1 Description............................................................................................

2
2 Purpose................................................................................................. 2
3 Are focus areas for OH&S and Process Safety the same............................... 2
4 Why do we need PSM........................................................................... 3
5 Statistics................................................................................................ 5
6 PSM Challenge...................................................................................... 6
7 Process Safety Management (PSM)...................................................... 6
8 PSM at GPIC......................................................................................... 7
9 How we measure our PSM Performance............................................ 26
10 Inadequate PSM impacts all stakeholders.......................................... 28
 Process Safety Management

1.0 DESCRIPTION
1.1 What is Process Safety?
• A management system to help prevent major incidents
• Essential for managing complex chemical operations
• Process Safety focuses on:
-- Technology
-- Facilities
-- Personnel
1.2 Process Safety Management (PSM)
Is the proactive identification, evaluation and mitigation or prevention of chemical releases that could occur as a
result of failures in processes, procedures, or equipment?

2.0 PURPOSE
• Prevent Catastrophic Releases of Highly Hazardous Chemicals
• Minimize Consequences of Such Releases to Employees and the Community

3.0 Are focus areas for OH&S and Process Safety the same?
• OH&S codes and standards do not specifically address issues related to Process Safety. In part, this is because OH&S
risks are typically of higher frequency and lower consequence than process risks. Indeed, their focus is different.
• Occupational Health & Safety • Process Safety Management
-- Focus: Eliminate harm to people, assets and the environment -- Focus: Eliminate process related incidents

2
Process Safety Management

4.0 WHY DO WE NEED PSM?

• March 6, 2007
Explosion and Fire at Formosa Plastics Illinois, USA

• March 2005 - BP Texas City

15 contractor fatalities; 170 + injuries
Total Cost impact: > $3 Billion

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 Process Safety Management

Significant Process Industry Incidents and Responses in Last 35 Years

Lacation of Accident Year incident Regulatory response
EXPLOSION FIRE.27KILLED.OCER
Flixborough UK 1974 CIMAH (1984) COMAH(TODAY)
100 Injured
Dioxin release.2.000 Poisoned.
SEVESO.ITALY 1976 Seveso Directive (1982)
Environmentalcontamination.mass evacuation
Changes to Atlantic
Newfoundland Canada 1982 Ocean Ranger lost. 84 dead
Accord Acts
3.800 People killed. 20.000
Bhopal. India 1984 CAER Program (1985)
Injured.200.000 evacuated
Toxic gas release. no fatalities .but Emergency Planning and community Right to
Institute. USA 1985
happened just after Bhopal know (1986)
Rhine river contamination. Severe
Basel Switzerland 1986 Changes in Seveso Directive
environmental damage
165 killed. Loss of piper Alpha Lord Cullen›s report/
North Sea.UK 1988
platform Safety Case Regulations (1992)
ExPlosion and fire.23 deaths. 100 OSHA PSM 1910 (1992)
Pasadena USA 1989
injured and EPA RMP (1999)
Nova scotia Canada 1992 Westray mine explosion. 26 dead Bill C-45 (2004)
Langford. Explosion and fire. 2 deaths. Major Hazard Facilities
1998
Australia Melbourne without gas for 19 days Regulations (2004)
Toulouse. Explosion and fire 30 deaths. 2000
2001 Changes in seveso Directive
France Injured.600 homes destroyed
Baker Report (2007)
Suggested creating 2 new ANSl standards.including
Texas city. USA 2005 15 killed. 180 injured
2005-4-l-tx-R6
(Performance indicators for Process safety)
Hertfordshire.UK 2005 Explosion and fire at Buncefield Depot pending
4
Process Safety Management

5.0 STATISTICS

Other 32%
Mechanical
Integrity 44%

PTW & Isolation

failures 5% Operations
& SOP 19%

Especially with respect to

Start-up and Shut-down
The majority of large scale losses are due to process accidents. More than 80% of the largest losses
on record have been experienced in the past 25 years.

5
 Process Safety Management

6.0 PSM CHALLENGES

• Large volumes of flammable materials • Aging facilities
-- Process vessels. -- Vessels and piping reaching end of useful life.
-- Storage tanks. -- Quality of fireproofing.
-- Piping. -- Instrument and/or control systems obsolescence.
• New plants are more often world-scale single train -- ESD testing.
-- Potential scale-up issues. -- Resistance to retrofit since “that was how the plant
-- Larger flammable working inventories. was designed

7.0 Process Safety Management (PSM)

• As per OSHA 1910.119, PSM is the development of a comprehensive management program which integrates
technologies, procedures, and management practices to prevent or minimize the consequences of a catastrophic
release of toxic, reactive, flammable or explosive hydrocarbons.
i.e. KEEP IT IN THE PIPES!

