accident Leads to DisasterBhopal, India (1984) • 2,000 deaths Isocyanate release Pasadena, TX (1989) • 23 deaths, 132 injuries Petroleum explosion Cincinnati, OH (1990) • 2 deaths Explosion Sterlington, LA (1991) • 8 deaths, 128 injuries Chemical releaseOverview EHS Management for Chemical Industry243. Process Safety ManagementCauses of the Process AccidentFlixborough 1974 • Management of modification failure • Inadequate experience • Overstretched resourcesPiper Alpha 1988 • Failures in shift handover • Permit to work • Training • Communications • AuditingOverview EHS Management for Chemical Industry253. Process Safety Management1 2 3 4 5 6 7 8 光气及光气化工艺 Phosgenation process 电解工艺（氯碱） chlor-alkali production 氯化工艺 Chlorination process 硝化工艺 Nitrification process 合成氨工艺 Ammoniacal synthesis process 裂解（裂化）工艺 Cracking process 氟化工艺 Fluorination process 加氢工艺 Hydrogenation processChina Regulated High Risk ProcessOverview EHS Management for Chemical Industry 269 10 11 12 13 14 15重氮化工艺 Diazotization process 氧化工艺 Oxidation process 过氧化工艺 Peroxidation process 胺基化工艺 Amination process 磺化工艺 Sulfonation process 聚合工艺 Polymerization Process 烷基化工艺 Alkylation Process3. Process Safety Management14 Elements of PSM01. Process Safety Information 02. Process Hazard Analysis 03. Operating Procedures 04. Employee Participation 05. Training 06. Contractors 07. Pre-Startup Safety Review 08. Mechanical Integrity 09. Hot Work Permit 10. Management of Change 11. Incident Investigation 12. Emergency Planning and Response 13. Compliance Audits 14. Trade SecretsAdobe Acrobat DocumentOSHA 3132Overview EHS Management for Chemical Industry 273. Process Safety ManagementPSM StructureCommitment to PSMLearn from ExperienceUnderstand Hazards and RiskManage RiskOverview EHS Management for Chemical Industry283. Process Safety Management3.1 Process Safety Information• Material Safety Data Sheets (MSDS) • Piping and instrumentation diagrams (P&IDs) • Block flow diagrams • Material and energy balance calculations • Relevant consensus standards • Materials of construction • Available to all affected employees • Available for Process Hazard Analysis and revalidationsOverview EHS Management for Chemical IndustryP&ID Sample293. Process Safety Management3.2 Process Hazard Analysis• Arguably the Most Difficult Part of Performing the Standard • PHA process is dynamic and subject to revision whenever changes are made • Performed by Your PSM Team • Takes Significant Time & Effort • PHA’s are Never Ending • What-if • Hazop • FTA • PHA SoftwarePHAWorks 5.0Overview EHS Management for Chemical Industry303. Process Safety Management3.3 Operating Procedures• • • • Standard Operating Procedures Do in tandem with Job Hazard Analysis (JHAs) Mesh with training program Partner with Quality Team (ISO 9001) to create training matrix and managed documentsOverview EHS Management for Chemical Industry313. Process Safety Management3.4 Employee Participation• Employees are required to be an active part of the process and your written programs need to document what roles employees play, their involvement in the development of the programs, and continuing participation in the process. • Participation with training and supervision to determine the frequency and content of initial and refresher training. • Participation to develop and review operating and maintenance procedures. • Participation in incident investigations regarding the covered process.Overview EHS Management for Chemical Industry 323. Process Safety Management3.5 Training• The employer shall prepare a record: a. Identity of employee b. Date of training c. Means to verify that employee understood training • At a minimum, refresher training shall be provided at least every three years and more often if necessary to each employee involved in operating a process.Overview EHS Management for Chemical Industry333. Process Safety Management3.6 ContractorsEmployer Documentation: • Contract employee injury and illness logs related to work in covered process areas.Contract Employer Documentation: • Records showing employees received training in and understands safe work practices related to the process on or near where they will be working so they perform their jobs safely.Overview EHS Management for Chemical Industry343. Process Safety Management3.7 Pre-Startup Safety Review• Check, double check, and review any changes, modifications, additions made in a PSM covered area – before you flip the switch.Overview EHS Management for Chemical Industry353. Process Safety Management3.8 Mechanical IntegrityThe employer shall develop and maintain a master list of all equipment specifically covered by the standard, and equipment that is important to safety of the process and conduct preventive maintenance. •Pressure vessels and storage tanks •Piping systems including valves and other piping components •Relief and vent systems and devices •Emergency shutdown systems •Controls (including monitoring devices and sensors, alarms, and interlocks) •Pumps •Rotating equipment •Heat exchange equipment •Electrical generation and distribution equipment •Un-interruptable power supplies •Emergency power supply equipment •Fire protection equipmentOverview EHS Management for Chemical Industry 363. Process Safety Management3.9 Hot Work Permit• Welding, cutting, braising – make sure only trained personnel perform these functions • Have trained fire watchers (align with fire extinguisher / fire response training)Overview EHS Management for Chemical Industry373. Process Safety Management3.10 Management of ChangeRelated to: • PSI • Mechanical Integrity • P&IDs • Hot Work • Contractor Safety • Employee Training • PSSR • Operating ProceduresCreate formalized system to review all changes to process areas including: • Raw material changes / substitutions • Personnel changes • Process parameters • Facility changes (HVAC / roof / fire protection / HH..)Overview EHS Management for Chemical Industry383. Process Safety Management3.11 Incident InvestigationInvestigate Incidents & Near-MissesBegin within 48-hoursReatain Reports 5-yearsIncident InvestigationTeam with Process KnowledgeFollow-up System for RecommendationsReport with Conclusions & RecommendatonsOverview EHS Management for Chemical Industry393. Process Safety Management3.12 Emergency Planning and ResponseCall in all resources and make plan comprehensive: • Information Technology (IT) Disaster Recovery Plan • Business Continuity • Security • Communications / Public Relations • Employee AssistanceOverview EHS Management for Chemical Industry40Acute Result ——Occupational Safety。