The New Three-Dimensional Safety Approach for the Implementation of Process Safety Management (PSM) and Improving Safety Aspects for the Pharmaceutical Industry in India – An Overview

Alavandar Yudhistra  Kumar

doi:10.47540/ijias.v4i1.1269

Authors

Alavandar Yudhistra Kumar Porus Labs Pvt Ltd (Bain Capital), Unit 6, Visakhapatnam, Andhra Pradesh, India

DOI:

https://doi.org/10.47540/ijias.v4i1.1269

Keywords:

Good Safety Practices, Human Failures, Safety Culture, Safety Precautions

Abstract

Implementation of the fourteen elements of process safety management (PSM) helps to build a good safety culture in the organization. The new three-dimensional approach, which consists of good safety practices, safety precautions, and frequent checking of the process equipment and its devices has been applied to the various elements of the process safety management. The elements of process safety management are six, four, and three are good safety practices, safety precautions, and frequent checking of process equipment and its devices but one of the elements is the combination of all the three-dimensional approach, which is a trade secret, which insists that all the people in the organization should follow all the documented procedures from two to thirteen elements of the process safety management, the controlled copy should only be used inside the company premises. We have taken secondary published data for assessing the deviations of the three-dimensional safety approach for the human failures in the pharmaceutical industry, which has led to various incidents/accidents from October 2017 to September 2021. The deviation, which we have observed for the good safety practices, safety precautions, and frequent checking of process equipment and its devices was ten, nine, and one numbers before implementation of the process safety management. After the implantation of the process safety management, the incidents were reduced to three numbers from January 2022 to August 2023, in which deviation has been found in the two and one for the good safety practices and safety precautions.

References

Bai, M., Qi, M., Shu, C. M., Reniers, G., Khan, F., Chen, C., & Liu, Y. (2023). Why do major chemical accidents still happen in China: Analysis from a process safety management perspective. Journal of Process Safety and Environmental Protection, 176, 411-420.

Behie, W. S., Pasman, H. J., Halim, S. S., Shell, K., El-Kady, A. K., & Khan, F. (2023). The business case for process safety: The foundational requirements to sustain success. Journal of Loss Prevention in the Process Industries. 85, 105159.

Bhusnure, O. G., Dongare, R. B., Gholve, S. B., & Giram, P. S. (2018). Chemical hazards and safety management in pharmaceutical industry. Journal of Pharmacy Research, 12(3), 357 – 369.

Bu, Y., Addo, A., Amyotte, P., Yuan, C., Li, C & Hou, X. (2022). Insight into the dust explosion hazard of pharmaceutical powders in the presence of flow aids. Journal of Loss Prevention in the Process Industries, 74, 104655.

Cartwright, P., Prugh, R. W., & Ebadat, V. (2021). COMPARED: A solvent vapor explosion in Germany and a combustible dust explosion in the United States. Journal of AIChe, process safety progress. 40(4), 191-194.

Chandwani, A., Chauhan, M. K., & Bhatnagar, A. (2019). Ergonomics assessment of office desk workers working in corporate offices. Int J Health Sci Res. 9(8), 367-375.

Cheng, L., Guo, H., Wang, C & Li, S. (2020). Research on multilevel information loss of the sharing process for safety information. Journal of Loss Prevention in the Process Industries, 67, 104223.

Chen, X., Gao, W., Yang, M., Jiang, H., Zhang, Z & Zhang, K. (2021). Experimental investigation on PMMA dust explosion venting at elevated static activation pressure. Journal of Powder Technology, 392, 402-411.

Dakkoune, A., Hassimi, L. V., Leveneur, S., Lefebvre, D., & Estel, L. (2019). Analysis of thermal runaway events in French chemical industry. Journal of Loss Prevention in the Process Industries, 62, 103938.

Eckhoff, R.K. (2019). Chapter Two - Dust explosions: Fundamentals, Editor(s): Paul R. Amyotte, Faisal I. Khan, Methods in Chemical Process Safety. Elsevier, 3, 7-32.

Eckhoff, R.K & Li, G. (2021). Industrial Dust Explosions. A Brief Review. Journal of applied Science. 11, 1669.

Egan, S. (2017). Learning lessons from five electrostatic incidents. Journal of Electrostatics, 88, 183-189.

Ebadat, V & Cartwright, P. (2023). Electrostatic hazards: Identifying the early warning signs to reduce explosion risk. Journal of Process Safety Progress.

Fabiano, B., & Bernatik, A. (2023). Loss prevention in the process industries in a rapidly evolving world. Journal of Process Safety and Environmental Protection, 178, 392-395.

Haleem, R. M., Salem, M. Y., Fatahallah, F. A., & Abdelfattah, L. E. (2015). Quality in the pharmaceutical industry – A literature review. Saudi Pharmaceutical Journal, 23 (5), 463-469.

Herrera, M. A., Luna, A. S., Costa, A. C. A., & Lemes, E. M. B. (2015). A structural approach to the HAZOP – Hazard and operability technique in the biopharmaceutical industry. Journal of Loss Prevention in the Process Industries, 35,1-11,

Jia, Y., Yao, Y., & Zhang, Q. (2023). Prediction of lower explosion limit of liquid fuel aerosol. Journal of Combustion Theory and modelling.

Kwon, H., Lee, C-J., Seo, D., & Moon. (2016). Korean experience of process safety management (PSM) regulation for chemical industry. Journal of Loss Prevention in the Process Industries, 42, 2-5.

Liaw, H. J. (2023). Improved management practice and process hazard analysis techniques for minimizing likelihood of process safety incidents in Taiwan. Journal of Loss Prevention in the Process Industries, 81, 104966.