• PSM should form an integral part of an organization’s safety culture, but the tendency in a large number of
companies is to focus on personal safety.

• Near Miss reports, more often than not, highlight slips, trips and falls, rather than hydrocarbon releases, fires,
overdue inspections/maintenance and close out of HAZOP action items.
Plants with limited personnel accidents become considered “safe”.

6
Process Safety Management

8.0 PSM AT GPIC

8.1 Performance NOT Specification Standard.

Process Safety Management Of Hazardous Chemicals

Identifying the equipments which involves storage and handling of Highly Hazardos Chemicals
(HHC) or flammable liqids and gases above a specified quantity.

PSM Critical Equipment List

PSM Elements
1. Employee Participation (EP) 8. Mechanical Integrity (MI)
2. Process Safety Information (PSI) 9. Hot Work Permit (HWP)
3. Process Hazard Analysis (PHA) 10. Management of Change (MOC)
4. Operating Procedures (OP) 11. Incident Investigation (II)
5. Employee Training (ET) 12. Emergency Planning and Response (EPR)
6. Contractors (CO) 13. Compliance Audit (CA)
7. Pre-Startup Safety Review (PSSR)

7
 Process Safety Management

8.2 What is covered?

In each industry, PSM applies to those companies that deal with any of more than 130 specific toxic and reactive
chemicals in listed quantities; it also includes flammable liquids and gases in quantities of 10,000 pounds (4,535.9
Kg) or more.

Employee
Competence Audit
Participation

Emergency Planning Process

and Response Safety Information

Incident
Investigation PSM Process Hazard

Management
Elements Analysis

Of Change
Operating
Procedures
Hot Work Permit

Employee Training
Mechanical
Integrity

Pre-Startup Contractors
Safety Review

8
Process Safety Management

8.2.1 Employee Participation

In order to achieve a high degree of “Employee” involvement, the element
directs organizations to give its employees access to Process Hazards
Analysis and all its related practices and systems. This includes all types of
information concerning the safety of plants and personnel
• GPIC Compliance
Employees are consulted and are fully involved during the development and
implementation of any Process Hazard Analysis (PHA) study.
• Controlling Documents
Process Safety Management of Hazardous Chemicals

8.2.2 Process Safety Information

• GPIC Compliance
Information related to Material Safety Data Sheet (MSDS) of chemicals, codes and standards used, equipment
details, Process & Instrumentation
Diagrams (P&IDs) and Process Flow Diagrams (PFDs) is captured through the Technical Data Books (TDB),
Maintenance Data Books (MDB), Operation
Manuals and Basic Engineering Documents. These documents are available at 6 locations.
• Controlling Documents
-- Management of Change (MOC) -- Process Hazard Assessment (PHA) Procedure
-- Material Safety Data Sheet Technical Data Book -- Process Safety Information Procedures
-- Updating Technical Documents

9
 Process Safety Management

8.2.3 Process Hazard Analysis

The element requires that a Process Hazard Analysis (PHA) is carried out for all processes handling highly hazardous
chemicals. This helps to identify all hazards in the process. All such PHAs are revalidated at least once every five
years.
• GPIC Compliance
A Process Hazard Analysis (PHA) for all plants has been completed and documented. The PHA studies were also
revalidated in 2014. The next revalidation of all plants is scheduled for 2019. Furthermore, in GPIC, a PHA review is
carried out on each and every change as part of the Management of Change (MOC) cycle.
• Controlling Documents
-- Process Hazard Assessment (PHA) Procedure
-- Management of Change (MOC)

8.2.4 Operating Procedures

The element requires that there are clear documented operating procedures to safely carry out activities concerning
normal startups and shutdowns, emergency shutdowns, Operations of a temporary nature, and the handling
and exposure to hazardous chemicals, etc.
• GPIC Compliance
GPIC’s existing Standard Operating Procedures and Standing Instructions include:
-- Normal startups and shutdowns
-- Emergency shutdowns considering various scenarios and plant upsets.
-- Simplified trip logic diagrams, catalyst manual

10
Process Safety Management

• Controling Documents
-- Standard Operating Procedures -- Complex Emergency Procedure
-- Standing Instructions -- Material Safety Data Sheets
-- Plant Trip Logic Diagrams -- Relevant P&IDs
-- Permit to Work Procedure -- Relevant Vendor Manuals

Example of PSM SOP structure

INDEX

S No. Topic
1 Purpose.
2 Scope.
3 Description.
4 Safety, Health and Environment related Information.
5 Requirements.
6 Preparations to Start
7 Start-up.
8 Shutdown.
9 Operating Limits, Deviations, & Corrective Actions.
10 Equipment & Instruments in the section.

