Process Safety Management Improves Worker Safety, Focusing on Avoiding Incidents in Oil Refineries and Chemical Plants

    Process Safety Management Improves Worker Safety, Focusing on Avoiding
               Incidents in Oil Refineries and Chemical Plants

PR Newswire

CHICAGO, Oct. 24, 2013

November ASSE Professional Safety journal  examines how the implementation of
process safety management has minimized incidents at India's Essar Oil

CHICAGO, Oct. 24, 2013 /PRNewswire-USNewswire/ -- A string of disasters in oil
refineries and plants that produce materials such as fertilizer and chemicals
has drawn increased attention tothe industry's safety practices. In response,
India's Essar Oil Limited has implemented Process Safety Management (PSM) a
practice developed by OSHA, and designed to minimize the consequences of
catastrophic release of toxic, reactive, inflammable or explosive chemicals.
Essar Oil's adoption of PSM is outlined in Process Safety Management, the
Experience of Essar Oil a peer-reviewed feature in the November issue of
Professional Safety, the American Society of Safety Engineers' (ASSE) journal.

When released, chemicals could have a major impact on workers, surrounding
communities or facilities. The consequences of these incidents have
significant life-threatening, environmental, legal and financial implications.

PSM provides an environment for improvement and increased the awareness of the
safety impacts of technology, personnel and management of process hazards.

According to the article, PSM is still in the developmental stages in India.
Essar Oil which produces nearly 400,000 barrels per day began the PSM process
integration in 2010.

Essar adopted a basic framework consisting of 13 elements based on the OSHA
rule and Center for Chemical Process Safety (CCPS) guidelines, as well as
guidelines in India. The elements accepted into the Essar Oil PSM framework
are: employee participation, process safety information, process hazard
analysis, operating procedures, training, contractor safety management,
pre-startup safety review, mechanical integrity, hot work permit, management
of change, incident investigation, emergency planning and response and
compliance audits.

Implementation of PSM at the refinery occurred in phased, beginning with
employee participation. Each phase also referred to three pillars of integrity
– Operational, Plant and Design Integrity.

"The inclusion of employees in all aspects of process safety has been the
point that has enabled its implementation in the refinery," explained Gopal
Jayaraman, Ph.D, the article's author.

As of August, 2013, Essar Oil has achieved over 2,000 Lost Time Injury
(LTI)-Free Days and over 1500 major fire-free days.

"Implementing PSM in the refinery has been a fruitful challenge," said
Jayaraman. "The approach that it provides guides us in the formation of a
positive safety culture within the complex."

For more than 50 years, ASSE's Professional Safety journal has been sharing
the latest technical knowledge in SH&E—information that is constantly being
developed through research and on-the-job experience. Each issue delivers
practical guidance, techniques and solutions to help SH&E professionals
identify hazards, protect people, prevent injuries, improve work environments
and educate management that investing in safety is a sound business strategy.
For more information please visit

Founded in 1911, the Chicago-based ASSE is the oldest professional safety
organization and is committed to protecting people, property and the
environment. Its more than 35,000 occupational safety, health and
environmental professional members lead, manage, supervise, research and
consult on safety, health, transportation and environmental issues in all
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SOURCE American Society of Safety Engineers

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