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Process Safety Management 

Problem

A large magnesium bisulfite pulp mill was required to develop an OSHA Process Safety Management (PSM) program for processes using chlorine, sulfur dioxide and anhydrous ammonia. The PSM program required developing, documenting and implementing a number of plant-wide operating, maintenance and safety procedures. The pulp mill did not have the expertise or in-house staff necessary to develop the program and was required to seek outside assistance.

Solution

Universal Dynamics was contracted to develop a plant-wide PSM program on a turnkey basis. Initially, a needs assessment was performed. The mill was found to have limited documentation of equipment and operating procedures. A significant effort was required to update piping and instrumentation drawings (P&IDs), and develop and document satisfactory operating procedures before other PSM requirements could be addressed. Since up-to-date P&IDs and proper operating procedures are required for the successful operation of any system, Universal Dynamics prepared this information for all twelve major operations from chipping to shipping.

With the process flow and operations defined and documented, our engineers developed and assisted with the implementation of the following fourteen-element PSM Program:

The PSM program was developed consistent with the plant's ISO 9000 quality program that Universal Dynamics also developed.

Results

Implementation of this PSM program resulted in developing and documenting badly needed equipment and operating procedures. This not only reduced the risk of hazardous chemical releases but also significantly improved operating performance and efficiency. The program was completed in nine months without adding new plant staff or disrupting operations. The mill is now in full compliance with PSM requirements and has an opportunity to make even further improvements in operating efficiency.