A

SEMINAR REPORT
ON

“PROCESS SAFETY MANAGEMENT IN CHEMICAL

INDUSTRIES”

BACHELOR OF TECHNOLOGY
In
CHEMICAL ENGINEERING

SUBMITED BY
ADIT ANIL SHIRKE
2230331507033

UNDER THE GUIDANCE OF

Prof. POOJA P. SANAP

DEPARTMENT OF CHEMICAL ENGINEERING

DR. BABASAHEB AMBEDKAR TECHNOLOGICAL UNIVERSITY,
LONERE 402103, Dist. Raigad, Maharashtra
2022-2023
 Dr. Babasaheb Ambedkar Technological University,

Lonere 402103, Tal. - Mangaon, Dist. - Raigad, (M.S.)

DEPARTMENT OF CHEMICAL ENGINEERING

CERTIFICATE

This is to certify that the seminar report titled “PROCESS SAFETY

MANAGEMENT IN CHEMICAL INDUSTRIES” is the bonafide work
carried out by Mr ADIT ANIL SHIRKE, Roll No: 2230331507033 of First
year Bachelor of Technology in Chemical Engineering. It is approved for
partial fulfillment of requirement of degree of Bachelor of Technology in
Chemical Engineering of Dr. BABASAHEB AMBEDKAR
TECHNOLOGICAL UNIVERSITY, Lonere, Raigad 402103.

Guide Head of Department

PROF. POOJA.P. SANAP Dr. A. R. Chavan

Dept. of Chemical Engg. Dept. of Chemical Engg.

Examiners: 1.

2.

Place: Lonere
Date:
 ACKNOWLEDGEMENT

I express my profound sense of gratitude to our pro-active staff without

whose guidance this work would have not been success. Their constructive
criticism and useful timely suggestions and encouragement in every step
immensely helped me. Their invaluable presence was great boost for me in
achieving our goal.
I would also like to thank Dr. A. R. Chavan, Head Department of Chemical
Engineering, DR.BABASAHEB AMBEDKAR TECHNOLOGICAL
UNIVERSITY, LONERE for their systematic guidance, valuable advice and
constant encouragement throughout the work. It was his motivation, which helped
me to learn new thing.

I would also like to thank all staff members in department, library, and
reference section (DR. B. A. T. U.) that extended all kind of co-operation for the
completion of this work.

Adit Anil Shirke

2230331507033
 Abstract

Process Safety Management (PSM) is a crucial aspect of ensuring the

safe operation of chemical industries. This seminar report provides a
detailed analysis of the key elements of Process Safety Management, its
significance, and its implementation in chemical industries. It also
discusses the importance of safety culture, risk assessment techniques,
emergency preparedness, and the role of regulations in promoting
process safety. The report emphasizes the need for continuous
improvement and proactive measures to prevent accidents, protect the
environment, safeguard the health and well-being of workers and the
surrounding community.
 TABLE OF CONTENTS

Chapter No. Particulars Page

No.
CERTIFICATE i

ACKNOWLEDGEMENT ii

ABSTRACT iii

1. Introduction 1

2. The Problem 2
3
3. Importance of Process Safety Management

4. Process Safety Information 4-5

5. Key Elements of Process Safety Management 6

6. Process Hazard Analysis 7-8

7. Operating Procedures 9

8. Mechanical Integrity 10

Conclusion
 CHAPTER 1
INTRODUTION

Chemical Industries play a vital role in modern society by producing a

wide range of products that cater to various needs. However the
handling and processing of hazardous chemicals or materials pose
inherent risks that require robust safety measures. Process Safety
Management (PSM) is a comprehensive approach aimed at preventing
major accidents, protecting personnel, the environment and the
surrounding community. Process Safety Management is a systematic
approach to prevent and mitigate the potential consequences of major
accidents during chemical processing. This report presents an in-depth
analysis of the importance of PSM in chemical industries, its key
elements, implementation strategies, and the role of regulations in
promoting process safety.
 CHAPTER 2
THE PROBLEM

