PSM Hazard Identification For All Industries

1
PSM Hazard Identification For All Industries
Halliburton Bryan Wollam
HSE Operational Excellence Manager Work
Phone [phone] bryan.wollam_at_halliburton.com

• FIVE STEPS to EXCELLENCE

2
JRC International Recognition 1st Company
Globally to obtain Trilogy RC
Certification ISO 9001-2008 QMS ISO 14001-2004
EMS OHSAS 18001-2007 HSMS ISO RC14001-2008
RCMS VPP Star of Excellence
3
Center of Excellence

• Jet Research Center
• A VPP Star of Excellence Site
• An OSHA VPP Benchmark
• Mentorship Site
• for the
• US Department of Defense (DoD)
• NAS-JRB

4
Process Hazard Analysis

• OSHA Process Hazard Analysis more effective than,
  JHA, JSA, HACCP, FMEA, SVA.
• Aligns with ISO 9001, ISO 14001, OHSAS 18001,
  ACC/ISO RC14001, ISO 2800.
• Meets criteria established by OSHA, DHS, NRC,
  EPA, DOT, MSHA, FDA.
• Meets OSHA VPP Requirements
• Management Leadership and Employee Involvement
  Planning Contractor Safety Annual Evaluation
  Pre-Use Analysis Safety and Health Surveys
  Hazard Reporting, Analysis, Control, and
  Elimination Accident/Incident Investigations
  Predictive Maintenance PPE Training and PSM

5
Management of Change A Five Step Process
Process Safety Information PSI
Process Hazard Analysis PHA
VALIDATION Follow-Up Establish Metrics for
Sustainability
Management of Change Evaluation MOC
Pre-Start Up Q HSE Review PSR
Process Information
Process Analysis
Process Review
MOC
SMART
MOC is a Continual Improvement Process
6
PSI

• STEP 1
• Process
• Safety
• Information

• Equipment Specification
• MSDS Information
• Current State
• Future State
• Customer Expectations
• Tact Time / Demand
• Ergonomics
• Product Materials
• Facility Layout
• Site Sitting
• Employee Competencies

7
PSI MOC

• Operating Limits
• Min/Max Specifications
• Consequences
• Controls

• Operating Phase
• Normal Start Up
• Work Methods
• Emergency Shutdown

• STEP 2
• Management
• of
• Change

• Training/Communication
• Operators Trained
• Contractors Trained
• Maintenance Trained
• Affected Employee Com.

• Hazardous Material
• Toxicity Information
• PEL/TWA
• Corrosive/Physical
• Thermal/Chemical Sta.

Current State Future State

• Technology Information
• Process Flow Diagram
• Product Prints
• Temp/pressure/flow
• Max Intended Inventory

• Equipment Information
• Material Construction
• PID/Electrical Diagrams
• Codes Standards
• Relief System Design

8
Management of Change
9
PSI MOC PHA

• Identify all Aspects
• Analyze the Impacts (Safety)
• Likely Hood, Exposure, Injury Severity
• Legal Consequences
• Company Reputation
• Establish and Rank the Controls
• Tolerate, Terminate, Treat, Transfer
• Types You cannot control what you do not know.
• Health Safety Aspects, Impacts Controls
• Environmental Aspects, Impacts Controls
• Quality Aspects, Impacts Controls

• STEP 3
• Process
• Hazard
• Analysis

Aspects, Impacts Controls
ELIMINATE/MINIMIZE YOUR BUSINESS RISK
10
Health and Safety PHA
11
Environmental PHA
12
Quality PHA
13
PSI MOC PHA PSR

• STEP 4
• Pre-Start
• Up
• Safety
• Review

• Completed in Stages
• Initial Testing Prior to Ops.
• Validates Controls
• All critical items completed prior to turning
  new/modified process to operations.
• All other items placed in your Corrective Action
  System and given reasonable business suspense
  dates.
• Involves
• HSE/Quality
• Engineering
• Operations

14
PSI MOC PHA PSR Validation

• STEP 5
• Validation
• Establish
• Metrics
• for
• Sustainability

• If you cant measure it you can not control it.
• Critical for Sustainability
• Crucial for administrative and behavior type
  controls.
• Recommend employees being involved in metrics.
• SQDC (Safety, Quality, Delivery, Cost Boards).
• May be eliminated once sustainability is
  validated.
• Results being realized in terms of SQDC.

15
Process Hazard Analysis

• It is the process from Conception to Deliver.
• Promotes Continual Improvement.
• Compliments Lean, Kaizen, Six Sigma, Quality.
• If done correctly, will eliminate business and
  employee risk.
• Establish controls for those risk that are not
  economically feasible to eliminate.
• Minimize Duplication of Efforts

16
Correlating PSM to ISO
17
Correlating PSM to Federal Regulatory Requirements
18
Management of Change A Five Step Process
Process Safety Information PSI
Process Hazard Analysis PHA
VALIDATION Follow-Up Establish Metrics for
Sustainability
Management of Change Evaluation MOC
Pre-Start Up Q HSE Review PSR
Process Information
Process Analysis
Process Review
MOC
SMART
MOC is a Continual Improvement Process
19
PSM Hazard IdentificationFor All Industries

• QUESTIONS??