PSM中文标准

化工工艺安全与风险管理 Process Safety and Risk Management,天津大学-阿斯利康过程安全联合实验室 卫宏远 教授,为什么悲剧不断重演？,本质安全企业和社会可持续发展的根本保障,过程安全是一门科学 过程安全是一种责任 过程安全是自身利益 过程安全是一种文化 科学、严谨、认真、重视、普及,Make chemistry / process as inherently safe as practicably possible (as early as possible in development limit risk & over-reliance on expensive engineered safety measures),识别,评估,控制,避免 (如果可能/可行),国家安全生产监督总局 化工企业工艺安全实施导则AQ/T 3034-2010 OSHA (Occupational Safety & Health Administration U.S. Department of Labor) 美国职业安全与健康管理局 工艺安全管理1910.119,目前主要的工艺安全管理标准,员工参与 Employee Participation 工艺安全信息 Process Safety Information 工艺危害分析 Process Hazard Analysis 操作规程 Operating Procedure 培训 Training 承包商 Contractors 开车前安全检查 Pre-Startup Safety Review 机械完整性 Mechanical Integrity 动火作业许可证 Hot work Permit 变更管理 Management of Change 事故调查 Incident Investigation 应急计划和反应 Emergency Planning and Response 符合性审计 Compliance Audits 商业秘密 Trade Secrets,OSHA PSM 1910.119,4.1 工艺安全信息 4.2 工艺危害分析 4.3 操作规程 4.4 培训 4.5 承包商管理 4.6 试生产前安全审查 4.7 机械完整性 4.8 作业许可证 4.9 变更管理 4.10 应急管理 4.11 工艺事故/事件管理 4.12 符合性审核,AQ/T 3034-2010化工企业工艺安全管理实施导则,风险管理概述 Risk Management Summary,识别重大风险 Significant risks identified 与所使用的风险标准进行比较 Comparison with risk criteria utilized 风险理解（危险和风险登记） Risks understood (Hazard and Risk Register) 分配资源的客观依据 Objective basis for allocating resources 风险控制到位，以控制所有风险 Risk controls in place for all high risks 持续的风险降低机制 Continuous Risk Reduction facilitated,工艺安全领导力 Process Safety Leadership,没有高层承诺 Lack of senior management commitment 财务状况限制 Financial constraints 不是全员来参与PSM Not all staff engaged in PSM 缺乏专业资源 Lack of specialized resources 活动过于规定化 受符合性驱动 Activities too prescriptive - compliance driven 组织受过去成绩蒙蔽 Organization blinded by past success PSM未与其它业务动机一体化 PSM not integrated with other business initiatives PSM与操作危险之间的联系不明显 Link between PSM and operational hazards not obvious,PSM框架在有些组织中未取得成功，原因在于： PSM frameworks have not been fully successful in some organizations because of:,PSM程序要求有领导强力支持 Executive support required for PSM program. 管理层必须表示出对PSM期望值，并提供资源，在公司内促进和强制执行相关程序 Management must identify clear expectations of PSM, provide resources, and promote and enforce the program within the company. PSM应当是业务计划不可分割的一部分，具有定期的审查 PSM should be in integral part of the business plan with regular reviews. 对所有工作者的岗位职责描述必须反映其PSM责任 Job descriptions of all workers must reflect PSM responsibilities. 员者参与是至关重要的 Worker participation is crucial. 应当选择工艺安全导向指示指标（KPIs） Process Safety leading indicators (KPIs) should be selected.,领导力和责任感 Leadership & Accountability,13,工艺安全管理的要素 Process safety management,个人安全|Personal Safety,员工对危害的认知 Hazard recognition by workers 不少危害都可以轻易识别出来，并不需要借助专业的知识与技能 Many of the hazards are such that they can be readily recognized without specialized knowledge and expertise 个人防护装备 Personal protective equipment 规程和培训 Procedures and training “基于行为的安全”程序 Behavior based safety programs 滑倒、绊倒、摔倒、移动设备，“撞击”事故 Slips, trips, falls, moving equipment, struck by accidents, etc.,工艺安全 |Process Safety,重大事故往往包含有害物质或能量释放 Major incidents involving the release of hazardous materials or energy 其后果可能导致安全问题（火灾、爆炸、有毒物质曝露），环境破坏或重大经济损失 Consequences can be safety issue (fires, explosions, toxic material exposure), environmental damage, or major economic losses,事故可能导致灾难性后果 Incidents can have catastrophic impacts 多人受伤或死亡事故 