Deficiencies frequently encountered in the management of process safety information

Abstract

Process Safety Information (PSI) provides the fundamental information necessary for developing the elements of Process Safety Management (PSM). We report the PSI management deficiencies found in PSM audits of more than 70 plants. It should be noted that the PSM audits were not limited to OSHA requirements. The deficiencies found were frequently encountered in the management of the PSI element. The chemical hazards information provided on the Safety Data Sheets (SDS) are not sufficient and may not be appropriate for the process condition used; therefore, the chemical hazards information should not be limited to only the SDS. Although the information provided by the SDS satisfies the OSHA requirements, it is suggested that management further develop the chemical hazards information necessary to ensure the safety of the process. Process incidents resulting from undesired reactions are more frequent than from the desired reaction. Therefore, in terms of safety, the process chemistry of the undesired reactions is essential information for the process technology. However, such undesirable reactions are not identified, and their process chemistries are lacking for most processes. The frequently encountered problem for the information of the process equipment is the inconsistency between the piping and instrument diagram and the actual process. Summarily, the necessary information of the PSI should be developed based upon the characteristics of the process.