11
 Process Safety Management

8.2.5 Employee Training

The element requires each employee operating a process, to be given
appropriate training. Thus, each employee is adequately trained before
being involved in operating a newly assigned process. Also, refresher
training in operating such processes must be provided to the employees
periodically. The training provided must also emphasize the specific safety
and health hazards
• GPIC Compliance
A structured training programme is provided to employees (including
operators, technicians, supervisors and engineers) prior to the assignment
of any new responsibility. Refresher trainings and lessons learned are also mainstreamed.
• Controlling Documents
Training and Development Programme for Trainee Supervisors and Engineers and other documents

8.2.6 Contractors
The element requires that contractors performing maintenance, repairs,
turnaround activities, major renovation work or specialty work on the
process or adjacent to the process shall be well trained in carrying out the
intended work and shall be informed about the known potential hazards
related to the work and/or the process involved.
• GPIC Compliance
GPIC’s direct hire and/or lump sum contractors go through a selection
process that starts from contractor pre-qualification assessment, trade
testing, rental equipment physical verification, and safety induction
12
Process Safety Management

training, on the job assessment, weekly contractor safety meetings and post service evaluation.
Contractors performing maintenance within the process areas are apprised of the hazards during the safety induction
training and regular Tool box talk.
• Controlling Documents
-- Establishing and Managing Approval Suppliers List
-- Contractor Prequalification Requirements
-- Contractor Services Management
-- Contractor / Vendor Performance Evaluation Form

8.2.7 Pre-Start up Safety Review

The element requires that a pre-startup safety review is carried out for any new facilities or modifications in the
process area. The review shall confirm that the changes are as per the design and specifications that the safety,
operation, maintenance and emergency procedures are adequate, and that sufficient training has been given to
employees with regard operating the new process or change.
• GPIC Compliance
A formal Standard Operating Procedure has been put in place to ensure that any newly installed facility or modification,
before being commissioned, has been executed as per:
-- Relevant design codes, specifications and engineering drawings
-- Relevant operation, safety and emergency procedures
-- HAZOP recommendations
-- Relevant training
• Controlling Documents
-- Pre-Startup Safety Review (PSSR) Procedure -- PSSR Checklists

13
 Process Safety Management

8.2.8 Mechanical Integrity

The element requires written procedures to be available to maintain:
• Pressure vessels, storage tanks, piping systems and pumps.
• Relief and venting systems, emergency shutdown systems and controls (such as alarms, trip interlocks, etc.)
The standard also requires quality assurance during the fabrication and installation of plant equipment.
• GPIC Compliance
At GPIC, a comprehensive inspection schedule, in line with international standards and the process licensor(s)
guidelines, is being followed. A Risk Based Inspection (RBI) technique is also employed to strengthen the inspection
programme.
Furthermore, a comprehensive critical equipment list exists at GPIC identifying process equipment that has an impact
on safety, health and theEnvironment.
• GPIC Mechanical integrity procedures
This procedure is one in a series of procedures drawn up to meet the overall requirements of the PSM standard
(OSHA 1910.119). Although the procedure deals specifically with
maintaining the Mechanical Integrity of certain listed process equipment, the contents must not be taken out of
context with the overall intent of the standard and the other
clauses therein.
• Purpose:
The purpose of the OSHA Standard, Process Safety Management of Highly Hazardous Chemicals – 1910.119 (PSM) is
to identify the requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive,
flammable or explosive chemicals. These releases may result in toxic, fire or explosive hazards.
This procedure serves to indicate how GPIC complies with the requirements of the PSM standard, clause Mechanical

14
Process Safety Management

Integrity. Section A gives an overall view about Mechanical Integrity and Section B gives the minimum requirement to
ensure the integrity of the identified Critical Equipment List that was derived after adopting the PSM standard at GPIC
The PSM standard applies specifically to processes which involve storage and handling of Highly Hazardous chemicals
(HHC) or flammable liquids and / or gases above a specified threshold quantity as specified in OSHA Standard.
This list has been drawn up based upon the criteria that failure of any listed equipment, along with their associated
safety protection devices, could reasonably cause a catastrophic release of one or more of the following listed
chemicals or gasses:
• Ammonia: Hold up more than 4535.9 kg;
• Ammonia Water Solution (conc >44%): Hold up more than 6808 kg;
• Hydrocarbon fuels-Gasoline/Diesel for vehicle refueling: Hold up exempted from PSM.