Multiple injuries or fatalities 重大经济、财产损失和环境、公司形象破坏 Major economic, property, environmental, and corporate image damage 冲击外部公众设施 Impact public outside facilities,工艺安全|Process Safety,预防 Prevention 设施设计与工程 Design and engineering of facilities 设计的目标是将人为失误降至最低、并将设备容差变大 Design to minimize human error, make equipment error tolerant 机械完整性和维修 Mechanical integrity and maintenance 控制、培训、规程、危险识别、变更管理、技术风险管理 Control, training, procedures, hazard identification, management of change, technical risk management,工艺安全|Process Safety,如何强调工艺安全？ How is Process Safety Addressed?,工程设计实践与标准 Engineering Design Practices and Standards 管理系统 Management Systems 管理流程（研发、工程、设计、施工、启动、操作、维护、更换等） Procedures (R&D, Engineering, Design, Construction, Startup, Operating, Maintenance, Change, etc.) 安全审查 Safety reviews 操作规程 Operating Procedures,How well an organization does these procedures and practices defines its process safety culture,管理系统 Management Systems 培训 Training 设备检查机械完整性 Equipment Inspections/ Mechanical Integrity 承包商工艺安全管理 Contractor process safety program 未遂事故事故调查 Near Miss/ Incident Investigations 性能管理目标 Performance Management / Goals 审计/现场调查 Audits/ Site inspections,一个组织机构开展这些规程和实践的情况可以体现它的工艺安全文化,如何强调工艺安全？ How is Process Safety Addressed?,员工参与 EMPLOYEE PARTICIPATION,员工参与是工艺安全管理最为重要的要素之一 OSHA views this as one of the most important of the PSM elements （OSHA所指的“职工”指的是非领导阶层的职工 ） By “employees” OSHA has in mind non-managerial employees 尤其是那些代表工会的职工 Particularly those who may be represented by labor unions 所有承包商职工必须包括在内 Contractor employees must be included,员工参与|Employee Participation,雇主应编写一份有关实施员工参与的书面行动计划 Employers shall develop a written plan of action regarding the implementation of the employee participation required 雇主应就工艺危害分析（PHA）和工艺安全管理其他要素的制定和实施与职工及其代表进行协商 Employers shall consult with employees and their representatives on the conduct and development of PHAs and on the development of the other elements of PSM in this standard 雇主应向职工及其代表提供获得工艺危害分析（PHA）和标准要求的其他信息的途径 Employers shall provide to employees and their representatives access to PHAs and to all other information required to be developed under this standard,员工参与|Employee Participation,OSHA认为员工及其代表有权参与工艺危害分析活动、事故调查和所有安全审计 OSHA believes that workers and their representative should have the right to participate in the development of PHA, incident investigations and all safety audits 应就相关培训、维护和应急项目以及其他工艺安全管理项目要素与职工及其代表协商 And that they should be consulted with respect to training, maintenance and emergency response programs and other PSM program elements,员工参与|Employee Participation,雇主应向涵盖的承包商员工提供（与直接雇佣的职工同等承担的）在同样标准下的有关工艺危害分析 The employer is required to provide access to PHAs and all other information to be developed under this standard to employees of covered contractors to the same extent that it must provide access to direct hire employees 如果情况类似 If similarly situated 合同雇主同样有责任向他们的职员提供所要求的信息 Contract employers share responsibility for assuring that their employees are provided with the requested information Source: OSHA Instruction CPL 2-2.45A, Appendix B.,员工参与|Employee Participation,提供可以迅速获取信息的途径 Provide prompt and ready access to information 雇主应记录下职工参与的情况 Employers should document employee participation 将承包商视同职工 Treat contractors as though they were employees 主要目标成果是员工 Objective