PROCESS SAFETY MANAGEMENT SERVICES 1. Gap assessment of existing process safety management systems to requirements of US OSHA 1910.

119 PSM Rule 2. Implementation of Process Safety Management (PSM) System as per US OSHA 1910.119 PSM Rule 3. Integration of PSM system with existing OHSAS 18001/ ISO 14001 systems

4. Asset Integrity and Quality Assurance program development 5. Emergency and Crisis Management System audit 6. Setting up foolproof system for Management of Change 7. Security Vulnerability Assessment 8. Setting up of a comprehensive Incident Investigation system based on Root Cause analysis. 9. 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 Mechanical energy lock out and tag out Cold work Pipeline breaking / equipment opening Fire water system lock out Emergency fire system closure Excavation Working on fragile roof About the PSM system: The Process Safety Management System as per US OSHA CFR 1910.119 PSM rule is a comprehensive management system that proactively avoids incidents in oil refineries, fertilizer, pesticides, pharmaceutical, explosives and chemical 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. 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. This system is mandatory in the USA for chemicals handling, storing or processing hazardous chemicals, above a threshold quantity. 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 Councils (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. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. The Process Safety Management System consists of 14 elements: Employee participation Process Safety Information Operating Procedures Process Hazard Analysis Contractor control Safe work practices Training Pre-Start up Safety Review Mechanical integrity Management of Change Incident Investigation Emergency response planning Compliance audits Trade secrets Benefits of the Process Safety Management System: Proactive management system, focuses on avoiding incidents. Safer workplace for employees. Reduced risk of adverse environmental impact. Compliance with 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 Demings 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, which is mandatory in the USA. All the elements of the PSM system are part of the requirements of the International Safety Rating System (ISRS). Companies which implement PSM system could expect to achieve a high score on the ISRS. Integrates effectively with Environmental Management System ISO 14001 and OHSAS 18001as 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. PROCESS SAFETY TRAINING Prism Consultants conducts the following training modules on Process Safety. These courses can be conducted at customers premises also. 1 day training on Developing Process Safety Culture Lessons for Management 2 Day training on Elements of Process Safety Management 1 Day training on Process Safety for Plant Operators 2 Day training on Management of change 2 Day training on Process incident investigation root cause analysis 1 Day training on Process Safety in API manufacturing and R & D

2 Day training on Introduction to Process Hazard Analysis and Hazard and Operability Study 2 day training on Hazards of non routine operations (including work permit systems) 1 Day training on Learning from incidents 2 Day training on Developing a Mechanical Integrity program 1 Day training on Writing Effective Operating procedures 2 day Internal Auditor training for developing auditing skills for auditing Process Safety Management System. 2 day training on " Engineering Design for Safety" In addition to the above, training on specific process safety related topics as per customer requirements are also conducted For a detailed brochure, please submit enquiry or contact us at info@prismcon.net HAZID / HAZOP STUDY HAZID The Hazard Identification (HAZID) is a high level review of potential hazards, based on checklists. Prism Consultants HAZCHEK proprietary checklists have been developed after years of experience and cover facility siting, human factors and best engineering practices. HAZID is the first step in primary risk assessment for a new facility. HAZOP Hazard and Operability (HAZOP) study for continuous or batch processes, or procedural operations is an excellent tool to identify potential hazards and operability issues and recommending preventive actions. Prism Consultants expertise facilitates HAZOP studies in the role of HAZOP Team leader and ensures that the HAZOP study identifies the following: The hazards of the process The identification of any previous incident which had a likely potential for catastrophic consequences in the workplace Engineering and administrative controls 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 of failure of controls on employees in the workplace. A good HAZOP study is also used as an input for proceeding with Layers of Protection Analysis. It must be remembered that a good HAZOP study is only as good as the skills of the facilitator and team members. Prism Consultants technical expertise and human factor approach to HAZOP studies helps to maximize the output of the HAZOP team. Prism Consultants have conducted numerous HAZIDs/HAZOP studies for their multinational clients. Their practical approach helps clients to correctly identify the hazards and implement cost effective solutions. The focus on the Human Factor approach to HAZOP studies assist the client to identify potential hazards that may not be spotted in a regular HAZOP study. Please submit enquiry or contact us at info@prismcon.net LAYERS OF PROTECTION ANALYSIS ( LOPA ) Layer of protection analysis (LOPA) is a semi quantitative tool for analyzing and assessing risk. LOPA can be used in all phases of the process life cycle. LOPA helps to make consistent decisions on the adequacy of the existing or proposed layers of protection to prevent incidents. LOPA looks at the safeguards on a process plant to evaluate the adequacy of existing or proposed layers of protection against known hazards. It typically builds on the information developed during a qualitative hazard evaluation, such as a process hazard analysis, and can be used to meet the risk assessment requirements of IEC 61508 and IEC 61511.

