HAZOP Study a Great Tool for Hazardous Industry to Identify Process Hazard

A hazard and operability study (HAZOP) is very important for identifying and evaluating problems that may represent risks to personnel or equipment within complex processes and operations. Multi-disciplinary teams are required to carry out a HAZOP, some of which may not have experience in the area before, or may need a guideline for best practice. TheSafetyMaster provides Hazard Identification and Risk Assessment Training Programme.

There are some ways to assess a process or workplace for hazards, and every approach has strengths and weaknesses. For example, the worker-focused Job Hazard Analysis (JHA) is especially effective for the protection of workers, because it considers each task that a worker must perform. The technique includes an in-depth examination of the method and engineering intention of the latest or existing facilities to assess the hazard potential of operation outside the planning intention or malfunction of individual items of kit and their consequential effects on the facility.

HAZOP is led by an experienced facilitator. For an oil & gas project, a specific team would require a person from Machines, Project Engineering, Process, Instruments, and Operations, and it’d require the involvement of process technologists, environmental specialists and company Health & Safety and Environment (HSE) staff for few parts of the work.

HAZOP studies provide a particular method to enhance plant safety by taking consideration of technical and organizational hazards, human error and external influences. In addition to determining which safety measures provide genuine benefits, HAZOP studies also can help identify the qualitative solutions for functional safety assets of process control. The results can be used to reduce the likelihood of costly and time-consuming malfunctions while increasing operational safety and availability.

By the end of the Hazop training, employees will be able to:
• Make a successful HAZOP study that clearly identifies the scope and timeframes
• Select and motivate the HAZOP team to finish the study on time and with results
• Guide productive HAZOP study meetings to succeed in positive outcomes
• Identify and solve problems that occur during HAZOP studies
• Create effective and user-friendly HAZOP study reports
• Analyze HAZOP study results and form the organization’s improvement recommendations

This Training will benefit:
• All key persons in the organization, who by their discipline and/or position are likely to be called on to plan, organize or manage a HAZOP study.
• All who have responsibility for the management of process plant safety assessments using the HAZOP technique including but not limited to Senior Management, Plant Managers, Process and Maintenance engineers (all disciplines), Safety Specialists, and Process Training Instructors.

How Can We Help
TheSafetyMaster has conducted numerous HAZID’s/HAZOP studies for many clients. Our practical approach helps clients to correctly identify the hazards and implement cost-effective solutions. The focus on the Human Factor approach to HAZOP studies assists the client to identify potential hazards that may not be spotted in a regular HAZOP study. Organizations can ensure good Hazop quality by developing the Hazop skills of their professionals. HAZOP training is provided by an expert trainer with long years of experience, utilizing a practical and interactive approach. 

TheSafetyMaster provides several workshops and mock Hazops, therefore giving the employees invaluable hands-on-experience. We also provide Hazard and Operability Analysis (HAZOP).

Send us your enquiry to info@thesafetymaster.com or speak to our expert at +917665231743 for conducting in- house HAZOP study.

Pre Startup Safety Review by TheSafetyMaster

Management of Change and Pre-startup Safety Review (PSSR) Management of Change is the element for which all other foundation elements of Process Safety Management (PSM) are implemented. It is the PSM element that controls the introduction of new risk. Recognizing change, analyzing the danger of every change, and doing small changes efficiently are just a few of the hurdles that managers face with MOC implementation.

The aim of a pre-startup safety review is to assist make sure that proper safety measures are taken and are operational before a new chemical is placed or the current chemical plant is modified. The pre-startup review confirms that before the introduction of a modified chemical or a modification to the current hazardous chemical inventory:

·         Construction of equipment is in conformity with design specifications;

·         Safety, maintenance, operating, and emergency procedures are in their proper place and correct;

·         For new chemicals, a PHA has been performed and recommendations have been resolved or implemented before the chemical arrives on the site;

·         For changed processes, the Management of Change requirements have been met; and

·         Training of each employee involved in handling the dangerous chemical has been completed.

