Process Safety Management for the Hydrogen Industry

The hydrogen industry as it builds out will need to maintain the highest of safety standards to justify the validity of the industry for its many applications. Process Safety Management (PSM) is a proven approach to managing risks of facilities handling highly hazardous chemicals and is the global benchmark for managing catastrophic risks of chemical-related operations. Producers, suppliers, facility operators, users, and their contractors and employees would all benefit from an enterprise approach to PSM voluntarily applied even if not required by regulation and in addition to industry codes and standards. Some operations may be subject to PSM regulations, which may vary depending on the country of operation and their regulatory frameworks. Others may operate in countries that do not have a PSM regulation.

Experience of over 30 years of PSM has shown that it has changed the way business is managed and is deeply integrated into day-to-day operations. This paper will explain the application of PSM to hydrogen operations in manufacturing of hydrogen related products, the production of hydrogen, and the use of hydrogen as a fuel. Lessons learned from these applications will be explained to show the value and benefits.

Despite many accomplishments in preventing and managing catastrophic losses, it is clear that PSM requires a discipline to be truly effective. We believe that breakthroughs to a highly reliable and safe operation are only possible with PSM being oriented toward “process safety excellence”, including modern frameworks such as the AIChE CCPS Risk-Based Process Safety model, and then an emphasis on internal compliance to standards and practices.

To achieve process safety management excellence requires Conduct of Operations (COD) and Operational Discipline (OD). Formalizing COD/OD makes the difference between good and great control of process safety risks. Leadership in process safety requires clear direction, clear communications, and disciplined execution. This allows for improved process safety implementation including:

• auditable, documented compliance to standards
• more collaborative execution of key process safety activities
• improved communications
• improved process safety culture
• and many other benefits

Topics will include:

• The importance of global PSM application for the hydrogen industry
• Examples of successful application of PSM to the hydrogen industry
• The AIChE CCPS Risk-Based Process safety framework
• A model of COD/OD for process safety management
• Expected value and improvement potential

This paper will be particularly useful for companies who are producers or users of hydrogen to make them aware of the advantages of a formal management system for PSM. It will also benefit those who practice PSM but want breakthroughs in process safety performance and who recognize the leadership skills and efforts required.