Unexpected releases of toxic, reactive, or flammable liquids and

gases in processes involving highly hazardous chemicals have been
reported for many years. Incidents continue to occur in various
industries that use highly hazardous chemicals which may be toxic,
reactive, flammable, or explosive, or may exhibit a combination of
these properties. Regardless of the industry that uses these highly
hazardous chemicals, there is a potential for an accidental release any
time they are not properly controlled. This, in turn, creates the
possibility of disaster.
Recent major disasters include the 1984 Bhopal, India, incident
resulting in more than 2,000 deaths; the October 1989 Phillips
Petroleum Company, Pasadena, TX, incident resulting in 23 deaths
and 132 injuries; the July 1990 BASF, Cincinnati, OH, incident
resulting in 2 deaths, and the May 1991 IMC, Sterlington, LA,
incident resulting in 8 deaths and 128 injuries.
Although these major disasters involving highly hazardous
chemicals drew national attention to the potential for major catastrophes,
the public record is replete with information concerning many
other less notable releases of highly hazardous chemicals. Hazardous
chemical releases continue to pose a significant threat to employees
and provide impetus, internationally and nationally, for authorities
to develop or consider developing legislation and regulations to
eliminate or minimize the potential for such events.
 CHAPTER 3
IMPORTANCE OF PROCESS SAFETY MANAGEMENT

The chemical industry deals with numerous hazardous materials and

processes that can pose significant risks both to human life and the
environment if not managed properly. The implementation of process
safety management is essential for the following reasons:
 Preventing Accidents: PSM system are designed to identify
potential hazards and mitigate them to prevent catastrophic
accidents such as explosions, fires, and toxic releases.
 Protection of Personnel: By adhering to strict safety protocols,
PSM ensures the protection of workers and surrounding
communities form potential harm.
 Environment Stewardship: Effective process safety management
minimizes the risk of chemical spills or releases, reducing the
environmental impact.
 Regulatory Compliance: Many countries have specific regulations
and standards related to process safety management that chemical
industries must adhere in order to operate legally.
 CHAPTER 4
PROCESS SAFETY INFORMATION

Employers must complete a compilation of written process safety

information before conducting any process hazard analysis required
by the standard. The compilation of written process safety information,
completed under the same schedule required for process hazard
analyses, will help the employer and the employees involved in
operating the process to identify and understand the hazards posed
by those processes involving highly hazardous chemicals. Process
safety information must include information on the hazards of the
highly hazardous chemicals used or produced by the process,
information on the technology of the process, and information on the
equipment in the process.
Information on the technology of the process must include at least
the following:
• A block flow diagram or simplified process flow diagram,
• Process chemistry,
• Maximum intended inventory,
• Safe upper and lower limits for such items as temperatures,
pressures, flows or compositions, and
• An evaluation of the consequences of deviations, including
those affecting the safety and health of employees.
Information on the equipment in the process must include the
following:
• Materials of construction,
• Piping and instrument diagrams (P&IDs),
• Electrical classification,
• Relief system design and design basis,
• Ventilation system design,
• Design codes and standards employed,
• Material and energy balances for processes
 CHAPTER 5
KEY ELEMENTS OF PROCESS SAFETY MANAGEMENT

This section delves into the fundamental components of robust PSM

program, covering the following aspects:
 Process Hazard Analysis (PHA): Explanation of various
techniques used in PHA such as HAZOP, FMEA, and Fault- Tree
Analysis and their role in identifying potential hazards.
 Risk Management: Detailed discussion on risk assessment, risk
reduction strategies and the use of safety layers and barriers to
manage risks effectively.
 Operating Procedures: The importance of well-defined and
documented operating procedures, including safe operating limits
and emergency shutdown procedures.
 Training and competency: Highlighting the significance of proper
training for personnel to ensure they have the necessary knowledge
and ski9lls to handle hazardous materials safely.
 Mechanical Integrity: Understanding the importance of
maintaining equipment integrity through inspections, testing, and
preventive maintenance.
 Management of Change(MOC): explanation of the MOC process
which involves assessing and managing modifications to
equipment, processes, personnel that could impact safety.
 Emergency Preparedness: Detailed discussion on emergency
response planning, including drills and simulations to prepare
personnel for potential incidents.
 CHAPTER 6
PROCESS HAZARD ANALYSIS

The process hazard analysis is a thorough, orderly, systematic

approach for identifying, evaluating, and controlling the hazards of
processes involving highly hazardous chemicals. The employer must
perform an initial process hazard analysis (hazard evaluation) on all
processes covered by this standard. The process hazard analysis
methodology selected must be appropriate to the complexity of the
process and must identify, evaluate, and control the hazards involved
in the process.
The employer must use one or more of the following methods, as
appropriate, to determine and evaluate the hazards of the process
being analyzed:
• What-if,
• Checklist,
• What-if/checklist,
• Hazard and operability study (HAZOP),
• Failure mode and effects analysis (FMEA),
• Fault tree analysis, or
• An appropriate equivalent methodology.