The Pre- Startup Safety Review is a safety review conducted before the startup of a modified or new manufacturing factory or facility to make sure that installations meet the first design, to catch and re-assess any potential hazard from the changes during the detailed construction and engineering phase of the project. In other words, it makes sure the status of the processing facility.

The Main Activities in the PSSR of a Project

Following activities are administered during a PSSR with coordination between Contractor and Owner of the plant/facilities:

·         Do PSSR participation from the authorized Contractor and Owner personnel

·         Do Technical and HSE reviews of documentation

·         Verify all construction and equipment is in conformity with safety, environmental and health regulation, and standards.

·         Complete all corrective action items raised within the PSSR.

·         Complete Post- Start-up corrective action items.

·         The representative of the Project Owner signs the PSSR checklists for approval of the commissioning/start-up of the plant.

·         Documentation of PSSR.

How TheSafetyMaster can Help:

1.      TheSafetyMaster provides training and certifications for Pre-startup Safety Review.

2.      TheSafetyMaster has a team of experts who are specialized in Pre- Startup Safety Review and they help your organization to conduct PPSR and train your employees to conduct the same after then.

3.      We are a renowned company for conducting a HAZOP Study for the organization if required. We also give Behavior-Based Safety Training and many more.

4.      We also provide standard document development for the Pre-startup safety review.

Send us your enquiry to info@thesafetymaster.com or speak to our expert at  +91 7665231743 to conduct the PSSR in your organization.

Safety Culture Transformation by TheSafetyMaster™

Accidents and injuries do happen a lot of times in the industry. Indirect costs such as loss of worker life, productivity, poor quality of goods and services, and damage to customer relations and public image can be two to four times the direct costs.

The impact of accidents, injuries, reaches far beyond the physical safety of the workplace. Workplace injuries often require employees to take time off or result in restricted work duties or the need to transfer to less physically demanding positions. In addition, there is the cost to repair and replace damaged equipment and the cost of lost or limited production stemming from an unexpected disruption of operations, all of which decrease operational effectiveness and productivity.

Companies and Industries that are serious regarding protecting their employees should do far more than react after an injury or rely on awareness-based safety efforts and usually, this approach only delays the next injury. Safety is not just about responding to injuries but is about the ongoing identification of exposure, the implementation of control systems, and assuring these controls are used to neutralize the exposure. Nowadays it has become very important to implement a proper safety culture in an organization. TheSafetyMaster is a leading Process Safety Management Consultancy (PSM) and Process Safety Management Incidents India.

The organization is taking actions that encourage their workers to be more engaged in safety, make it a higher priority and take personal responsibility for being safe. It requires action to get through everyone. The people that work for these firms know-how necessary safety is, and often view it as a core value of the organization.TheSafetyMaster understands that a great Safety Culture is an integrated socio-technical system of values, beliefs, behaviors, structures, and processes that work together to achieve the ultimate goal of no harm. And from our experience, the key to a great Safety Culture starts with visible leadership commitment at every level of the organization.

Introducing and embracing the concepts of culture and values in most organizations, and especially those in technical or engineering remains an uphill battle. The main thing is that it is very necessary to transform the safety culture.

How TheSafetyMaster™ can help
Our consultants are having hands-on expertise in Behavior Based Safety Management and are well-versed in any international practices in BBS. Our respective experience will help your company to avail following services

Objectives of a Risk Assessment
1) Safety Culture Survey
2) Training on Behavior Safety at all level of hirearchy
3) Safety Culture Transformation-BBS Implementation & Facilitation

Send us your enquiry to info@thesafetymaster.com or speak to our expert at +917665231743 for conducting Hazard Identification and Risk Assessment Certificate Training at workplace.

