Safety (IEC 61511)

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Process safety is the framework for managing the integrity of production systems and processes that handle hazardous substances. It is based on good design, engineering, and operation and maintenance practices. Typical examples of process safety events are dust, gas or vapour explosions, explosions or flashes of high-energy materials, rapid decomposition of thermally unstable substances or mixtures, and the rapid build-up of overpressure in a process plant as a result of exothermic chemical processes.

Businesses that use hazardous materials in their production systems must prevent structural failures or loss of stability of the hazardous materials they use or the energy they use, which could lead to a major event, and this is only possible with process safety management. The main elements of process safety management are listed below:

  • Employee participation: Employees participate in trainings, surveys and feedback.
  • Process safety information: Documentation should summarize specific safety protocols.
  • Process hazard analysis: Systematic assessment of potential hazards in the work.
  • Operating Procedures: Operating procedures that contain clear instructions and are available to all employees should be written.
  • Training: Workers should be trained to follow specific safety protocols.
  • Pre-launch safety inspection: Any plant that opens or is reorganized must undergo a safety inspection.
  • Mechanical Integrity: Critical process equipment must be properly designed and installed. This includes tanks and storage vessels, pumps, piping and valves, emergency shutdown and control systems.
  • Permit to operate: A permit must be issued for hot work carried out on or near a closed process.
  • Change Management: Manages the procedure that everyone must follow when implementing changes in process, equipment or personnel.
  • Incident Investigation: In the event of a safety or health related incident, including a near miss, a thorough investigation must be conducted.
  • Emergency planning and response: Training should be provided to employees outlining the details of emergency planning and response.
  • Compliance audits: Employers must confirm that compliance with the EMS is assessed at least every three years.
  • Trade secrets: There are no protective materials or monitoring data of any kind. All company documents, analytical and operational data must be protected.

Process safety management is a complex process and requires a multidimensional approach that includes both technological and management solutions. Oskon Automation supports you with its professional consultants in all your process safety processes and certification procedures.

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