API RP-750

Objective of Process Hazard/Safety Management (PSM) is prevention of catastrophic release through :

1) 2) 3) 4) 5) 6) 7) Process Safety Information (PSI) Process Hazard Analysis Management of Change (MOC) Operating Procedures Safe Work Practices Training Assurance of quality and mechanical integrity of critical equipment Pre-Start-Up Safety Review (PSSR) Emergency Response and Control Investigation of process-related incidents Audit of PSM systems

8) 9) 10) 11)

Principle of This Recommended Practice (RP)

PSM is an integral part of the design, construction, maintenance and operation of facility

The RP is intended for facility that use, produce, process or store following substance:
Flammable or explosive substance quantity and condition that a sudden cause catastrophic release Toxic substance that have Substance Hazard Index (SHI) greater than 5000 and present in amount above treshold quantity

This RP is developed for refineries, petrochemical operation and major processing facilities, except:
Distribution, retail and jobber operations (contractor) LNG facilities, pipeline and transportation by US DOT Oil & Gas well drilling, services and production covered by US Mineral Management Services (MMS) Storage of flammable or combustible nonreactive, bulk liquid at atmospheric pressure without benefit of chilling or refrigerant Storage of hydrocarbon fuel solely for on-site consumption Natural Gas processing excluded process with extraction process of LPG

PSI element :
Process Design Information
PFD, process chemistry, maximum intended inventory, acceptable upper and lower limit i.e. temperature, pressure, flow Process Design information could be developed in conjuction with Process Hazard Analysis

Mechanical Design Information

material of construction, P&ID, Electrical Are Classification, design and basis of relief system, design of ventilating system, description of shutdown and interlock Mechanical design information could be developed from available equipment and inspection records

Purpose of PHA
Minimize likelihood of occurance and consequences

Methodology
General Identification Assessment Alternative

Initial Analysis : existing and new facilities Periodic Analysis : 3-10 years Analysis Team
Knowlegeabele person in engineering, process, prod.

Type of Change

Change in Technology, i.e. Change in Facilities, i.e.

Bypass connection, change operating procedure Temporary connection, replacement of equip.different from original

Procedure should consider :

Process and mech.design basis for proposed change Analysis of HSE consideration, incl.PHA Necessary modification of operating procedures Communication of proposed change and consequence Required authorization Duration of change

Written Procedure should incl :

R&R of facilities operating area Clear instruction ~ PSI Operating Condition and steps of operation
Initial S/U, normal op.,S/D, emergency, S/U during T/A

Operating limit where consideration are present

Steps required to avoid deviations, function of safety system

OHS Consideration, i.e. MSDS explanation

Operation procedure before start up Review periodically : 3 5 years

SWP for Operation, maintenance, and modification activities

Opening Equipment, LOTO, Confined Space

Control of Material
Specification and inventories critical to process safety QC procedure should be established to ensure all materials received and used meet the specifications

Initial Training
Required knowledge and skill for all personnel to carry out duty and responsibility, incl. S/U and S/D

Communication of Change
To all operating personnel before operate the facility

Periodically, at least per 3 year

Procedure to ensure adequate retention of required knowledge and skills

Qualified Instructor Documented

 Critical equipment: designed, fabricated, installed and maintained in a manner

Written QC procedure during Fabrication Checks and Inspection before start up (installation) Ensure Mechanical Integrity in Maint.System:
Maintenance procedure and work practice (API 2007) Training of maintenance team prior procedure application QC procedure to ensure maintenance material and spare equipment and part as per design Procedure to ensure maintenance employee and contractors are qualified Procedure to ensure change are review & implemented

PSSR performed for new and modified facility PSSR element :

Construction is in accordance w/ specification Safety, Operating, Maintenance and Emergency Procedure are in place, as appropriate PHA recommendation already considered and completed Training of operating personnel has been completed

Emergency Action Plan following

Emergency Control Center, equipped w/:

OSHA 1910.38(a) Employee Emergency Plan and fire prevention plans OSHA 1910.120 Hazardous Waste Operation and Emergency Response If Fire Brigade established, OSHS 1910.156 Fire Brigade Plant Layout and Community Plan Utility drawing, included fire-water system Emergency Lighting Emergency Communication Reference : plan, MSDS, phone number List of emergency equipment (location), mutual aid info Access to meteorogical

Finding of investigation should be kept by facility for possible use in next PHA update Management system to determine and document finding f/u

To ensure effectiveness of performance 1-10 Audit interval 3-5 years Audit team : knowleageable in process and specialist deemed necessary f/u Report to Management