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The designer normally follows the sequence given below to eliminate hazards or to reduce the frequency of undesired consequences: Inherently safer concepts Basic process control system Safety instrumented systems Passive devices (such as dikes and blast walls) Active devices (such as relief valves) Prism Consultants expertise facilitates Layers of protection analyses in the role of facilitator. PROCESS INCIDENT INVESTIGATION Prism Consultants independently carry out third party investigation of process incidents like fires, explosions, runaway reactions, tank collapses, abnormal situations etc that have a direct bearing on process safety. The aim of these investigations is to enable management to pinpoint the root causes of the incident including human factors that led to the incident and to avoid recurrence of the incident. The investigation also helps to identify management issues that may be having an effect on process safety. These issues could include communication, culture and competency issues. Prism Consultants fully understands the confidentiality of company specific information and will hold all information, findings, observations, reports, etc in strictest confidence. Prism Consultants have conducted process incident investigation for flare explosions, storage tank failures, catalyst poisoning incident, runaway reactions, fired heater coil rupture, centrifuge fires, batch process feeding fire incident etc. Prism Consultants use widely accepted and proven techniques (causal factor charting, fault tree analysis and change analysis, barrier analysis, MTO analysis etc) to gather and analyze information to identify the root and contributing causes of the incident.

The steps followed for investigation of incidents are: Gathering the relevant data Analyzing the data to determine causal factors Identifying root and contributing causes of the incident Developing recommendations to address the root causes Documentation of the incident investigation report RESPONSIBLE CARE GAP ASSESSMENT AND RCMS (RESPONSIBLE CARE MANAGEMENT SYSTEM) IMPLEMENTATION Background of Responsible Care: Responsible Care was first launched in Canada and has since spread across 46 countries. A social responsibility initiative of the global chemical industry, Responsible Care is built around a set of guiding principles, and six codes of management practice that help in achieving them.

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The six codes as conceived by the ICC (Indian Chemical Council) are: Process safety code Employee health and safety code Pollution prevention code Emergency response code Distribution code Product stewardship code The aim is to ensure that chemical companies act responsibly towards the environment and the public, so that society can enjoy the benefits of chemicals without risk. Companies that are signatories to the initiative have to show continuous improvement in all areas that relate to the safety and health of their employees and the

general public. Prism Consultants provide services to assess an organizations existing management systems against the requirements of the codes of Responsible Care as well as Responsible Care Management System. Based on the gap assessment, Prism Consultants also provides assistance to plug these gaps. Please submit enquiry or contact us at info@prismcon.net SAFETY, HEALTH & ENVIRONMENT DUE DILIGENCE AUDIT FOR ACQUISITIONS: A fundamental principle in jurisprudence is that "ignorance of law is not excusable." After the Bhopal gas disaster in December 1984 and other incidents, amendments were made to Indian Safety, Health and Environment (SHE) regulations. In the factories act, the responsibility of Occupier was changed to one of the board of directors (in a public limited company). The Occupier is responsible for the safety of workers and surrounding public. For lapses in safety, health and environment provisions, the occupier can be criminally prosecuted both under the Penal code 1860 and as absolute offences, where breach of provision in the law (by neglect or by commission) becomes punishable, even when no intention to commit an offence need to be proved before punishment is given. Breaches of provision in the Factories act 1948 and amendments fall within the laws understanding of absolute offences. Today, organization are growing through the acquisition of assets. The Safety, Health and Environment liability of the newly acquired assets should be carefully scrutinized prior to acquiring the assets to avoid potential issues later. Prism Consultants provide a comprehensive Safety, Health and Environment Due Diligence assessment for potential acquisitions of Chemical units in India. ENVIRONMENT MANAGEMENT SYSTEM - ISO 14001 IMPLEMENTATION Prism Consultants provide implementation support to organizations implementing the international voluntary Environmental Management System standard ISO 14001 Many organizations are going in for this voluntary standard due to the growing environmental awareness. Implementing an Environmental Management System conforming to ISO 14001 yield the following benefits: Improved environmental performance Increased efficiency resulting in reduced wastes and consequent savings in costs. Ongoing compliance to legislations, existing and potential. Enhanced image in the eyes of external parties. Preference from financial institutions in granting loans. Continual improvement in environmental performance Improved accountability within an organization Prism Consultants provide practical and cost effective methods for implementing the ISO 14001 Environmental Management System in our customers organization. The approach is based on the experiences gained in implementing the system in large organizations, with emphasis on change management. The services provided by Prism Consultants for ISO 14001 include:

Implementation support from start to finish (till certification), covering: Policy formulation Identification of environmental aspects and significant aspects Identification of legal and other requirements Development of objectives and programmes

Competence, training and awareness Communication Documentation and control of documents Development of operation control procedures Development of emergency preparedness and response plans Monitoring and measurement Evaluation of compliance Non Conformity , corrective action and preventive action Control of records Internal Audit Management review Tailor-made training packages for creating environmental awareness, covering management and nonmanagement staff. (In large organizations, train the trainer's sessions will be conducted). Independent audits of the Environmental Management System as per audit criteria set by the customer. Integration of ISO 14001, environmental management system, with OHSAS 18001 (Occupational safety and health standard) and Process Safety Management Systems. What makes Prisms services for implementation of OHSAS 18001 and ISO 14001 different from others? Years of experience in implementing systems has provided Prism consultants a unique understanding of the change management strategies which are effective in Indian conditions. Prism consultants strongly believe that a system will be sustainable only when the belief in that system develops among all employees. Prism adopts a professional team based approach in implementing the systems, involving non-management staff also. Prism consultants work closely with the individual teams to ensure complete understanding and sustainable implementation of the system. Prism consultants assist the client organizations throughout the spectrum of implementation of OHSAS 18001 and ISO14001 till certification is achieved. At all stages, the focus is on feedback mechanisms to enable continual improvement of the implementation program. Prism consultants operate ethically and follow a code of confidentiality, which includes safeguarding client information obtained during the implementation and non-disclosure of such information to any third party without written approval from the client. OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT SYSTEM - OHSAS 18001 IMPLEMENTATION Prism Consultants provide implementation support to organizations implementing the international voluntary Occupational health and safety management system based on the OHSAS 18001 standard. OHSAS 18001 is a comprehensive, certifiable Occupational Health and Safety (OH&S) management system standard, designed to enable organizations to control OH&S risks and improve its performance. The OHSAS 18001 standard is internationally recognized. Conformance auditing and certification to OHSAS 18001 by a third party accrediting body, assure credibility of the programs and periodic evaluation to ensure maintenance and continual improvement. OHSAS 18001 can be applied to any type of business, organization or industry that wishes to manage its risks for Health & Safety in the work place. The OHSAS 18000 series that includes OHSAS 18001 Occupational Health and Safety Management Systems (OHSMS) grew out of the international success of the ISO 9000 and ISO 14000 series of Standards and the need for managing safety in the work environment. OHSAS 18001 was jointly developed by national standards organizations and international certification bodies. In addition to the OHSAS 18001 standard, a guidance document in this series known as OHSAS 18002 Occupational Health and Safety Management Systems Guidelines for the implementation of OHSAS 18001 is

available. Organizations self certify or register to only the OHSAS 18001 Standard. OHSAS 18001 has been developed to be compatible with ISO 9001 and ISO 14001 to allow for easy integration. Top management commitment, legislative & regulatory commitment and continual improvement are important aspects of OHSAS 18001. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 1. 2. 3. 4. The elements of OHSAS 18001 include: OHS policy Hazard identification, risk assessment & determining risk controls Legal and other requirements Objectives & programmes Resources, roles, responsibility, accountability and authority Competence, training and awareness Communication, participation and consultation Documentation & control of documents Operational Control Emergency preparedness and response Performance measurement & monitoring Evaluation of compliance Incident investigation, non conformity, corrective & preventive action Control of records Internal audit Management review Benefits of OHSAS 18001 include: Support OH&S regulatory obligation compliance Improve safety culture within the organization Reduce severity of incidents and improves productivity Improves organizations reputation OHSAS 18001 is almost identical to ISO 14001 in its auditable elements. Prism consultants also provide support for integrating both the systems.
USEFUL LINKS

Indian Legislation connected with Safety and Environment: Environmental regulations updates from Ministry of Environment and forests, India: www.envfor.nic.in Petroleum and explosives Safety organization: www.peso.gov.in Factories act, rules, India: www.dgfasli.nic.in Process Safety and Occupational Health and Safety: Process Safety India http://indiaprocesssafety.blogspot.com Health, Safety, Executive, UK: www.hse.gov.uk US Chemical Safety Board: www.csb.gov National Institute of occupational safety and health: www.cdc.gov Occupational Safety and Health Administration, USA: www.osha.gov General: Chemical engineering on the web: www.che.com National association of corrosion engineers: www.nace.org National Fire Protection Association: www.nfpa.org Environmental protection agency, USA: www.epa.gov