Section A:
Scope:
This procedure relates to the mechanical integrity of process equipment, as identified in the Critical Equipment List.
The list contains the following types of equipment:
• Pressure vessels and storage tanks;
• Piping systems (including piping components such as valves);
• Relief and vent systems and devices;
• Emergency shutdown systems
• monitoring devices and sensors, alarms, and trip logic
• Instrument valves including control valves;
• Emergency Response Equipment
15
 Process Safety Management

Responsibilities
Given the broad scope of the equipment covered and the requirement of ensuring the mechanical integrity of the
critical equipment listed, it is the responsibility of the Operation, Maintenance, Technical Services, Training and
Development and SHE Superintendents, and any other related superintendent(s) to ensure this procedure is correctly
applied in their areas of responsibility.

Definitions
Owner: The plant superintendent responsible for operating the identify critical equipment
Craft: The maintenance and inspection superintendents responsible for the integrity of the identified critical equipment,
establishing the Preventive maintenance frequency and establishing the stock level requirements.

Reference
Process Safety Management of Highly Hazardous Chemicals – 1910.119 (PSM).

Maintenance Procedures:
Each relevant section head in GPIC is required to develop comprehensive procedures, the purpose of which is to
maintain the ongoing integrity of process equipment within
their area of responsibility. A list of equipment types must be developed in each related section indicating the
applicable procedure numbers for that equipment.
Some maintenance work is undertaken by the operations department. This work, such as oil top up equipment
monitoring etc. is undertaken on routine basis as per the ongoing procedures of each applicable section.
Maintenance work is carried out by the maintenance sections through the work request system (SAP), administered
by the maintenance Planning Section.
All work requests are initiated either manually (corrective maintenance) or automatically (preventive maintenance).
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Process Safety Management

Work order management is implemented by the maintenance planning section through the application of, Maintenance
Work Order Management.
The preventive maintenance system is implemented by the maintenance planning section through the application of,
Preventive Maintenance Management.
Adequate spare parts are made available for proper maintenance of process equipment. Material Management,
describes the process of setting up and reviewing spare parts
requirements.
Stock Levels Management, describes how maintenance spare parts stock levels are established and maintained.

Training:
Each section head, within his area of responsibility, will ensure that maintenance activities on process equipment are
carried out by suitably competent personnel.
Such personnel will be competent to undertake the technical aspects of the job task. Such personnel will have
undergone training in an overview of the process in which the
equipment is located, along with the hazards and procedures applicable for the safe
performance of the job task. Such refresher training must be undertaken for all relevant personnel at least every
three years, Refresher Training for Staff Involved in Plants Operation & Maintenance.

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 Process Safety Management

Inspection and Testing:

Depending upon the Type of inspection and testing required, different sections of the company are responsible to
undertake such activities.
All section heads are required to develop procedures for attending the routine testing of equipment, including the
ones listed in the Critical Equipment List, which is undertaken by personnel within their sections. The procedure must
include the method of inspection or test along with the frequency and basis for such.
The procedures must be reviewed at least annually and more frequently if inspection and test results indicate such
requirement.
Records of such inspection or tests must be available for verification and analysis. Records of such tests must contain,
as a minimum, the following information:
• Date of inspection or test;
• Name of person(s) who performed the inspection or test;
• Serial or/and tag number of the equipment on which the inspection or test was performed;
• Description of the inspection or test performed,
• The results of the inspection or test.

Equipment Deficiencies:
Where equipment deficiencies are identified, such as material out of tolerance, calibration errors etc., actions must
be taken to rectify the deficiency in a time frame and manner dependent upon the potential impact of the deficiency
identified. Such actions will be agreed by the relevant personnel at the operations morning meeting. If the deficiency
is considered to be an immediate risk, then the relevant manager(s) and superintendent(s) are informed and an ad-
hoc meeting convened to determine the appropriate course of action. The equipment owner is responsible to invoke
such emergency response as is deemed adequate.

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Process Safety Management

Normally, calibration errors / instrument malfunctions are addressed immediately. Where this cannot be achieved,
then the requirements of Standing Instruction, Override
of plant / equipment trip systems / long term overrides / instrument trip system settings, must be followed.
Where deficiencies of a mechanical or electrical nature are identified, the relevant Plant owner/superintendent
(where the equipment failed) is to be advised of the appropriate course of corrective action by the relevant section
head (maintenance, inspection, engineering, SHE etc.). Where the proposed corrective action does not comply with
standard codes and practices, such actions must be approved through the application of Management of change.

Quality Assurance:
All modifications and additions to plant and equipment and capital expenditure (capex) projects must be implemented
through the application and controls of the following procedures:
• Implementation of capital projects.
• Management of change.
• Inspection of new static equipment.

Section B
Mechanical integrity minimum assurance level requirement
As stated above, given the broad scope of the equipment covered, and to ensure the ongoing mechanical integrity
of the identified Critical Equipment, below are the minimum requirement and concepts to ensure the ongoing
mechanical integrity:
1- The identified Critical Equipment List is the most critical from safety and hazardous material release point of view
and therefore; they require most focus and attention during operation and maintenance activities.