PPE’s Personal Protective Equipments Training by TheSafetyMaster™

Safety is a major issue for day laborers and skilled laborers. Each year, accidents happen frequently in the construction industry and often times it is due to the absence of Personal Protective Equipment (PPE) or failure to wear the provided PPE. PPE is equipment that will protect workers against health or safety risks on the job. The purpose is to reduce employee exposure to hazards when engineering and administrative controls are not feasible or effective to reduce these risks to acceptable levels. These hazard risks can be anything from wet floors to falling debris and everything in between. PPE should only be considered as a last line of defence between a hazard and the worker.

Even where engineering controls and safe systems of work have been applied, some hazards might remain. These includes injuries to.

• The lungs, e.g. from breathing in contaminated air.
• The head and feet, e.g. from falling materials
• The eyes, e.g. from flying particles or splashes of corrosive liquids
• The skin, e.g. from contact with corrosive materials
• The body, e.g. from extremes of heat or cold.

These injuries and illness may result from contact with chemical, radiological, physical, electrical, mechanical, or other workplace hazards. Making the workplace safe includes providing instructions, procedures, training, and supervision to encourage people to work safely and responsibly.

Workplace safety should begin with a hazard assessment. Once the hazards and risks have been identified, a plan can be put forward to prioritize and reduce risk of injury. Useful systems and tools to perform hazard assessments include performing a Risk Assessment and a Job Safety Analysis.

Basic Types of PPE

A hazard assessment can help identify which specialized PPE will be required. However, the following basic types of PPE should be made available in every worksite.

  1. Head Protection

PPE includes hard hats and headgears and should be required for tasks than can cause any force or object falling to the head. When performing head protection safety checks, ensure that there are no dents or deformities on the shell and connections are tightened inside. Do not store in direct sunlight and always replace a hard hat if it was used for any kind of impact, even if damage is unnoticeable.

  2. Face and Eye Protection

PPE includes safety goggles and face shields and should be used for tasks that can cause loss of vision and an eye, burns, splashes, sprays of toxic liquids etc. When conducting equipment safety checks, ensure that there are no cracks or deformities on the lenses, ensure the strap is in good working order and is firmly sealed to the cheek and forehead.

  3. Foot Protection

PPE includes knee pads and safety boots and should be used for tasks that can cause serious foot and leg injuries from falling or rolling objects, hot substances, electrical hazards and slippery surfaces. Use boots with slip-resistant soles that protect against compression and impact.

  4. Hands Protection

PPE includes safety gloves and should be used for tasks that can cause hand and skin burns, absorption of harmful substances, cuts, fractures or amputations. When inspecting hand protection equipment, ensure that they fit perfectly with no spaces and are free from cuts, burns and chemical residue. Always replace them if any sign of contamination was observed.

  5. Body Protection

PPE includes safety vests and suits and should be used for tasks that can cause body injuries from extreme temperatures, flames and sparks, toxic chemicals, insect bites and radiation. Ensure that they are clean and free from cuts and burns. Always get a good fit to ensure full body protection.

  6. Hearing Protection

PPE includes ear muffs and plugs and should be used for tasks than can cause hearing problems and loss of hearing. When ensuring hearing safety, the equipment must fit the ear canal perfectly. Recommended types include formable earplugs to fit on different sizes of ear canals.

  7. Fall Protection

PPE includes safety harnesses and lanyards and should be strictly used for task that can cause falling from heights and serious injury or death. When inspecting equipment, ensure that the straps are free from tears, deformities and burn marks and buckles are connected securely and tightly. It is very important to dispose them if used after a falling incident.

  8. Respiratory Protection

PPE includes respirators and should be used for task that can cause inhalation of harmful materials to enter the body. When conducting respiratory protection safety, ensure that the equipment is fit-tested and the employee has undergone proper training before wearing one.

PPE Safety Checklists

Personal Protective Equipment (PPE) Safety Checklists are used by safety officials and supervisors to help identify tasks that require PPE, ensure staff is using the right equipment and reduce overall harm.

Send us your enquiry to info@thesafetymaster.com or speak to our expert at +917665231743 for conducting PPE’s Safety Training in the workplace.

