E
nvironmental Compliance
Management Services
Who's ECM Services?
Specialize in Regulatory Compliance for Industrial
Operations with over 20 years of hands-on experience
Regulatory Experts
Industrial Chemistry
Manufacturing and Process Engineering
Risk-Based Approach to Compliance Management:
“Manage The Risk-Don’t Chase the Regulation”
EMS/ISO 14001 Lead Auditor Certified
Developed 100’s of successful and effective
multi-media industrial compliance programs, including
nearly 100 RMPs, in the toughest regulatory
environments for some of the most
high-hazard/complex industrial operations
Regulatory Background
40 CFR 68: Accidental Release Prevention Program
Section 112(r) of the 1990 Clean Air Act
Citizen Right to Sue Provisions
Regulated Substances (RS) Above Threshold
Quantities (TQs)
40 CFR 355
Ammonia, Anhydrous: TQ= 10,000#
Ammonia, 20% : TQ= 20,000#
Chlorine: TQ= 2,500#
Propane: 10,000 #
State/Local TQs (California’s CalARP)
Ammonia, 1%: TQ= 1,000#
Chlorine: TQ= 100#
Program 1
No Offsite impacts
No accidents w/in last 5 years
Program 2
Not either Program 1 or Program 3
Program 3
Subject to OSHA Process Safety Management
Regulations
Certain specified industrial classifications
5-Year Review & Update
At least once every five years from the date of
initial submission:
Revise and Update the RMP and re-submit
Review and update Offsite Consequence Analysis (OCA)
Update and revalidate PHA, Prevention & Management
Programs
Steps to Compliance:
Goal: Defendable & Technically Justified
Review last 5-year history of regulated process
Verify/update that previous PHAs, Hazard Assessment,
hazard prevention and management programs represent
current process conditions and controls are
appropriate and adequate for current conditions
Resubmit RMP documentation/registration to
Risk Management Program
"Continuous Improvement"
Continuous
Process
Review Revise Identity Risk and Controls Implement MonitorMeasure
Continuous
Process
Hazard Assessment Prevention Program Management Program Inspection & Record KeepingRMP Update & Revalidation
Do not have to “start from scratch”
Quality of Previous PHAs
Changes to Processes In Last 5 Years
Adequacy of Prevention Program Elements
Effectiveness of Management Program
Hazard Assessment
Review Process History
Changes to Process Equipment (MOC/PSSR)
PSI/P&IDs
Maintenance Records
Incident Investigations (Releases and Near-Miss)
Operating, Safety Procedures
Company Policies
Personnel/Sitting Changes
Employee turnover/Knowledge Base
Land Use/Development
Regulatory Changes
Hazard Assessment
Apply history and verify/update that:
PHAs adequately represents current process
conditions; and
Hazard Controls (i.e., prevention and
management programs) are effective and
appropriate for current process conditions
Technically justified
Demonstrated
PHAs
Quality of Previous PHAs
Complete/Through?
All fail modes identified & evaluated: PHA Method
Review
Critical Fail Points: Process Flow Diagram “Nodes”
Chemical or physical change in regulated substance
Requires personnel to make process decision and take
action
Consequences of Deviation From Design Conditions
1
st
:Possibility
2
nd
: Probability, considering existing controls
External Events
PHA Results Drive Prevention
and Management Programs
Nearly all RMP violations are a result of failure to implement
adequate prevention and management programs
Where compliance is measured and where the “real work”
begins
Prevention Program: Systems, procedures and programs to
prevent and/or mitigate a release of the regulated substance
PHA Results
Technically Justified
Document, measure Prevention Program effectiveness and
adequacy
ECM Services RMP Compliance Management Tool
Prevention and Mangement
Program Requirments
Overview
RMP
PSM
Training and Qualification Recording Keeping and Document Control
Management Element
DEMONSTRATION OF COMPLIANCE
Program
Administration Prevention Program
RMP ISM Database
Administration
Equipment Maintenance (Mechanical Integrity) Program Element Review
Contractor Management
MOC/PSSR
RMP Compliance Management Tool (RMP CMT) Structure
RMP CMT Elements
Program Management Procedures: 1. Section A: Policy
2. Section B: Employee Participation 3. Section C: PSI
4. Section D: PHA
5. Section E: Operating Procedures a. OPs
b. MPs
6. Section F: Training 7. Section G: Contractors
8. Section H: Mechanical Integrity
a. Equipment/Process Maintenance & Inspection Program
9. Section I: Hot Work (SWP) 10. Section J: MOC/PSSR
11. Section K: Incident Investigation
12. Section L: Emergency Response Planning/EPs 13. Section M: Compliance Audits
14. Section N: Document Control
15. Section P: Recommendation Action Plan (RAP)
RMP Information Management System (IMS): 1. Equipment Classification Data (Data Elements
Forms/PSI) 2. Contractor Information 3. PM Requirements 4. PM Schedule 5. PM Log 6. MRR Report
7. Training Requirements & Schedule a. Employees
b. Contractors
8. Document Control Records
a. Program Management Procedures b. SOPs (OPs)
c. MOPs (MPs) d. SWPs
e. EPs
f. Training Programs
g. Process Flow Diagrams /PI&Ds h. Process Hazard Review (PHAs) i. RMP Review: 5-year
9. RAP Reports
10. MOC/PSSR Reports 11. Compliance Audit Reports 12. Incident Investigation Reports
MAIN MENU
ADD NEW RECORD
PROGRAM ELEMENT REVIEW
REPORTS
Compliance Schedule
EDIT/REVIEW
EXISTING RECORD
UPDATE CODE LISTS
OPs & EPs
CODE
UPDATE
OPs & EPs
DESCRIPTION
UPDATE
SAFETY CODE
UPDATE
PROGRAM
ELEMENT
UPDATE
PROGRAM
ELEMENT FORM
MAIN MENU
ADD NEW RECORD
ADMINISTRATION
INCIDENT
INVESTIGATION
EDIT/REVIEW EXISTING RECORD
PSSR
CONTRACTOR
RAP
MANAGEMENT
REPORTS
Compliance ScheduleGENERAL EMPLOYEE
ADMINISTRATIVE TASKS
Employee Demographic Information
1. Request For Change 2. PSSR Header 3. PSSR Checklist 1. General Information 2. Performance Evaluation 3. Quality Evaluation 4. Training Records 1. Header Form 2. Preferred RAP 3. Alterative RAP 4. Review & Approval
PHA
3 Yr Compliance Audit Incident Investigation 5- Yr PHA Review MOPs SWPs ERPs SOPs Document Control TrainingReview and update written procedures, training program materials
Log changes in DB Review/update DB elements