evidence that employees 被告知相关的工艺危害性分析结果 Were briefed regarding PHA results 而不是仅仅在公司总部准备一份工艺危害分析报告 just making a copy of the PHA report available in a central location 获取工艺安全信息的途径 Have access to PSI 其他由工艺安全管理产生的数据和信息 And other PSM-generated data and information,员工参与|Employee Participation,按照第1910.119(c) (1)段，雇主应编写一份有关实施职工参与的书面行动计划 Employers shall develop a written plan of action regarding the implementation of the employee participation required by this paragraph 1910.119(c) (1) 雇主应就工艺危害分析（PHA）和工艺安全管理其他要素的制定和实施与员工及其代表进行协商 Employers shall consult with employees and their representatives on the conduct and development of PHAs and on the development of the other elements of PSM in this standard (1910.119(c) (2) 雇主应向员工及其代表提供获得工艺危害分析（PHA）和在此标准其他所有要求开发的信息途径 Employers shall provide to employees and their representatives access to PHAs and to all other information required to be developed under this standard 1910.119(c) (3),具体要求 REQUIREMENTS,设计一项自下而上的计划 Design a bottoms-up program 对职工进行工艺安全管理的培训和教育 Train and educate employees in PSM 根据他们的需要 According to their needs 鼓励职工广泛积极地参与 Involve employees broadly and actively,员工参与实施指南 EMPLOYEE PARTICIPATION IMPLEMENTATION GUIDELINES,主动与职工交流有关工艺安全管理程序的信息 Proactively communicate PSM program information to employees 比如：告知受害职工事故调查、审核和工艺危害分析的发现 e.g. inform effected employees of the findings from incident investigations, audits and PHAs,实施指南 IMPLEMENTATION GUIDELINES,提供可以迅速获取信息的途径 Provide prompt and ready access to information 雇主应记录下职工参与的情况 Employers should document employee participation 将承包商视同自己的员工 Treat contractors as though they were employees,实施指南 IMPLEMENTATION GUIDELINES,建立处理各个工艺安全管理要素的小组 Form teams to handle various PSM elements 对于规模大的设施，小组就由各组的代表组成，比如操作员 For large facilities, teams will have representatives from different groups, e.g. operator 对于规模小的设施，小组包括一个组中的所有成员 For small facilities may have all members of a group involved,实施指南 IMPLEMENTATION GUIDELINES,职工参与行动计划 Employee participation action plan,所需的文件 REQUIRED DOCUMENTATION,向职工开展有关工艺安全管理的岗前培训之客观证据 Objective evidence of orientation training for all employees on PSM 职工协商会议和工艺安全管理要素会议的客观证据，例如，会议纪要、会议出席表等 Objective evidence of employee consultation and briefing on PSM elements, e.g. minutes of meetings, meeting attendance lists, etc. 例如: 有关新职工培训次数的协商 e.g. consultation regarding refresher training frequency,推荐的文件 SUGGESTED DOCUMENTATION,客观证据 Objective evidence that employees 告知职工工艺危害分析结果的 Were briefed regarding PHA results 不仅是在公司总部准备一份工艺危害分析报告 Not just making a copy of the PHA report available in a central location 获取工艺安全信息的途径 Have access to PSI 其他由工艺安全管理产生的数据和信息 And other PSM-generated data and information,推荐的文件 SUGGESTED DOCUMENTATION,员工参与这一要素经常没有得到充分的重视 This element is often given inadequate attention 员工参与对工艺安全管理项目大有裨益 PSM programs will benefit from employee participation OSHA对这一要素非常放在重要的地位 OSHA places great value on it,结论 CONCLUSIONS,工艺安全信息 PROCESS SAFETY INFORMATION,编写有关工艺的书面信息 Compilation of written information about the process 使那些参与工艺的人知晓危害 Enables those involved with the process to identify and understand its hazards 开展工艺危害分析和工艺安全管理其他活动的基础 Foundation for the development of PHAs and other PSM elements,伤害金字塔图 THE INJURY PYRAMID,死亡事故 Death,工伤残废 Lost Work Day,可记录事故 Recordable,急救 First-Aid,未遂事故 Near Miss,不安全行为危险行为和不安全条件 Unsafe Actions - At Risk Behaviour and Unsafe Conditions,从严重性角度来看，未遂事故和死亡事故的结果有很大的不同而且我们对它们的响应也迥然不同 From the perspective of severity, there is a huge difference between the consequences of a near miss and of a fatality and there is a huge difference in our responses to them,未遂事故报告 Near Miss Report,究竟什么是未遂事故？ “What is a Near Miss ?”,“未遂事故”是潜在地造成伤害或者职业病，和/或人员、财产、环境或声誉的损害（损失）的事故。 A “Near Miss” is an incident that had the potential to cause Injury, or Occupational Illness, and/or Damage (loss) to people, assets, the environment or reputation.,重伤 Serious Injury,轻伤 Minor Injury,财产损失 Property Damage,未遂事故 Near Misses,不安全的行为和不安全的条件 Unsafe Act & Unsafe Condition,安全三角 Safety Triangle,Statistical Evidence (adapted from Bird 1969) 统计数据 -（摘自Bird 1969）,究竟什么是作业观察？ “What Is a Job Observation?”,作业观察是衡量安全行为和衡量是否符合安全要求的系统方法 Job Observation is a systematic technique for measuring safety behavior and compliance to safety requirements. 作业观察找出：Job Observations recognize: 违章行为 -non-compliance behaviors 积极的安全行为 -positive safety behaviors,工艺安全信息 PSI,雇主应在进行标准要求的工艺危害分析之前完成书面工艺安全信息的编写 The employer shall complete a compilation of written PSI before conducting any PHA required by the standard 编写书面工艺安全信息，以便参与工艺操作的雇主和职工确定和了解涉及高危化学品的工艺的危害 The compilation of written PSI is to enable the employer and the employees involved in operating the process to identify and understand the hazards posed by those processes involving HHCs 工艺安全信息包括 : This PSI shall include information pertaining to: 工艺中使用或产生的高危化学品的危害 Hazards of the highly hazardous chemicals used or produced by the process 工艺技术 Technology of the process 工艺中使用的设备 Equipment in the process,有关下列方面的信息 Information relating to: 毒性信息 Toxicity information 接触容许限值（PEL）或其他职业接触限值（OEL） Permissible Exposure Limits (PELs) or other Occupational Exposure Limits (OELs) 物理数据 Physical data 火灾和爆炸数据 Fire and explosion data 化学反应数据 Reactivity data,工艺安全信息危险化学品 PSI Hazardous Chemical,腐蚀性数据 Corrosivity data 化学和热稳定性数据 Thermal and chemical stability data 与其他物质混合可能导致的危害 Hazardous effects of inadvertent mixing with other potential substances 对已知的或预测的化学危害采取应急措施 Emergency response actions to be taken to respond to and protect against known or suspected chemical hazards,有关于工艺信息 Information relating to: 流程框图或工艺流程简图 Block flow or simplified process flow diagrams 工艺化学 Process chemistry 预期存货最高值 Maximum intended inventories 安全作业限制范围（例如，设计温度、压力、流量、结构） Safe upper and lower operating limits (e.g. Design temperatures, pressures, flows, compositions) 潜在偏差的后果 Consequences of potential deviations 对后果或偏差的评估（例如工艺危害分析） An evaluation of consequences or deviations (e.g. PHAs),工艺安全信息工艺技术 PSI Process Technology,工艺化学品的库存水平 Inventory levels for process chemicals 预期储存最高值：雇者为工艺化学品的存放量设置的最高标准 安全限制设有高低限：超出这一范围便视为不符合条件 Safe upper and lower limits are limits beyond which would be considered upset conditions 偏差后果的评估指对偏差（如果在超出设定工艺限制范围的情况下操作便有可能产生）导致的后果或结果进行的一项量化估算 An evaluation of the consequences of deviations is a qualitative estimate of the consequences or results of deviation that could occur if operating beyond the established process limits,工艺安全信息工艺技术 PSI Process Technology,工艺安全信息工艺设备 PSI Process Equipment,与下列方面有关的信息 Information relating to: 带仪表控制的工艺管线图 Plant engineering line diagrams (P&IDs) 操作和维护规程 Operation and maintenance procedures 电气分类 Electrical classifications 爆炸分区 