FEATURE
| JURUTERA March 2012 20
The Growing Demand for
Process Safety Management in Malaysia
by Ir. Abdul Aziz bin Salim
PROCESSVDIHW\³VPDLQREMHFWLYHLVEDVLFDOO\WRSUHYHQW»UHVH[SORVLRQV and accidental chemical releases in chemical process facilities or other IDFLOLWLHV GHDOLQJ ZLWK KD]DUGRXV PDWHULDOV VXFK DV UH»QHULHV DQG RLO DQG gas (onshore and offshore) production installations.
History has recorded many catastrophic process accidents such as the )OL[ERURXJKH[SORVLRQZKHUHSHRSOHZHUHNLOOHGWKH%KRSDO OHDNZKHUHSHRSOHZHUHNLOOHGWKH&KHUQRE\OOHDNZKHUHPRUH WKDQSHRSOHZHUHNLOOHGDQGWKHUHFHQW)XNXVKLPDQXFOHDUOHDNV7KHVH accidents alone are enough to remind us just how important process safety management (PSM) is.
7KHRFFXSDWLRQDOVDIHW\DQGKHDOWK26+ODZHQIRUFHGLQWKLVFRXQWU\
26+$FRYHUVPDLQO\WKHJHQHUDODVSHFWVRIVDIHW\PDQDJHPHQWDQG SULPDULO\IRFXVHVRQWKHGXW\RIWKHHPSOR\HUHPSOR\HHDQGRWKHUSDUWLHV ,QLQGXVWULHVZKHUHKLJKO\KD]DUGRXVFKHPLFDOSURFHVVHVDUHLQYROYHGWKH 26+PDQDJHPHQWDORQHPD\QRWEHVXI»FLHQWWRDGGUHVVWKHLVVXHVHYHQ WKRXJKDWWLPHVZHOOGHYHORSHGPDQDJHPHQWVDIHW\V\VWHPVPD\GRVR
7KH WRROV WHFKQLTXHV DQG SURJUDPPHV UHTXLUHG WR PDQDJH ERWK WKH SURFHVVDQGRFFXSDWLRQDOVDIHW\FDQVRPHWLPHVEHWKHVDPHIRUH[DPSOH D :RUN 3HUPLW V\VWHP ZKLOH LQ RWKHU FDVHV LW PD\ KDYH YHU\ GLIIHUHQW DSSURDFKHV )RU H[DPSOH /23& /RVV RI 3ULPDU\ &RQWDLQPHQW RU 45$
4XDQWL»HG5LVN$VVHVVPHQWIRFXVHVRQSURFHVVVDIHW\ZKHUHDV3HUVRQDO 3URWHFWLYH(TXLSPHQW33(RU2SHUDWLQJ3URFHGXUHV23LVYHU\PXFKDQ occupational safety issue.
ELEMENTS OF PSM
:LWKLQLWV360UHJXODWLRQV26+$86OLVWVVHSDUDWHHOHPHQWV 1. Employee Participation
Process Safety Information (PSI) 3. 3URFHVV+D]DUG$QDO\VLV3+$
4. 2SHUDWLQJ3URFHGXUHV23 7UDLQLQJ
&RQWUDFWRUV
7. 3UH6WDUWXS6DIHW\5HYLHZ3665DOVRNQRZQDV3$65 Mechanical Integrity (MI)
9. +RW:RUN3HUPLWV
0DQDJHPHQWRI&KDQJH02&
11. Incident Investigation
(PHUJHQF\3ODQQLQJDQG5HVSRQVH(53 13. &RPSOLDQFH$XGLWV
14. 7UDGH6HFUHWVRU3URSULHWDU\/LFHQVHV 7HFKQRORJ\$VVHVVPHQW3/7$
2XW RI WKHVH HOHPHQWV VRPH DVSHFWV RU HOHPHQWV KDYH DOUHDG\ EHHQ LQFRUSRUDWHGLQWRWKHH[LVWLQJ26+PDQDJHPHQWV\VWHPVSUDFWLVHGE\WKH LQGXVWULHVFRQFHUQHG7KHVHHOHPHQWVDUHHPSOR\HHSDUWLFLSDWLRQWUDLQLQJ FRQWUDFWRUVKRWZRUNSHUPLWVLQFLGHQWLQYHVWLJDWLRQV(53DQGDXGLWV Mackenzie Industries Sdn Bhd
Visit us at www.mackenzieind.com Tel : +603 5123 0018 Fax : +603 5123 0028
E-mail : [email protected] We specialise in the engineering design, manufacturing and supply of….
