Process Safety Management (PSM) Compliance Audits Building a Path to Excellence

John Keefe Work Processes Manager Lloyds Register Capstone Dick Baum Risk Management Services Manager Lloyds Register Celerity3

Welcome to Lloyds Register

2010

Building a Path to Excellence

Outline: Lloyds Register Why implement PSM? PSM Compliance Audit How we can help you

life matters
safety, Click integrity, performancetitle style to edit master 2010 Month YY

The Lloyds Register Group

Values We are a non-profit distributing organisation; impartial with complete financial, political and technical independence Our offer is distinct, transparent and results orientated We have 7,000 dedicated and highly competent employees worldwide

trusted un-biased recognised

safety, Click integrity, performancetitle style to edit master 2010 Month YY

Lifecycle solutions
Commissioning Operations Management Maintenance & Inspection Plan Development

Construction

Integrity
Design

Safety

Maintenance & Inspections Management

Performance
LifeLife-extension / ReRe-use / DeDe-commissioning ShutShut-down & Project Management Compliance Management Spare Parts Management

safety, Click integrity, performancetitle style to edit master 2010 Month YY

Why implement PSM?

Safety Compliance Business advantage

PSM is widely credited for reductions in major accident risk and in improved chemical industry performance. CCPS [emphasis added]

PSM is a business issue DuPont

safety, Click integrity, performancetitle style to edit master 2010 Month YY

History of PSM - DuPonts Perspective

Over 160 years operating hazardous processes Pre 1960 1960 1965 Explosion Louisville, Kentucky 1970 OSHA and states began developing regulations Bhopal 1984 1980 1979 First corporate standard (PHM) 1986 1990 1991 OSHA writes PSM ZIP Teams 1996 2000 2007 Ref NEP Chem NEP 2009 2010

Several accidents New Jersey 1970s

DuPont work with other companies

safety, Click integrity, performancetitle style to edit master 2010 Month YY

Inputs to PSM Compliance Audit

OSHA Process Safety Management (1910.119) EPA Regulation Part 68 Chemical Accident Prevention

PSM Compliance Audit Supporting Regs 1910.38 1910.120 1910.165 1910.252 1910.1200

Company Requirements

Recognized Practices

safety, Click integrity, performancetitle style to edit master 2010 Month YY

Process

Pre-Audit Evaluation On-Site Evaluation Kickoff Meeting Gather evidence interview, document review, records check, plant tour, personnel observations Protocol - scoring and findings Daily briefing Closing Meeting preliminary findings After On-Site Issue draft report Client feedback on draft / Appeal process Issue final report Debrief

safety, Click integrity, performancetitle style to edit master 2010 Month YY

On-Site Evidence Gathering

Broad examination of organization, process units, and physical assets

Detailed review of evidence to measure if program complies with regulation and if program is being implemented successfully

safety, Click integrity, performancetitle style to edit master 2010 Month YY

PSM Compliance Audit Components

Protocol and Scoring Tool PSM Compliance Audit

Pre-Audit Questionnaire

Interview Questions

Experienced Auditors

Guidance Notes

safety, Click integrity, performancetitle style to edit master 2010 Month YY

safety, Click integrity, performancetitle style to edit master 2010 Month YY

safety, Click integrity, performancetitle style to edit master 2010 Month YY

safety, Click integrity, performancetitle style to edit master 2010 Month YY

Scalable Scope

One-week gap analysis objectives: identify gaps minimize impact on personnel base scores on evidence Multi-week comprehensive analysis objectives: improve safety culture empower personnel streamline work processes establish leading and lagging KPIs maximize capabilities of existing information systems

safety, Click integrity, performancetitle style to edit master 2010 Month YY

PSM Compliance Audit Components

Protocol and Scoring Tool PSM Compliance Audit

Pre-Audit Questionnaire

Interview Questions

Experienced Auditors

Guidance Notes

safety, Click integrity, performancetitle style to edit master 2010 Month YY