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 Process Safety Management

2- Each Plant Owner is responsible to ensure the safe operation of the items under his jurisdiction. Planning Section
have identified the PSM equipment in the SAP system. For any required corrective maintenance (CM), it is the
Owner responsibility to ensure the appropriate and justified priority is logged during raising the said notification
to ensure attending the same on TOP PRIORITY. All Quality documents maintenance procedures associated with
the integrity of the equipment as indicated in section (J-2) above are to be revalidated and reissued (if needed)
to reflect the CM review .

3- The Preventive Maintenance (PM) are set by the Craft and it reflects the level of attention required to ensure the
ongoing integrity of the equipment. The revalidation and review of PM are to be done every 2 years and after
every turnaround for non- turnaround and turnaround equipment respectively.

4- Maintaining the record required to demonstrate that all equipment’s PM/CM are done in accordance with the
established procedures is the responsibility of relevant Craft.

5- The Craft is responsible for ensuring appropriate level of stock (spare parts) are available to conduct the PM and
CM activity in an effective and timely manner. The stock level review should be part of the PM revalidation as
indicated in points 2&3 above. The guidelines to be followed for ensuring the minimum stock levels for spares of
the PSM Critical Equipment List are as below;

5.1 PSVs spares assessment criteria

20
Process Safety Management

Examples:
We have selected two PSVs from the PSM critical PSV list and have elaborated the spares assessment based on the
above matrix.
5.2 PSM Critical Instrument valves and mechanical isolation valves 100% spare internals are required for every
PSM critical valve
5.3 PSM Critical Analyzers/ detectors
Consumables are required to maintain the analyzers/ detectors.
5.4 PSM Critical Instrument transmitters/ trip switches Minimum one spare for common trip switches/
transmitters.
5.5 PSM Critical Level glasses
Consumables are required to maintain the level glasses.

5.6 PSM Critical Equipment (reactors, vessels, heat exchangers etc)

For PSM Critical equipment such as reactors, vessels, heat exchangers etc. a Spare equipment is not
required.
5.7 PSM Critical piping
One standard length of pipe for every type of PSM critical piping is to be Maintained.
5.8 PSM Critical Rotating equipment
100% spare parts/ consumables are to be maintained
5.9 PSM Critical equipment consumables
100% consumables such as gaskets, gland packing etc. are to be maintained.
5.10 PSM Critical emergency response vehicles Necessary consumables to be made available

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 Process Safety Management

6- Engineering in charge is responsible to ensure that modification

and closing of HAZOP actions associated with critical items are
done in effective and timely manner. In general, modification
that have immediate impact on the integrity of the Critical
Equipment are to be addressed in 14 days, other modification
to do with enhancement of the existing systems can be
processed with 2 months.

7- The respective Owner and Craft are to ensure that employees

and contractors working on critical items are trained on
regular basis on the procedure(s) applicable to the jobs and
tasks. The training is to ensure that employee and contractors
working on Critical Equipment/item are competent to conduct
the required activities. The training can be on-the-job training,
table-top training, or trade testing. The Owner and Craft are
responsible to maintain the records of such training.

8.2.9 Hot Work Permit

The element requires that a hot work permit is to be issued for
any hot work operation conducted on or near a process area.
The protocol calls for strict control starting from hazard identification,
gas testing, controls and mitigation

22
Process Safety Management

8.2.10 Management of Change

The element requires that written procedures are established and implemented to manage changes to
processes, chemicals, technology, equipment and procedures that are not “replacement in kind”.
Employees or contract employees whose job is affected by the change, should be informed and trained on the
changes prior to commissioning and statup

PHA

Screening Egfineering
Raise Rfc Implementation Implementation
& Processing & Approvel

Archive Updating FAC

of PSI PSSR

23
 Process Safety Management

8.2.11 Incident Investigation

The element requires that each process incident which resulted in or could reasonably have resulted in a
catastrophic release of highly hazardous chemicals is investigated. The standard further requires that the findings
and recommendations arising from the investigation are resolved and documented

Reporting
the incidenth
Minor
Incident
Reviews the
Incident
Serious
Incident

OP. Manager Executive Management

Interim Final
Report Report

Investigating Team

24
Process Safety Management

8.2.12 Emergency Planning and Control

The element requires that an emergency action plan for the entire complex is available. The plan must also be
designed to handle small releases.

8.2.13 Compliance Audit

The element requires that the Process Safety Management (PSM) processes are evaluated once every three years
through a compliance audit conducted by at least one person knowledgeable in the process. The standard also
requires that an appropriate response to each of the findings is reported and that any deficiencies are corrected..