Process hazard analysis must address the following:

• The hazards of the process;
• The identification of any previous incident that had a potential
for catastrophic consequences in the workplace;
• Engineering and administrative controls applicable to the
hazards and their interrelationships, such as appropriate application
of detection methodologies to provide early warning of
releases. Acceptable detection methods might include process
monitoring and control instrumentation with alarms, and
detection hardware such as hydrocarbon sensors;
• Consequences of failure of engineering and administrative
controls;
• Facility siting;
• Human factors; and
• A qualitative evaluation of a range of the possible safety and
health effects on employees in the workplace if there is a failure
of controls.
At least every five years after the completion of the initial process
hazard analysis, the process hazard analysis must be updated and
revalidated by a team meeting the standard’s requirements to ensure
that the hazard analysis is consistent with the current process.
 CHAPTER 7
OPERATING PROCEDURES

The employer must develop and implement written operating

procedures, consistent with the process safety information, that
provide clear instructions for safely conducting activities involved in
each covered process. The procedures must address at least the following
elements:
Steps for each operating phase:
• Initial startup;
• Normal operations;
• Temporary operations;
• Emergency shutdown, including the conditions under which
emergency shutdown is required, and the assignment of shut
down responsibility to qualified operators to ensure that emergency
shutdown is executed in a safe and timely manner;
• Emergency operations;
• Normal shutdown; and
• Startup following a turnaround, or after an emergency shutdown

To ensure that a ready and up-to-date reference is available, and to

form a foundation for needed employee training, operating procedures
must be readily accessible to employees who work in or
maintain a process. The operating procedures must be reviewed as
often as necessary to ensure that they reflect current operating
practices, including changes in process chemicals, technology, and
equipment, and facilities. To guard against outdated or inaccurate
operating procedures, the employer must certify annually that these
operating procedures are current and accurate.
 CHAPTER 8
MECHANICAL INTEGRITY

It is important to maintain the mechanical integrity

of critical process equipment to ensure it is designed and installed
correctly and operates properly. PSM mechanical integrity
requirements apply to the following equipment:
• Pressure vessels and storage tanks;
• Piping systems (including piping components such as valves);
• Relief and vent systems and devices;
• Emergency shutdown systems;
• Controls (including monitoring devices and sensors, alarms,
and interlocks); and
• Pumps.

The employer must establish and implement written procedures to

maintain the ongoing integrity of process equipment. Employees
involved in maintaining the ongoing integrity of process equipment
must be trained in an overview of that process and its hazards and
trained in the procedures applicable to the employees’s job tasks.
Inspection and testing must be performed on process equipment,
using procedures that follow recognized and generally accepted good
engineering practices. The frequency of inspections and tests of
process equipment must conform with manufacturers’ recommendations
and good engineering practices, or more frequently if determined
to be necessary by prior operating experience. Each inspection
and test on process equipment must be documented, identifying
the date of the inspection or test, the name of the person who performed
the inspection or test, the serial number or other identifier of
the equipment on which the inspection or test was performed, a
description of the inspection or test performed, and the results of the
inspection or test.
 CONCLUSION

The conclusion summarizes the key finding of the seminar

report, reiterating the importance of process safety management
in chemical industries. Process Safety Management is a vital
aspect of chemical industry, playing a crucial role in
safeguarding human lives, protecting the environment, and
ensuring the industries sustainability. By adhering to the key
elements of PSM, chemical industries can significantly reduce
the likelihood of accidents and foster a culture of safety, thereby
promoting responsible and sustainable operations. Continued
commitment to process safety will not only protect the
workforce and the environment but also contribute to the
industry’s sustainability and success in the long run.