Investigation of Process Safety Management (PSM) Approach for Process Industries: Operating Procedures (OP)

Unexpected releases of highly hazardous chemicals have occurred numerous times in process industries. One of the keys contributing factors that could prevent these accidents are by managing operating procedures according to established standards. One of the established industrial standards to manage Operating Procedures (OP) is specified under the code of federal regulations Chapter 29 Section 1910.119(f) in Process Safety Management (PSM) regulations. However, accident still can happen if the requirements of the standard not implemented as intended. Investigations revealed that despite the prevention efforts, the classical safety management approach is not effective enough to prevent major accidents from happening. The unavailability of easy technique for industries to comply with PSM requirements had delayed industries‟ efforts to accomplish best practices of PSM.
This study proposes a structured system to simplify the working process of OP that complies with OSHA PSM 29 CFR 1910.119(f). Piping and Instrumentation Diagram (P&ID) is used as a foundation for OP data management. It act as the basis to manage documentation, track required actions related and captures critical information pertaining to the process and thus prevent the missing of information related to Operating Procedures.
With a structured and systematic way in implementing the OP element of PSM, it is expected that best practices of PSM program helped to achieve operational excellence, manifesting in increased productivity, higher quality of deliverables, reduced waste, lowered operational costs, enhanced business performance and prevent major accidents.