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 Process Safety Management

9.0 HOW WE MEASURE OUR PSM PERFORMANCE?

Process Safety Management Goals, Targets & Indicators 2016
PSM Elements Goals Indicator name Target Owner 2016 Programs/Remarks
A-To conduct a minimum of one Regular review of shift talks data
A-Number of shift/safety 90% completed
PSM related topic/PHA in plant shift/ electronic data base to ensure shift talks
Employee talks completed shift talk per year
safety talks. ENVS are done timely.
Participation (EP)
B- To ensure operators attend least B- Number of operators Close follow up on the PHA attendance to
95% attendance
95% of PHA studies attending HAZOP studies ensure satisfactory attendance.
Number of outstanding
Process safety To update at least 90% of received CNV/Reem el Periodic reminders to concerned to ensure
documents update (MSDS, 90%
information (PSI) FACs within 2 weeks otalbl compliance.
..etc.)
To complete all PHA Number of outstanding PHA
Process Hazard Periodic reminders to concerned to ensure
recommendations within 15 days recommendations related to Zero SPRE
Assessment(PHA) compliance.
from issuing the PHA reports critical equipment
Number of outstanding PSM
Operating To review all the PSM related Close follow up with concerned operation
related procedures pending 100% URS/NAYEF
Procedures (OP) procedures superintendents.
review
To ensure the accumulative overdue
Employee Training Number of individual with TDS liases with section superintendents to
refresh training is less than 10% of Less than 10% TDS
(EP) overdue refresher training ensure training program is followed.
the annual program plan
PSM related tool box topics will selected
To conduct a minimum of one PSM 95% Completed
Number of tool box talks from the knowledge sharing data base and
Contractors (CO) related tool box talk per month for tool box talks per PLS
completed other resources such as process safety
contractors. year
beacons available in multi-languages.
To ensure all PSSR To facilitate PSSR recommendations
Pre-startup Safety
recommendations are closed out Number of outstanding PSSR Zero ENVS tracking an e-data base will be
review (PSSR)
within 7 days established.

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Process Safety Management

PSM ELements Goal INDICATOR NAME TARGET Owner 2016 PROGRAMMS/REMARKS

Mechanical A-TO ensure no overdue inspection A-Number of overdue zero INS close follow up and reminders by ins
integrity (MI) items for more than one month inspection

B-TO ensure no system challenges B-The Number of challenges Zero over INS/ Monthly review of the trip override log to
overdue for more than 14 days to automated safety devices , 14 days Haya ensure compliance
such as Number of trip old

HOT WORK To close out Hot Ptw violations within Number of outstanding hot ptw zero ENUS Regular review of the accident / invcident
PERMIT (HWP) 7 days violations data base to ensure compliance

Management of Technical committee to approve all Number of outstanding MOC zero ENS/ Weekly status of capex and RFCS IS Sent
change(Moc) moc request within two months from Related to critical equipment reem al by ENS
receiving the RFC otaibi

Incidents TO Close OUT ALL in cadent The Number of outstanding Zero fsst Regular review of the accident /incident
investigation (II) investigation recommendations PSM within data base to ensure compliance
within 7days incident recommendations 7days

Emergency Number of PSM emergency 4 per year Fsst Issue the annual mock drills schedule
planning & To conduct the annual planned psm mock drills carried out Follow up with consumed fsss the mock drill
response(EPR) Emergency mock DrillS execution
Follow up and address any raised
recommendation/short comes
Raised from the drills

Compliance To close all issues raised in the PSM Number of pending NCRS OR zero MSS Issuing the yearly PSM audit schedule. close
Audits (CA) audits , i.e NCRS OR OAIS WITH IN OAiS follow up with internal auditors to ensure the
30 DAYS audits are conducted as per schedule
Close follow up with audited to ensure al
audits findings are addressed and closed with
30 days of issuing

27
 Process Safety Management

10.0 INADEQUATE PSM IMPACTS ALL STAKEHOLDERS

• Employees and their families • Community

• Environment

28
Process Safety Management

29
 Standard Operating Procedure

Standard Operating Procedure

1 Purpose............................................................................................ 32
2 Scope............................................................................................... 32
3 Description...................................................................................... 32
4 Safety, Health and Environment related Information..................... 32
5 Requirements.................................................................................. 37
6 Preparations to Start FCW System................................................. 37
7 Start-up............................................................................................ 37
8 Shutdown of Fresh Cooling water system...................................... 39
9 Filling And Priming Of Standby Fresh Cooling Water Pump......... 39
10 Changing Over the Fresh Cooling Water pumps, P-3203A/B....... 40
11 Operating Limits, Deviations, consequences& Corrective Actions. ...... 40
12 Equipment & Instruments in the section........................................ 42

30
Standard Operating Procedure

1.0 Purpose
For the reference and guidance of the Urea Plant Operations personnel in start-up, shut down and normal and
emergency operation of cooling water system. The following operational practices have proven to be appropriate in
start-up and shutdown of such systems.