x Biomass Boiler
x Heat Recovery Steam Generator (HRSG) x High Pressure Boiler
x Oil/Gas Fired Packaged Boiler
with auxiliary equipment to enhance boiler ƉĞƌĨŽƌŵĂŶĐĞĂŶĚĞĸĐŝĞŶĐLJ
x 'ƌĂƚĞ͗sŝďƌĂƟŶŐ͕ZĞĐŝƉƌŽĐĂƟŶŐ x Boiler Feedwater Economiser x Air Preheater
A Member of tĂŚ^ĞŽŶŐŽƌƉŽƌĂƟŽŶŚĚ
PROVIDE STEAM SOLUTION FOR TOMORROW’S INDUSTRY ENERGY NEEDS
Our strengths:-
t1SPWJEFDVTUPNJTFETQFDJmDBUJPOT t)JHIFGmDJFOUTUFBNTPMVUJPO t4VTUBJOBCMFFOFSHZHFOFSBUJPO
FEATURE
March 2012 JURUTERA | 21 7KLV OHDYHV EHKLQG VHYHQ HOHPHQWV $QG E\ DGGLQJ WKH
HOHPHQWRI'HVLJQ,QWHJULW\',WKLVPDNHVDWRWDORIHLJKW elements which are used or adopted by most organisations when it comes to PSM implementation.
$PRVWLPSRUWDQWRUFUXFLDO360HOHPHQWLVWKH3URFHVV +D]DUG$QDO\VLVRU3+$$3+$LVEDVLFDOO\DV\VWHPDWLF evaluation of the hazards involved prior to initiation of a SURFHVV DQG VKRXOG EH FDUULHG RXW DW OHDVW RQFH HYHU\
»YH\HDUVWKHUHDIWHURUZKHQHYHUWKHUHLVDFKDQJHLQWKH SURFHVV7KHHYDOXDWLRQWHDPVKRXOGEHPXOWLGLVFLSOLQDU\
DQGLQFOXGHPDLQWHQDQFHRSHUDWLRQVDQGHQJLQHHULQJ 7KHUHDUHYDULRXVPHWKRGVWKDWFDQEHXVHGWRFRQGXFW D 3+$ LQFOXGLQJ WKH :KDWLI +D]DUG DQG 2SHUDELOLW\
6WXGLHV +$=23 DQG )DLOXUH 0RGH DQG (IIHFW $QDO\VLV )0($7KHPHWKRGVHOHFWHGZLOOGHSHQGRQWKHPDWXULW\
RIWKHSURFHVVDQGRSHUDWLRQDOH[SHULHQFHLQDGGLWLRQWRWKH SURFHVVVL]HDQGFRPSOH[LW\7KHIDFLOLWDWRURIWKH3+$PXVW EHWUDLQHGLQWKHPHWKRGRORJ\EHLQJXVHG7KDWSHUVRQFDQ WKHQVHOHFWWKHPHWKRGZKLFKKHRUVKH»QGVVXLWDEOHZLWKLQ that particular industry.
7KH QH[W LPSRUWDQW HOHPHQW LV WKH 3URFHVV 6DIHW\
,QIRUPDWLRQ 36, )RU D SURSHU FRQGXFW RI 3+$ WKH 36, PXVW EH DV FRPSOHWH DV SRVVLEOH 8QGHU WKLV HOHPHQW complete and accurate written information concerning SURFHVV FKHPLFDOV SURFHVV WHFKQRORJ\ DQG HTXLSPHQW should be prepared. Process technology includes Process )ORZ 'LDJUDPV 3)'V 3LSLQJ DQG ,QVWUXPHQWDWLRQ 'LDJUDPV3 ,'VRSHUDWLQJDQGVWRUDJHFRQGLWLRQVDVZHOO as operating procedures and operating history. Process HTXLSPHQWLQIRUPDWLRQVKRXOGLQFOXGHWKHXQGHUO\LQJFRGHV and standards relied upon.
PROCESS SAFETY INCIDENTS
,Q RXU FRXQWU\ WKH LQFLGHQFH RI SURFHVV VDIHW\UHODWHG DFFLGHQWV LV FRQVLGHUHG ORZ +RZHYHU LQ UHFHQW \HDUV a number of process safety-related incidents have occurred and have been investigated by the Department RI2FFXSDWLRQDO6DIHW\DQG+HDOWK'26+7DEOH7KHVH LQFLGHQWVVKRZXVWKDWWKHUHDUHVRPHZHDNQHVVHVLQWKH 360EHLQJLPSOHPHQWHG7KH360DVSHFWVWKDWDUHVHHQWR EHRIFRQFHUQDUH3+$0,DQG23
:KLOHWKHLPSRUWDQFHRI3+$KDVDOUHDG\EHHQGLVFXVVHG 0, UHTXLUHV HPSOR\HUV WR KDYH D ZULWWHQ SURJUDPPH WR HQVXUHWKHLQWHJULW\RISURFHVVHVDQGHTXLSPHQW
$VSHFWV LQFOXGH OLVWLQJ DSSOLFDEOH HTXLSPHQW WUDLQLQJ PDLQWHQDQFH SHUVRQQHO LQVSHFWLRQ DQG WHVWLQJ DQG WKH PDLQWHQDQFHRIV\VWHPVVXFKDVFRQWUROVYHVVHOVSLSLQJ UHOLHYH YDOYHV DQG HPHUJHQF\ V\VWHPV$Q\ GHYHORSPHQW DQG PRGL»FDWLRQ WR WKH PHFKDQLFDO LQWHJULW\ SURJUDPPH VKRXOGEHPDGHEDVHGRQRSHUDWLRQDOH[SHULHQFHUHOHYDQW codes and industry standards.
