Institutionalising Process Safety Management in Pulp & Fibre Business
The Pulp & Fibre (P&F) Business has undertaken a structured approach to strengthen Process Safety Management (PSM) by implementing various best practices across multiple units. The goal is to institutionalise a robust process safety culture by improving alarm management, enhancing hazardous material handling, optimising transportation safety, and streamlining process safety event (PSE) reporting.
Given the complexity of operations involving hazardous chemicals such as Carbon Disulphide (CS₂), the business has systematically introduced engineering and administrative controls, ensuring alignment with global safety standards. The initiative is a critical step in creating a sustainable, safe, and efficient operating environment.
Key Initiatives and Implementation
1. Alarm Management System (BC Kharach Unit)
Challenge:
Operators at the BC Kharach plant were overwhelmed with excessive alarms, leading to inefficiencies and safety risks.
Solution:
- Conducted alarm rationalization in line with industry standards.
- Engaged a third-party expert to train teams and define an alarm rationalization format.
- Implemented phase-wise rationalization across Distributed Control System (DCS) units.
- Integrated a third-party software dashboard for real-time alarm monitoring.
Outcome:
- Reduced alarm frequency from 7 lakh+ alarms/day to manageable levels.
- Strengthened safety barriers through engineering control.
- Improved response time and process safety performance.
2. CS₂ Transportation Safety Enhancement
Challenge:
Lack of defined Indian regulations for CS₂ transportation posed risks during transit.
Solution:
- Adopted international standards such as IMDG, EU, and USA safety requirements.
- Implemented stringent ISO tank integrity checks at defined intervals (every trip, every 6 months, 2.5 years, and 5 years).
- Installed GPS tracking, auto-plant device integration, and emergency response measures for enhanced safety.
Outcome:
- Reduced transportation-related risks through real-time tracking and emergency preparedness.
- Established a transportation safety guideline and sustained monitoring through leadership engagement.
Key Impacts and Sustainability
The structured PSM framework led to:
- Enhanced workforce safety and operational reliability across all units
- Standardised process safety guidelines, ensuring sustainability of best practices.
- Leadership-driven monitoring and continuous improvement, fostering a proactive safety culture.
Through these initiatives, the Pulp & Fibre Business has institutionalised process safety management, aligning with global best practices and regulatory expectations.