Road Safety Training by TheSafetyMaster™

The present transport system has minimized the distances but on the opposite hand increased the life risk. Every year road crashes result in loss of lakhs of lives and serious injuries to several people. It is vital to remember that road traffic injuries remain a crucial public health problem. When road safety products are utilized correctly or efficiently, they will help save lives,  prevent accidents and injuries, and keep a society functioning within the most optimal way.

ROAD SAFETY TRAINING

It aims to equip new drivers with the vital skills and knowledge they need to stay safe on the roads before they start formal driving lessons. Participants are trained to analyze road safety problems  and the way to return to effective and efficient solutions, making use of the growing stock of information and knowledge.

HOW TheSafetyMaster™ CAN HELP?

·       This includes the growth and implementation of load safety strategies adapted to local conditions.

·       The courses provide practical, easy-to-use learning to assist you to improve road safety in your workplace.

·        Preventing workplace crashes saves lives and avoids property damage, serious injuries, downtime and lost productivity. These courses are created to assist you to do just that.

Send us your enquiry to info@thesafetymaster.com or speak to our expert at +917665231743 for conducting Road Safety Training certificate Course in the workplace.

PSM Gap Assessment by TheSafetyMaster™

Process safety management is a management system of preventing hazards and risks from highly hazardous chemical or energy release while a process is any activity or combination of activities including any use, storage, manufacturing, handling or the on-site movement of highly hazardous chemicals.

In highly hazardous chemical production units wherein working with chemicals and other hazardous energies is commonplace; catastrophic hazards are pronounced and the risk of injury and health complications to the business and workers engaged in the production sector are substantially increased.

PSM Gap Assessment is one of the most important parts of the PSM system and includes identifying deficiencies related to PSM system, technical safety Infrastructure, planning, capability, following-up, and how is documenting the PSM system. A PSM Gap Assessment is a systematic series of assessment to identify gaps and problem areas associated with elements of Risk Based PSM programmer installed in operation, design and maintenance. The review allows proper identification of gaps at the beginning of a project and provides a detailed list of system/people/physical gaps that can pose catastrophic dangers that may be faced by the facility; based on this list, it is possible to ensure the monitoring and traceability of the implementation of measures that will help to avoid them. The elements under assessment are

·          Risk Based Thinking

·          Governance and Organisation

·          Process Safety Information

·          Process Hazards Review Analysis

·          Operating Procedures

·          Management of Change

·          Pre Startup safety review

·          Training

·          Employee Participation

·          Trade Secret

·          Mechanical Integrity

·          Incident Investigation

·          Emergency Response

·          Contractors

·          Hot Work

·          Compliance Audits

·          Risk Assurance

How TheSafetyMaster™ can improve your process safety:

Every chemical manufacturing unit has a process for manufacture, storage, handling, transport of highly hazardous chemicals and TheSafetyMaster™ is committed to the take care of Process Safety Management and Operational Risk Management.

The overwhelming goals of our Process Safety Management Audit are to ensure process safety at production units through PSM System. The aim is to minimize occupational risks and hazards for production floor workers by means of...

·         Identifying and correcting deficiencies in any Process Safety Management System

·         Effective Emergency Response Creation and Implementation

·         Mechanical Integrity Evaluation and Quality Assurance at a Contractor Level

·         Final Analysis of Process Equipment prior to first time use

·         Hazard Analysis and subsequent Corrective Measures

.

Our Team will facilitate client team to have assessments, implementations or due diligence done to acquire and Implement the master plan of successful process safety mainframe management model. TSM offers unique local or global TSMMM service by which site or corporate safety practices and organizations arise and persist, leading to successful business.

To enhance your Process Safety Management Audit program and to guarantee the well being of your production unit workers and prevent/mitigate catastrophic incidents by closure of audit actions. 

Send us your enquiry to info@thesafetymaster.com or speak to our expert at +917665231743 for conducting PSM Gap Assessment.