7KH 23 RQ WKH RWKHU KDQG LQFOXGHV QRW RQO\ WKH VWHSVIRUQRUPDORSHUDWLRQVEXWDOVRIRUXSVHWFRQGLWLRQV WHPSRUDU\RSHUDWLRQVVWDUWXSDQGVKXWGRZQZKHQPRVWRI WKHLQFLGHQWVDUHOLNHO\RUSURQHWRRFFXU0RUHLPSRUWDQWO\
safety information must also be included in operating procedures. Such information includes the basic hazards of H[FHHGLQJRSHUDWLRQDOOLPLWVDSSURSULDWHUHVSRQVHWRXSVHW FRQGLWLRQV VDIHW\ DQG KHDOWK LQIRUPDWLRQ DQG HPHUJHQF\
RSHUDWLRQV7KHSURFHGXUHVQHHGWREHUHYLVHGUHJXODUO\
CURRENT SCENARIO OF PSM
'26+ KDV FRQGXFWHG SUHOLPLQDU\ DXGLWV RQ WKH FKHPLFDO SURFHVV LQGXVWU\ )URP WKLV VXUYH\ LW ZDV IRXQG WKDW IRU PXOWLQDWLRQDO FRPSDQLHV WKH\ KDYH DOUHDG\ HPEDUNHG RQ 360 TXLWH FRQYLQFLQJO\ ZKHUHDV RWKHUV DUH VWLOO ODJJLQJ EHKLQG DQG ODFN WKH ULJKW NQRZOHGJH DQG H[SHUWLVH ,W LV common for the process owners surveyed to assume that 360 LV DGHTXDWH E\ GRLQJ RU FRQGXFWLQJ +$=23 ZLWKRXW understanding that it is only one of the sub-elements of the 3+$LWVHOI
Most of the process industries (which are using considerable amount of hazardous chemicals) surveyed is LQWKHVWDJHRIHVWDEOLVKLQJDQGH[HFXWLQJWKH360ZLWKLQ WKHLU RUJDQLVDWLRQV 7KH HIIRUW LV GRQH PDLQO\ WR FRPSO\
ZLWK26+$SDUWLFXODUO\WKH&RQWURORI,QGXVWULDO0DMRU
$FFLGHQW+D]DUGV&,0$+UHJXODWLRQV
FUTURE DEVELOPMENTS
7KHSURFHVVLQGXVWU\HVSHFLDOO\WKHRLODQGJDVVHFWRULVD PDMRUFRQWULEXWRUWRRXUFRXQWU\³VHFRQRPLFJURZWK7KLVLV H[SHFWHGWRFRQWLQXHXQWLOWKH\HDU
No Aspects of PSM Concerned
Incident Summary
1. 3+$0, )LUHVWDUWHGIURPOHDNLQJSLSHOLQHFDXJKW IURPKRWHTXLSPHQWQHDUE\
233+$
Mi
3LSHOLQHVRQ»UHGXULQJGHSUHVVXULVDWLRQ
3. '/0, Fire in a reactor process unit.
4. 3/7$23 3+$
Vessel containing chemical compound H[SHULHQFHGH[RWKHPLFUHDFWLRQWKXVFDXVLQJ WKHSUHVVXUHWREXLOGXSDQGH[SORGH 233+$ )XUQDFHH[SHULHQFHGH[WHUQDO»UHGXHWR
positive draft.