Explosion zoning 泄压系统设计和设计基础 Relief system design and design basis 计算 Calculations 数据表排放量和设定点 Data sheets relief capacity and set point,通风系统设计 Ventilation system design 设计规范和标准 Design codes and standards 安全系统 Safety systems 联动装置 Interlocks 检测系统 Detection systems 抑制系统 Suppression systems 有关工艺设备的基本信息 Basic information on process equipment 生产日期 Manufacturer dates 竣工图 As-built drawings 制造材料 Material of construction,工艺安全信息工艺设备 PSI Process Equipment,需要编制的信息和具体要求 Information to be compiled and in what detail 搜集信息的方法 How it is to be collected 负责搜集信息的人员 Who is responsible for collection 负责管理信息的人员 Who is responsible for maintenance 信息保存的地方 Where it will be stored 搜集/更新信息的计划 Schedule for collection/updating,工艺安全信息实施 PSI Implementation,向职工开放的途径 How it will be made available to employees 操作人员应对下列方面有清楚认识 Operator has a clear understanding of: 工艺中使用的化学品的物理和化学特性 the physical and chemical properties of materials used in the process; 化学反应期待和不期待的 chemical reactions - both desired and undesired; 原材料、中间物、产品和多用途材料不慎混合在一起导致的后果 consequences of inadvertent mixing of raw materials, intermediates, products and utility materials. 保留要求 Retention requirements,工艺安全信息实施 PSI Implementation,没有规定采取什么方法编制工艺安全信息 Method used to compile PSI is not specified 雇主可以选择编制分类信息 An employer may choose to compile electrical classification information: 专用于某项用途的图纸 On drawings specifically dedicated for that purpose 对现有计划或图纸进行注解 By annotations to existing plans or drawings 使用其他方法或综合使用几种方法，比如表格、书面注解等 By other methods or combination of methods including tables, or written commentary,工艺安全信息实施 PSI Implementation,工艺安全信息不需要包含在中心文件里 PSI does not need to be in a central file 只要可以随时得出硬拷贝（印刷文本），电子资料管理也可以接受 Electronic data management is acceptable so long as hard copies can always be generated,工艺安全信息实施 PSI Implementation,化学品安全技术说明书（MSDS） MSDSs 对工艺化学的描述 Description of process chemistry 设备操作的限制范围 Upper and lower operating limits for equipment 对偏差后果的定性评估 Qualitative evaluation of the consequences of deviations 预期存货最高值 Maximum intended inventories 安全设备/系统的（技术）描述 Description (technical) of safety equipment/systems,工艺安全信息所需的文件 PROCESS SAFETY INFORMATION REQUIRED DOCUMENTATION,最新的BFD或PFD Updated BFDs or PFDs 最新的保障工程安全的施工图/图表 Updated drawings/diagrams for engineered safeguards 最新的电力分类图或其他文件 Updated electrical classification drawings or other documents 建设材料 Materials of construction 工艺物料和能量平衡 Material and energy balances for processes built,工艺安全信息所需的文件 PROCESS SAFETY INFORMATION REQUIRED DOCUMENTATION,工程/设计文件（编制设计和建造工厂的规则和标准） Engineering / design files that document which codes and standards were used to design and build the plant 工程/设计文件（编制工程安全保障和通风系统的设计基础）Engineering / design files that document what the design basis was for engineered safeguards and ventilation system,工艺安全信息所需的文件 PROCESS SAFETY INFORMATION REQUIRED DOCUMENTATION,工艺安全信息跟踪记录 PSI tracking log 日期、描述、地点、负责人 Date, description, location, person responsible 设备数据表 Equipment data sheets 其他文件 Other documents 例如，确定热稳定性和化学反应的文件，如测试报告 E.g. confirmation of thermal stability and reactivity such as test reports,工艺安全信息推荐的文件 PROCESS SAFETY INFORMATIONSUGGESTED DOCUMENTATION,工艺安全信息对工艺安全管理的其他要素至关重要 PSI is vital for all other PSM elements 在进行工艺危害分析前编写 Compile prior to PHA efforts 包含的信息量很大 Consists of a large amount of Information 