Lindqvist, K. (2023). Human factor and safety culture in safety research in the process and chemical industries. Master’s thesis for the degree of Master of Science in Technology submitted for inspection, Espoo. 1-103

Lu, Q., Wang, Z., Zhang, S., Qin, Z., Yu, X., Chen, Z., & Yu, J. (2023). Dust explosion in fusion reactors: Explosion characteristics and reaction mechanism of tungsten micro-powder. Journal of Combustion and Flame. 248, 112551.

Maniar, M. S., Kumar, A., & Mentzer, R. A. (2020). Global process safety incidents in the pharmaceutical industry. Journal of Loss Prevention in the Process Industries, 68, 104279.

Miadlicki, K., & Pajor, M. (2015). Overview of user interfaces used in load lifting devices. International Journal of Scientific & Engineering Research. 6(9), 1215-1220.

Moron, W., & Ferens, W. (2024). Analysis of fire and explosion hazards caused by industrial dusts with a high content of volatile matter. Journal of Fuel. 355, 129363.

Murad, M. S., Farnworth, L. O. L., & Chien, C. W. (2013). Health Status of People with work related musculoskeletal disorders in return-to-work Programs: A Malaysian Study. Journal of Occupational therapy in health care, 27(3), 238-55.

Nwankwo, C. D., Theophilus, S. C., & Arewa, A. O. (2020). A comparative analysis of process safety management (PSM) systems in the process industry. Journal of Loss Prevention in the Process Industries, 66, 104171.

Oamen, T. E., & Ihekoronye, M. R. (2022). The Nexus of Altruistic and Courteous Behaviors on Job Satisfaction and Affective Organizational Commitment among Pharmaceutical Executives. Indonesian Journal of Innovation and Applied Sciences (IJIAS), 2(3), 204-211.

Odu, J. O., Hamedon, T. R., Mahmud, A., & Baharudin, M. R. (2023). Systematic Review of Intervention Programs to Improve the Level of Knowledge, Attitude, and Practices towards Work Safety Culture among Office Workers. Mal J Med Health Sci., 19(1), 263-271.

Pingle, S. (2016). Country report - Occupational safety and Health in India: Now and Future. Journal of Industrial health. 250, 167-171.

Prasad, M & Suresh, L. (2023). Another side of industrial growth in India: Environmental damage from industrial accidents. Journal of Safety Science, 164, 106152.

Shariff, A. M., Aziz, H. A., Majid, N. D. A (2016). Way forward in Process Safety Management (PSM) for effective implementation in process industries. Journal of Current Opinion in Chemical Engineering. 14, 56-60.

Sohrabi M. S., & Babamiri, M. (2021). Effectiveness of an ergonomics training program on musculoskeletal disorders, job stress, quality of work-life and productivity in office workers: a quasi-randomized control trial study. International Journal of Occupational Safety and Ergonomics, 15, 1-8.

Wang, B., Yun, M., Liu, Q., & Wang, Y. (2023). Precision safety management (PSM): A novel and promising approach to safety management in the precision era. Journal of safety science, 157, 105931.

Wei, M. C., Cheng, Y. C., Lin, Y. Y., Kuo, W. K., & Shu, C. N. (2020). Applications of dust explosion hazard and disaster prevention technology. Journal of Loss Prevention in the Process Industries, 68, 104304.

Wu, D., Zhao, P., Spitzer, S. H., Krietsch, A., Amyotte, P., & Krause, U. (2023). A review on hybrid mixture explosions: Safety parameters, explosion regimes and criteria, flame characteristics. Journal of Loss Prevention in the Process Industries, 82, 104969.

Wu, Y., Ye, H., & Dong, H. (2023). An inherently safer design approach based on process safety time for batch chemical reaction processes. Journal of Process Safety and Environmental Protection, 171, 353-364.

Wu, Y., Ye, H & Dong, H. (2023). A multi-objective optimization for batch chemical reaction Processes: The trade-off between economy and safety. Journal of Chemical Engineering Science. 265, 118231.

Xin, W. (2023). Analysis and improvement of hot work management in China. Journal of Process Safety Progress, 42(1), 72-78.

Yang, L., Wang, H., Bai, K., & Chen, S. (2021). Dynamic intelligent risk assessment of hazardous chemical warehouse fire based on electrostatic discharge method and improved support vector machine. Journal of Process Safety and Environmental Protection. 145, 425-434.

Yu, M., Quddus, N., Peres, S. C., Sachdeva, S., & Mannan, M. S. (2017). Development of a safety management system (SMS) for drilling and servicing operations within OSHA jurisdiction area of Texas. Journal of Loss Prevention in the Process Industries, 50, Part A, 266-274.

Yu, M., Li, S., Li, H., Han, S., Wang, F., Lou, R., Zheng, K., & Yu, Y. (2023). Numerical evaluation of the influence of initial pressure / temperature on the explosion properties and soot formation of methane/coal volatiles mixtures. Journal of fuel, 331(1), 125698.

Zhang, K., Gao, W., Li, Y., Zhang, Z., Shang, S., Zhang, C., Chen, X., & Sun, K. (2022). Lower flammability limits of ethanol, acetone and ethyl acetate vapor mixtures in air. Journal of Loss Prevention in the Process Industries, 74, 104676.

Zhang, G., Li, L., Zhou, Q., Liang, C., Meng, H., Lan, Q., Cao, Z., Chen, X., & Ma, J. (2023). Electrostatic discharge pattern and energy probability distribution of different polarity powders in industrial silo. Journal of chemical Engineering Research and Design.192, 91-101.

Zwetsloot, G., Kampen, J. V., Steijn, W., & Post, S. (2020). Ranking of process safety cultures for risk-based inspections using indicative safety culture assessments. Journal of Loss Prevention in the Process Industries, 64, 104065.