Process Safety Management Dynamics AX

Process Safety Management Dynamics AX

By Randy Goldbeck, Fullscope Services Director

 

Whatever business you are in, there is always the possibility of an accident or damage to someone's health. All work exposes people to hazards: manually handling loads, dangerous machinery, toxic substances, electricity, display screen equipment or even psychological hazards such as stress.

 
Thanks to the systems of prevention that are in place, there haven’t been more accidents and diseases in the workplace. But safety does not come about by accident: most accidents happen because they have not been prevented. Despite all the precautions that are taken, there are still thousands of workplace injuries every year.

 
In this Blog series, we will focus on the major elements of a Process Safety Program and how Dynamics AX can help your company setup a Process Safety Management system to provide for a better work environment.
The major objective of Process Safety Management (PSM) is to prevent unwanted hazardous conditions that could expose employees and others to serious dangers. An effective process safety management program requires a systematic approach to evaluating the whole process. Using this approach, the process design, technology, changes, operational and maintenance activities, non-routine activities, emergency preparedness plans and procedures, training programs, and other elements that affect the process are all considered in the evaluation. The purpose of the standard as a whole is to aid employers in their efforts to prevent or mitigate hazards that could lead to accidents in the workplace and possibly in the surrounding community.

 
To control these types of hazards, employers need to develop the necessary expertise, experience, judgement, and initiative within their work force to properly implement and maintain an effective process safety management program as envisioned in the Occupational Safety and Health Administration (OSHA) standard.

 

Safety Management Area Description Dynamics AX Feature
1.

Hazards of chemicals used in the process.

Complete and accurate written information concerning process chemicals, technology, and equipment is essential to an effective process safety management program and to a process hazard analysis. Formulas and Document Management
2.

Technology of the Process.

Process technology information is a part of the process safety information package and should include employer-established criteria for maximum inventory levels for process chemicals. Formulas

Bills of Materials

Production Routes

 

3.

Equipment in the Process.

Diagrams are used to describe the relationships between equipment and instrumentation as well as other relevant information that will enhance clarity. Document Management
4.

Employee Involvement.

Train employees regarding their efforts in developing and implementing the process safety management program elements and hazard assessments
  • Human Resources
  • Workers
  • Injury and Illness
  • Absence
  • Skills Analysis
5.

Process Hazard Analysis.

A process hazard analysis (PHA), or evaluation, is one of the most important elements of the process safety management program. Used to identify and analyze the significance of potential hazards associated with the processing or handling of highly hazardous chemicals Questionnaire

 

6.

Operating Procedures.

Operating procedures describe tasks to be performed, data to be recorded, operating conditions to be maintained, samples to be collected, and safety and health precautions to be taken Production Routes

Document Management

7.

Employee Training.

All employees, including maintenance and contractor employees involved, need to fully understand the safety and health hazards of the processes they work with so they can protect themselves, their fellow employees, and the citizens of nearby communities Human Resources
  • Workers
  • Skills Analysis
  • Courses
8.

Contractors.

Employers who use contractors to perform work in and around processes that involve highly hazardous chemicals have to establish a screening process so that they hire and use only contractors who accomplish the desired job tasks without compromising the safety and health of any employees at a facility Human Resources
  • Contractors
  • Skills Analysis
  • Courses
9.

Pre-Startup Safety Review.

For new processes, the employer will find a PHA helpful in improving the design and construction of the process from a reliability and quality point of view. Questionnaire

 

10.

Mechanical Integrity of Equipment.

Employers must review their maintenance programs and schedules to see if there are areas where "breakdown" is used rather than the more preferable on-going mechanical integrity program Questionnaire

Quality testing

 

11.

Written Procedures.

Compile and categorize a list of process equipment and instrumentation included in the program. Document Management
12.

Quality Assurance.

A quality assurance system helps ensure the use of proper materials of construction, the proper fabrication and inspection procedures, and appropriate installation procedures if applicable Quality Management:
  • Certified of Analysis/Assurance
  • Nonconformance tag
  • Corrective actions
13.

Inspection and Testing.

The mean time to failure of various instrumentation and equipment parts would be known from the manufacturer's data or the employer's experience with the parts, which then influence inspection and testing frequency and associated procedures. Questionnaire

Quality Management:

  • Certified of Analysis/Assurance
  • Nonconformance tag
  • Corrective actions
14.

Non-routine Work Authorizations.

Non-routine work conducted in process areas must be controlled by the employer in a consistent manner  
15.

Managing Change.

To properly manage changes to process chemicals, technology, equipment and facilities, one must define what is meant by change. In the process safety management standard, change includes all modifications to equipment, procedures, raw materials, and processing conditions other than "replacement in kind." Formulas

Bills of Materials

Production Routes

 

16.

Incident Investigation.

Incident investigation is the process of identifying the underlying causes of incidents and implementing steps to prevent similar events from occurring. Cases

Activities

Questionnaire

17.

Emergency Preparedness.

Each employer must address what actions employees are to take when there is an unwanted release of highly hazardous chemicals. Document Management
18.

Compliance Audits.

An audit is a technique used to gather sufficient facts and information, including statistical information, to verify compliance with standards. Employers must select a trained individual or assemble a trained team to audit the process safety management system and program. Questionnaire

Quality Management

Audit Workbench

19.

Planning.

Planning is essential to the success of the auditing process. During planning, auditors should select a sufficient number of processes to give a high degree of confidence that the audit reflects the overall level of compliance with the standard Questionnaire

Quality Management

Audit Workbench

20.

Staffing.

The selection of an effective audit team is critical to the success of the program. Team members should be chosen for their experience, knowledge, and training and should be familiar with the processes and auditing techniques, practices, and procedures. Human Resources
  • Workers
  • Skills Analysis
  • Courses
21.

Conducting the Audit

An effective audit includes a review of the relevant documentation and process safety information, inspection of the physical facilities, and interviews with all levels of plant personnel. Questionnaire

Quality Management

Audit Workbench

22.

Evaluation and Corrective Action.

The audit team, through its systematic analysis, should document areas that require corrective action as well as where the process safety management system is effective. Quality Management:
  • Certified of Analysis/Assurance
  • Nonconformance tag
  • Corrective actions

 

 

 

 

 


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