2.0 Scope
To start up, shutdown and carry out normal operations of the cooling water system in the Urea Plant.

3.0 DESCRIPTION
Parameters recommended for the CW:
pH : 8.5 ~ 10.5
Conductivity : < 6500 mcs
Chloride : < 200 ppm
NO2 : 500 ~ 700 ppm
Iron : < 3.0 ppm
Bacteria level : < 1000 Colonies/ml
Dosing frequency is adjusted according specialists recommendations.

4.0 Safety, Health and Environment related Information:

Cooling water is desalinated water added with special chemicals; NALCO TRAC 109 as anti-corrosive agent primarily
containing Nitrite for the purpose, Nalco-8514 as Biocide for prevention bio-fouling and Nalco 71-D5 as antifoam
agent.

31
 Standard Operating Procedure

Source of Information for this section:

Item NALCO TRAC 109 NALCO-8514 NALCO 71-D5

Reference MSDS MSDS MSDS

4.1 Physical &Chemical Properties:

Property NALCO TRAC 109 NALCO-8514 NALCO 71-D5

Reference MSDS MSDS MSDS

Iso-propanol Hydrotreated light distillate

NaOH 1-5 (w/w)
5-10 5-15
Composition Sodium Nitrite Didecyl-Dimethyl-Ammonium EthoxilatedOctylphenol
% (W/W) 30-60 (w/w) Chloride 10- <25 1-<5
Sodium Tetra Borate Hydrotreated
-
< 1% (w/w) Middle distillate 40-70
Appearance Red Solution Colourless Light Straw Coloured
Liquid & forms emulsion when
Physical State Liquid Liquid
dissolved in water
Odor Slight Alcoholic Hydrocarbon
Flash Point Not Applicable 36°C 127°C
Specific Gravity 1.31 – 1.33 (25 °C) 0.97 0.865 ( 25°C)
Viscosity 5.0 CPS (20°C) 10 CPS (25°C) 13.8CPS (27°C)
Freezing Point -8.0 °C -7.0 °C -
Boiling Point 100 °C 83 °C -

32
Standard Operating Procedure

4.2 Environmental Impact:

Note that NALCO TRAC 109 is a Nitrite based compound. Always prevent the material from entering storm water
drains. Contain the spill and control the disposal as defined in SOP-URE-95-05

4.3 Human Health Hazards and First aid measures:

NALCO TRAC
Indication First Aid Measure
109
Not a likely route of exposure. Elevated
First aid is normally not required. Remove to
temperatures or mechanical actions may
Inhalation fresh air, treat asymptotically. If symptoms
form vapors, mist or fumes which may be
develop, seek medical advice.
irritating to the eyes, nose, throat & lungs
Immediately flush with plenty of water for at
Skin Contact Can cause moderate irritation least 15 Minutes. If symptoms develop, seek
medical advice.
Immediately flush eyes with plenty of water
Irritating & may injure eye tissue if not for at least 15 Minutes while holding eyelids
Eye Contact
removed promptly open. If symptoms develop, seek medical
advice.
Not a likely route of exposure. There may
Do not induce vomiting. Urgent hospital
be irritation to Gastro intestinal tract. Toxic if
treatment is likely to be needed. Get
Ingestion swallowed. Ingestion of Sodium Nitrite can
immediate medical attention.
cause Methemoglobinemia which can lead to
cyanosis and possible death

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 Standard Operating Procedure

NALCO-8514 Indication First Aid Measure

Repeated or prolonged exposure may Get medical attention, Remove to fresh air,
Inhalation
irritate respiratory tract treat symptomatically

Get immediate medical attention. Immediately

flush with plenty of water for at least 15
Corrosive. Causes permanent skin Minutes. Wash of affected areas with plenty
Skin Contact
damage of water. Contaminated clothing, shoes and
leather goods must be discarded or cleaned
before use.

Get immediate medical attention. PROMPT

Corrosive. Will cause eye burns and ACTION IS ESSENTIAL IN CASE OF CONTACT.
Eye Contact
permanent tissue damage Immediately flush eyes with plenty of water for
at least 15 Minutes while holding eyelids open.

