• Gap assessment of existing process safety management systems to requirements of US OSHA 1910.119 PSM Rule and Risk Based PSM of CCPS, USA

  • Implementation of Risk Based Process Safety Management (PSM) System as per US OSHA 1910.119 PSM Rule and best practices of Risk Based PSM

  • Integration of Risk Based PSM system with existing OHSAS 18001/  ISO 14001 systems

  • Setting up foolproof system for Management of Change

  • Asset Integrity and Quality Assurance program development 

  • Emergency and Crisis Management System audit

  • Setting up of a comprehensive Incident Investigation system based on Root Cause analysis.

  • Setting up Work Permit Systems including the following:

    Confined space entry
    Hot work
    Working at heights
    Electrical energy lock out and tag out
    Feeder lock out and tag out
    Hazardous Energy lock out and tag out
    Cold work 
    Pipeline breaking / equipment opening
    Fire water system lock out 
    Emergency fire system closure
    Working on fragile roof

    About the Risk Based PSM System:

    The Risk Based Process Safety Management System as per US OSHA CFR 1910.119 PSM rule and best practices is a comprehensive management system that proactively avoids incidents in Oil and Gas, Petroleum refining, Petrochemicals, Fertilizers, Pesticides, Organic, Inorganic and specialty chemicals, Pharmaceuticals plants that handle, store or process toxic or flammable chemicals.

    These chemicals, if released, could have a major impact on workers, surrounding communities, or facilities. The consequences of these incidents have significant life-safety, environmental, legal, regulatory and financial consequences.

    Risk Based Process Safety Management System integrates all aspects of risks in a facility and puts them under the control of a management system. By establishing a heightened awareness of the safety impacts of technology, personnel and the management, the system provides a dynamic environment for continual improvement.

    In India, a growing number of factories covered under the Manufacture, Storage and Import of Hazardous Chemical rules, 1989 are voluntarily adopting this system. 

    Signatories to the Indian Chemical Council’s (ICC) Responsible Care® movement can demonstrate their public commitment, by voluntarily adopting the Process Safety Management System as per the Process Safety Code of the Responsible care program.

    Use Prism Consultants unique expertise:

    PRISM consultants have hands on experience in implementing the Process Safety Management System (PSM) in Fertilizer, Refineries, Pesticides and Petrochemical plants in India and abroad. 

    The Risk based Process Safety Management System consists of 20 elements:

  • Top Management Involvement and Commitment

  • Institutionalizing Risk Based Approach

  • Process Safety Knowledge Management

  • Process Safety Competency

  • Employee participation

  • Process Safety Information

  • Process Hazard Analysis

  • Operating Procedures

  • Management of Change

  • Pre-Start up Safety Review

  • Safe work practices (Work Permit Systems)

  • Training

  • Asset integrity

  • Contractor control

  • Process Incident Investigation

  • Emergency response planning

  • Measurement and Metrics

  • Compliance audits

  • Trade secrets

  • Management Review

    Benefits of the Risk Based Process Safety Management System:

  • Proactive management system, focuses on avoiding incidents.

  • Safer workplace for employees.

  • Reduced risk of adverse environmental impact.

  • Compliance with current industry codes, standards and practices.

  • Reduces downtime and losses.

  • Reduces risk to nearby communities.

  • Integrates with existing quality, environmental and safety management systems.

  • Is viewed favorably by external interested parties like Factory Inspectorate and Pollution Control Boards.

  • Implementation based on Deming’s cycle of Plan, Do, Check, Act.
    Continual improvement possible by utilizing performance metrics for measuring the performance of the system.

  • Total employee involvement in implementation of system makes the system sustainable.

  • Very powerful risk management tool.

  • Implementation based on World Class OSHA's (Occupational Safety and Health Administration, USA) standards CFR 1910.119 and Best Practices.

  • Integrates effectively with Environmental Management System ISO 14001 and OHSAS  18001 as part of "other requirements" in clause 4.3.2 - Legal and other requirements.

  • In organizations that have implemented OHSAS 18001 (Occupational safety and health standard) and handle hazardous or toxic chemicals, implementation of the Process Safety Management System brings the process associated risks under control. 

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