Training and Process Safety Management-Article 3

I wrote two articles on same topic in January 2021 and February 2022. This is my third article on same topic. Through these articles, I am trying to establish how training is inseparable from any of the elements of Process Safety Management (PSM). Training is an integral part of every PSM element and for implementation of every PSM element, training of core team and everyone else at site is must.

In this article I am covering six PSM elements. I am taking care to include vital information mentioned in my previous two articles. You don’t require to refer to my previous articles while going through this article. I shall cover remaining elements in subsequent separate articles.?

Once again going by basics- Process Safety Management (PSM) refers to a set of interrelated approaches to managing hazards associated with the process industries and is intended to reduce the frequency and severity of incidents resulting from releases of chemicals and other energy.

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.

Training is the process of imparting knowledge and skills to the participants on a topic finally for carrying out the specific task. This can take place in a classroom, workplace or through Online mode. Training is usually provided by subject matter expert or person/s having established knowledge and skills with respect to topic or task.

Every element of PSM is closely interlinked with other PSM elements. There are very close links of PSM training element with other elements of PSM.

Training Matrix for PSM Training-

For covering all employees of a Site or a company, a Training Matrix must be prepared clearly indicating which training will be imparted to which employee. This is a simple yet proven tool to ascertain that identified training is planned and imparted to every employee as per the requirement.

In all, three levels of PSM training are common in practice across all employees of a company.

Basic PSM Training:

-Everyone- employee and contractor, must be trained on basics of PSM.

-This can be half day to one day training normally imparted by an internal faculty from PSM core team.

- Objective is to create awareness across.

- This training will touch upon each of PSM elements being developed for the organization/site.

Intermediate PSM Training:

-This training is for every technical employee broadly. Employees in Operations, Maintenance, Process- Technical Services, and Central Engineering, Process Safety and HSEF department will be trained. These groups have direct roles in developing and sustaining PSM elements.

-This can be two to three days training and normally an external faculty is hired for this training. This can also be handled by internal team when internal team members are actually competent for imparting this training.

- Objective is to make the team acquainted with each of PSM elements in details.

Advanced/ Comprehensive PSM Training:

-This training is for PSM Core team and few other persons who are directly responsible for developing PSM for the organization.

-This may be number of days training taking place number of times. This training is imparted by an external consultant.

-Objective is to make the team competent to drive PSM for the organization.

Both initial and refresher training sessions are required.

Process Safety Information:?It is necessary to have a compilation of written process safety information before conducting any process hazard analysis required by the standard.

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.

Obviously, team developing documents for Process Safety Information will be trained for how to take care of the Standard and others need to be trained on how to understand the Process Safety Information document prepared by the team.

Process Hazard Analysis (PHA):?The process hazard analysis is a thorough, orderly, systematic approach for identifying, evaluating, and controlling the hazards of processes involving highly hazardous chemicals.

It is essential to perform an initial process hazard analysis (hazard evaluation) on all processes covered by this standard. There are different methods such as HAZOP, What-if, Checklist, Fault Tree etc. and appropriate method is to be selected.

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.

OSHA guidelines also state about who all should be members conducting Process Hazard Analysis.

PHA is vital for identifying and controlling hazards of processes. Team members involved in carrying out PHA have to be trained in depth. Even if you hire an external HAZOP leader, roles of HAZOP team members are really significant and team members have to be duly trained.

Operating Procedures

It is must to 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.

As per OSHA, tasks and procedures related to the covered process must be appropriate, clear, consistent, and most importantly, well communicated to employees.

There are number of factors which are to be considered for preparing and finalizing the Operating Procedures. Team members developing and finalizing are required to be trained for preparing and finalizing the procedures.

It is essential that updated procedures are available for employees for training and necessary references. Necessary review and updating will also be required. Job Cycle Check or crosschecking that actual tasks are carried out as per the Operating Procedures will be vitally useful.

Contractors

As per the standard, the contract employer must:

·??????Ensure that contract employees are trained in the work practices necessary to perform their job safely

·??????Ensure that contract employees are instructed in the known potential fire, explosion, or toxic release hazards related to their job and the process, and in the applicable provisions of the emergency action plan

·??????Document that each contract employee has received and understood the training required by the standard by preparing a record that contains the identity of the contract employee, the date of training, and the means used to verify that the employee understood the training;

?Pre-Start up Safety Review

It is important that a safety review takes place before any highly hazardous chemical is introduced into a process. PSM, therefore, requires the employer to perform a pre-start up safety review for new facilities and for modified facilities when the modification is significant enough to require a change in the process safety information.

Prior to the introduction of a highly hazardous chemical to a process, the pre-start up safety review must confirm for number of points including the following point on Training.

? Training of each employee involved in operating a process must be completed.

?Employee Participation

It is important to develop a written plan of action to implement the employee participation required by Process Safety Management.

It is must to consult employees for conducting and developing of various PSM elements. Employees must be provided with all necessary information required for conducting and developing various PSM elements.

As per OSHA, Initial training and subsequent Refresher training must be conducted after three years after initial training. Necessary record must be maintained indicating required details such as date of training and validation methodology for every concerned employee.

At Last-

Lot of training is already included in every PSM element. Training cannot replace any of other PSM elements; it can greatly support and strengthen the other elements. Even the best of the PSM system would fail if everyone involved in driving PSM is not adequately trained.

You cannot develop and sustain PSM without Training.

Feel free to contact for any discussion.

# Safety Training ## Training ## Leadership Focus## Process Safety Management ##Success in Oil & Gas#

?Shobhan M Mehta, Dip TD (?[email protected])

Qualified NEBOSH PSM professional, Tech IOSH

Senior Member- American Institute of Chemical Engineers