Corrosive, causes burns to gastro- Get immediate medical attention. Do not

intestinal tract. Nausea, vomiting and induce vomiting. If conscious, washout mouth
Ingestion
stomach pain may occur. In severe cases and give water to drink
blood may be vomited

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Standard Operating Procedure

NALCO 71-D5 Indication First Aid Measure

Mist or vapors may cause headache,
Remove to fresh air, treat symptomatically.
Inhalation nausea, vomiting, drowsiness, stupor or
If symptoms develop, seek medical advice
unconsciousness
Frequent and prolonged contact may defat and
Immediately flush with plenty of soap
dry the skin leading to discomfort & dermatitis
Skin Contact &water. If symptoms develop, seek
Repeated or prolonged exposure may cause
medical advice
skin irritation or dermatitis
Immediately flush eyes with plenty of
Eye Contact prolonged exposure may cause eye irritation water for at least 15 Minutes while holding
eyelids open. Get medical attention.
May cause lung damage if swallowed Do not induce vomiting, contains petroleum
May cause nausea & vomiting. Can cause distillates and/or aromatic solvents. If
Ingestion
chemical pneumonia if aspired into lungs conscious, washout mouth and give water
following ingestion. to drink. Get medical attention.

4.4 Precautions& PPEs:

The dosing of NALCO chemicals involves handling of these chemicals. Following Personal Protective Equipments have
to be used to reduce the potential health risks due to use of these chemicals.
Chemical Respiratory Protection Eye Protection Skin protection
NALCO TRAC 109 Face shield Safety Goggles Nitrile Gloves
NALCO-8514 Face shield Safety Goggles Nitrile Gloves Chemical splash suit*
NALCO 71-D5 Face shield Safety Goggles Nitrile Gloves
The emergency eye wash and safety shower is located near to the chemicals preparation area and should be used
in case such a need arise.
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 Standard Operating Procedure

5.0 REQUIREMENTS
1- Sea water is available from Utilities Plant.
2- Desalination water is available from Utilities Plant.
3- Electrical power is available.
4- NALCO.

6.0 PREPARATIONS TO START FCW SYSTEM

7.0 START-UP
7.1 COOLING SYSTEM:

NOTE
All the high point vents must be ensured to be clear & not blocked as this will cause vapor lock and charging
of circuit will be improper that can cause damage to lines

CAUTION
Special care needs to be taken while lining up the plate exchangers to ensure that CW & SW
sides are pressurized almost simultaneously to avoid one side pressurization that may cause a
failure of the gaskets between the plates in the plate pack

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Standard Operating Procedure

NOTE
1- Each of these four Plate Heat Exchangers are cleaned by chemical cleaning that is done occasionally
by engaging a specialized external contractor. The major steps involved in such cleaning are typically:
• Water Flushing
• Degreasing
• Acid Pickling
• Neutralisation
• Flushing
• Passivation

Specific procedure given by contractor for such chemical cleaning is agreed & approved by GPIC prior to
its use by the contractor
2- Each of the four Plate Heat exchangers are re-gasketted periodically when it is sent to a specialized
approved vendor where complete plate pack is opened, inspected, cleaned chemically & by hydrojet,
re-gasketted using new set of gaskets, assembled, pressure tested & then put in position for service

7.2 PREPARATION AND STARTUP OF CW PUMPS

NOTE
Nalco 71-D5 dosing to be done as fast as possible for shock dosing effect. If full charge of chemical (5 Kg)
is not available, do not dose to the FCW system

37
 Standard Operating Procedure

CAUTION
This check to be performed only during Urea Plant Total Shutdown and upon
instruction from Urea Shift Supervisor.

CAUTION
Check & ensure that the standby pump is kept on Auto mode for auto start in case required.

8.0 SHUTDOWN OF FRESH COOLING WATER SYSTEM

9.0 FILLING AND PRIMING OF STANDBY FRESH COOLING WATER PUMP

10.0 Changing Over the Fresh Cooling Water pumps, P-3203A/B

38
Standard Operating Procedure

11.0 Operating Limits, Deviations, consequences& Corrective Actions

Process Steps to PSVs/
Sl. Parameter Normal Consequence
Paramater correct/Avoid Safety System /
No. Limit Range of deviation
Instr. No. deviation Trip Logic

39
 Standard Operating Procedure

12.0 Equipment & Instruments in the section:

12.1 List of Trip/Pre-trip alarm switches on CW system

Instt.
Service Description System Loca-tion Set Point Remarks
Tag No.

40
Standard Operating Procedure

12.2 List of Instruments on CW system

Instt Tag Description

41
 Standard Operating Procedure

12.3 List of Control Valves/ Motor Operated Valves in CW system

Tag No Location

42
Standard Operating Procedure

12.4 List of PSVs in SW & FCW system

SET
PSV# POSITION SERVICE DESCRIPTION P&ID
POINT

43
 Standard Operating Procedure

12.5 Equipment List

Equipment Code Service

44
Standard Operating Procedure

Responsibilities

References
P&ID
MSDS Material safety data sheets

45