应制定一个良好的管理系统，以便组织和维护工艺安全信息 A good management system is needed to organize and maintain it 解释和理解工艺安全信息同等重要 Interpretation and understanding of PSI is equally important,结论 Conclusions,操作规程 OPERATING PROCEDURES,雇主应就安全操作规程提供适当的、明确的书面指示 Employers should provide appropriate, clear written instructions for safely operating processes 此类信息必须传达给雇员 This information must be communicated to employees 操作规程应涵盖某个工艺中所需实施的不同任务，比如： Operating procedures should cover the many different tasks needed to be performed for a process, e.g.: 初始开车 Initial startup 正常操作 Normal operation 临时操作 Temporary operations 紧急关闭 Emergency shutdown,操作规程 Operating Procedure,规程还应解决至少以下要素： The procedures shall address at least the following elements: 操作限值 Operating limits 偏差的后果 Consequences of deviation 纠正或避免偏差的所有步骤 Steps required to correct or avoid deviation,操作规程 Operating Procedure,操作规程应随时可供雇员使用 Operating procedures shall be readily accessible to employees who work or maintain a process 需要确保雇员在需要之时即可获得准备好的最新参考资料 This requirements assures that a ready and up-to-date reference is available to employees when needed 它也将构成雇员所需培训的基础材料 It will also form a foundation for training which employees need under this final rule,操作规程 Operating Procedure,操作规程应按照必要的频率进行审查，以确保其能反映当前的操作实践 The operating procedures shall be reviewed as often as necessary to assure that they reflect current operating practice 包括由于PSI变动以及设施变动所导致的变更 Including changes that result from changes in PSI and changes to facilities 雇主每年都应证明这些操作规程为最新且准确的规程 The employer shall certify annually that these operating procedures are current and accurate,操作规程 Operating Procedure,标准操作规范-实施指南 SOPS IMPLEMENTATION GUIDELINES,工艺概况 Overview of the process 实施的工艺操作 Tasks to be performed 工艺操作采取步骤的具体指导 Specific instructions on steps to be taken 需要记录的数据 Data to be recorded 需要保持的操作条件 Operating conditions to be maintained 操作参数的范围和限制 Ranges and limits for operating parameters 在不正常条件下应采取的措施 Actions to be taken in the event of upset conditions 异常情况发生之时的警报和相关措施 Alarms and instruments pertinent if an upset occurs 应采集的样品 Samples to be collected 采取的安全和健康预防措施 Safety and health precautions to be taken,标准操作程序的推荐内容 SUGGESTED CONTENT OF SOPS,反映工艺操作的最佳方式 Reflect the best way to operate the process 生产率、便利性和安全之间的平衡 Balance between productivity / convenience / safety 不太冗长也不过于简单 Not lengthy nor too brief 先前合格通过的操作人员应能够在休假之后利用其来安全操作工艺 Previously qualified operator should be able to use them to operate the process safely after a leave of absence 新雇员可以在没有已受训雇员在场情况下，利用标准操作规范进行培训 A new employee could be trained from the SOP without the presence of a trained employee,标准操作程序的推荐内容 SUGGESTED CONTENT OF SOPS,技术上准确 Technically accurate 已经过工程技术人员的审核 Reviewed by engineering staff 实用 Practical 已经过操作人员的审核 Reviewed by operating personnel 条理清晰 Well organized and structured 使用图形、图表、变体字等等 Use of figures, diagrams, varied fonts, etc. 使用员工易于理解的风格和语言 Use a style and language that is understandable by employees,标准操作程序的推荐内容 SUGGESTED CONTENT OF SOPS,操作规程是工艺安全管理项目的一个关键组成部分 Procedures are a critical part of a PSM program 操作规程需要普及使用 Their use needs to be made a way of life,总结 CONCLUSIONS,68,培训 TRAINING,适用于“与工艺操作有关”的雇员 Applies to employees who are “involved in operating a process” 必须向所有雇员提供培训，包括维护人员和承包商雇员 Must provide training to all employees including maintenance and contractor e