Table 1: Illustration for the type of process safety incidents investigated by DOSH in recent years
Figure 1: PSM Implementation status by one sample organisation (Source: DOSH)
PSN Aspects Implementation as of March 2011 100
90 80 70 60 50 40 30 20 10 0
Sustaining the system Execution
System in Place
MOC PSI PHA PSSR PLTA
Score, %
OP MI DI
FEATURE
| JURUTERA March 2012 22
REFERENCES
[1] The Occupational Safety and Health Act (OSHA), 1994
[2] Department of Occupational Safety and Health (DOSH) Report on PSM initial audits (unpublished), 2011
[3] The Occupational Safety and Health (OSHA, US) 3133 Process Safety Management Guidelines for Compliance, 2000
[4] Process Safety Management of Highly Hazardous Chemicals Standard, Title 29, Code of Federal Regulations (CFR) Part 1910.119, 1992
Central Geo
Think Big, Act Precisely
Tel : 605 - 357 4100 (Office) H/p : 012 - 505 7127 -(Lam) Email : [email protected]
Website : www.centralgeomachinery.com
Biggest
All Terrain Crane (880t) In Malaysia
Advancing Heavy Lifting Services In Malaysia
*Max Height (H) Radius (R) Loads (t)
H60m (107t)
H122m (8.8t)
H145m (6.9t)
R54m (21t)
R92m (2.2t)
R103m (2t)
880t (R3m)
60t (R14m)
125t (R14m) Main Boom
Lattice Fly Jib Luffing Lattice Jib
Crane's Specification (880t)
,QDUHFHQWGHYHORSPHQWRXU3ULPH0LQLVWHUKDGXQYHLOHG plans by a leading oil and gas company to build a new 50ELOOLRQLQWHJUDWHGUH»QHU\DQGSHWURFKHPLFDOFRPSOH[
LQ3HQJHUDQJ-RKRU
8SRQ FRPSOHWLRQ WKH QHZ FRPSOH[ FDOOHG 5$3,' 5H»QHU\ DQG 3HWURFKHPLFDOV ,QWHJUDWHG 'HYHORSPHQW ZLOO FRQVLVW RI D EEOGD\ FUXGH RLO UH»QHU\ D QDSKWKD FUDFNHU WKDW ZLOO SURGXFH DERXW PLOOLRQ WRQQHV RIHWK\OHQHSURS\OHQH&DQG&ROH»QVHDFK\HDUDQG D SHWURFKHPLFDO DQG SRO\PHU FRPSOH[ SOXV D OLTXH»HG QDWXUDO JDV /1* UHFHLYLQJ DQG UHJDVL»FDWLRQ WHUPLQDO ZLWKLQWKH5$3,'FRPSOH[WRVXSSRUWLWVRYHUDOORSHUDWLRQV 7KLVDQGRWKHUSURMHFWVZLOOUHTXLUHWKRURXJKSODQQLQJDQG implementation of PSM.
CONCLUSION
&RQVLGHULQJ WKH FXUUHQW DQG IXWXUH GHYHORSPHQW RI SURFHVV LQGXVWULHV LQ WKLV FRXQWU\ LW LV LPSRUWDQW IRU HYHU\SDUW\LQYROYHGWRWDNHQHFHVVDU\DFWLRQWRDGGUHVV the issue of PSM. Employers or companies which have already established such systems may further enhance WKHP ZKLOH WKH DXWKRULWLHV RQ WKH RWKHU KDQG VKRXOG produce at least some sort of guidelines (if not regulations per se) to assist the smaller industries in implementing PSM and to set the minimum standards for the process industries to follow through.
PSM can be an effective tool for increasing not only WKH VDIHW\ WR DQ RSHUDWLRQ EXW DOVR LWV HI»FLHQF\ FRVW HIIHFWLYHQHVV DQG TXDOLW\ DQG LV LQFUHDVLQJO\ EHFRPLQJ the standard to which the industry is being held. PSM is an LQVWUXPHQWIRUGHYHORSLQJLPSOHPHQWLQJDQGPDLQWDLQLQJ DVDIHDQGHI»FLHQWSURFHVVDVZHOO
CONDOLENCES
With deep regret, we wish to inform that Allahyarham Ir. Hj. Mohamad Naguib bin Mahfodz (M 04906) and Ir. Hong Nga Siang (M 11585) had passed away on 23 January 2012 and 25 May 2011 respectively.
On behalf of the IEM Council and management, we wish to convey our condolences to their families.
ANNOUNCEMENT
Non IEM Event
10 October 2012
ĚũƵĚŝĐĂƟŽŶŽŶĨĞƌĞŶĐĞϮϬϭϮŽŶ͞dƌĂŶƐĨŽƌŵĂƟŽŶďLJ^ƚĂƚƵƚĞ͗
ŽŵƉƵůƐŽƌLJĚũƵĚŝĐĂƟŽŶŝŶƚŚĞŽŶƐƚƌƵĐƟŽŶ/ŶĚƵƐƚƌLJ͟
Venue : Kuala Lumpur Contact Person : Ms. Alia
E-mail : [email protected] Website : www.rcakl.org.my
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