iFluids Engineering is a specialized leader in Process Safety Management (PSM) for the oil and gas sector, aligning with the latest OISD-GDN-206 guidelines issued by the Oil Industry Safety Directorate (OISD). Our in-depth expertise enables upstream, midstream, and downstream operators across India and abroad to build, implement, and audit comprehensive Safety Management Systems (SMS).
Process Safety Management (PSM) is a structured framework for preventing catastrophic releases of toxic, reactive, flammable, or explosive chemicals. In high-hazard industries such as oil & gas, petrochemicals, pharmaceuticals, and power, effective PSM is not just a regulatory requirement; it is a business imperative. We deliver end-to-end PSM solutions designed to identify, evaluate, and mitigate risks across the lifecycle of industrial operations.
Why Process Safety Management is Critical
👉 Operational and Asset Risk Reduction: Prevents incidents that could result in loss of life, equipment damage, and environmental harm.
👉 Regulatory Compliance: Aligns with standards referenced in the SOW, including OISD-GDN-206 and Risk-Based Process Safety principles.
👉 Reputation and Financial Protection: Minimizes potential liabilities and unplanned outages that can result in high costs.
👉 Cultural and Organizational Maturity: Embeds safety into the fabric of organizational behavior and decision-making
This service page outlines how iFluids Engineering delivers technically robust, field-tested, and OISD 206-compliant PSM services structured around the four foundational blocks defined in OISD-GDN-206: Commit, Assess, Control, and Verify.
COMMIT: Leadership, Policy, and Organizational Framework
- Safety Organization
OISD 206 Requirement:
Establish a formal safety structure that defines leadership responsibilities, resource allocation, and communication mechanisms to effectively manage safety risks.
Key Technical Requirements:
Clear assignment of safety roles and responsibilities.
Safety governance structures and reporting hierarchies.
Allocation of adequate resources for SMS implementation.
iFluids Approach:
We support our clients in defining and implementing their safety organization structures using:
Customized RACI matrices.
Safety leadership charters.
Integrated digital dashboards for SMS monitoring.
Real-world Application:
Our consultants have successfully restructured safety organizations in major Indian refineries, establishing direct reporting lines from operations to HSE committees - . Consultation & Participation
OISD 206 Requirement:
Promote two-way communication and active engagement of the workforce in SMS development and implementation.
Technical Scope:
Mechanisms for employee input in policy formulation.
Participation in HIRA studies, job safety analysis, and toolbox talks.
Safety suggestion schemes and open-door reporting policies.
iFluids Approach:
We develop participation strategies that integrate:
Safety perception surveys.
Safety committee frameworks.
On-site facilitation of worker-led safety campaigns
COMMIT: Leadership, Policy, and Organizational Framework
Hazard Identification and Risk Analysis (HIRA)
✅ OISD 206 Requirement:
Identify hazards and analyze associated risks through structured methodologies such as HAZOP, FMEA, LOPA, and QRA.
Technical Requirements:
Lifecycle-based application from design to decommissioning.
Revalidate every 5 years or post any significant process changes.
Documentation of all potential risk scenarios and mitigation strategies.
✅ Detailed Methodologies:
HAZOP (Hazard and Operability Study): Systematic study to identify process deviations.
FMEA (Failure Mode and Effects Analysis): Identification of failure points and consequences.
What-If Analysis: Scenario-based brainstorming for unusual events.
Bow-Tie Analysis: Visualization of risk pathways and barriers.
Fault Tree Analysis: Logical analysis of failure pathways.
LOPA (Layer of Protection Analysis): Assessing adequacy of existing safeguards.
QRA (Quantitative Risk Assessment): Numerical assessment of risk to life, property, and environment.
✅ iFluids Services:
Development of HIRA policy documents.
Execution of detailed workshops involving multidisciplinary teams.
ALARP (As Low As Reasonably Practicable) justification for residual risk.
CONTROL: Risk Mitigation through Structured Safety Systems
- Process Safety Information (PSI)
- Develop and maintain comprehensive PSI covering equipment specs, chemical hazards, design data, process parameters, and SOLs (Safe Operating Limits).
- Operating Procedures
- SOPs with emergency response protocols.
- Integration of startup, shutdown, and abnormal operation guidance.
- Inclusion of interlock checks and LOTO (Lockout/Tagout) procedures.
- Safe Work Practices and Work Permits
- Permit-to-Work (PTW) systems tailored for hot work, confined space, excavation, electrical isolation, and simultaneous operations.
- Training and Competence
- Competency frameworks by role (operators, engineers, contractors).
- Refresher training calendar and proficiency tracking.
- Contractor Management
- Pre-qualification audits.
- Onboarding safety inductions.
- Bridging documents that integrate contractor HSE responsibilities.
- Safe Operation Management
- Standardized shift handover procedures.
- Use of control room checklists and deviation logs.
- Asset Integrity Management (AIM)
- Development of RBI (Risk-Based Inspection) plans.
- Establishing Integrity Operating Windows (IOWs).
- Structured deferment management with justification protocols.
- Management of Change (MoC)
- Evaluation of the safety impact for each change.
- MoC workflow is integrated with document control and HIRA.
- Incident Reporting, Investigation, and Learning
- Near-miss reporting portals.
- Root Cause Analysis (RCA) and causal tree development.
- Learning dissemination via alerts and toolbox briefings.
- Emergency Response Management
- Site-specific ERP (Emergency Response Plans).
- Scenario-based drills (fire, gas leak, explosion).
- Transport Safety Management
- Safe practices for product transfer and dispatch.
- Defensive driving programs and fleet safety audits.
- Project HSE Management
- Project-specific HSE Plans (PHSEPs).
- PHSER (Project HSE Review) milestones and deliverables.
VERIFY: Assurance and Continuous Improvement
1. Pre-Startup Safety Review (PSSR)
Final safety review for new or modified installations.
Checklist-based evaluation of readiness.
2. Safety Management System Audit
Compliance audits based on OISD 206.
Corrective action tracking through closure matrices.
3. Management Review
Annual SMS review involving leadership.
Tracking of lagging and leading indicators.
Adjustments to policy and strategy based on audit outcomes.
Ready to Enhance Your Process Safety?
We understand that a robust Process Safety Management (PSM) system is not just about compliance, it’s about safeguarding lives, protecting assets, and ensuring business continuity. Whether you’re a refinery operator, terminal manager, EPC contractor, or HSE head of an offshore installation, our team is equipped to help you translate the OISD-GDN-206 requirements into practical, achievable, and auditable actions.
Here’s how we can support your journey to process safety excellence:
✔️ Compliance Audit Services: Identify gaps in your current SMS and receive a prioritized roadmap for full alignment with OISD 206 standards.
✔️ PSM Gap Analysis & Benchmarking: We provide detailed comparative studies and industry benchmarking to demonstrate how your systems align with best practices.
✔️ Turnkey Implementation Programs: From HIRA facilitation to development of Emergency Response Plans (ERP), we handle the full spectrum of SMS components.
✔️ Training & Capacity Building: Build in-house safety leadership through certified training modules tailored to your workforce profile.
✔️ Digital Tools for Safety Management: Implement risk dashboards, audit tracking systems, and permit-to-work software customized for your facility.
With iFluids Engineering as your partner, you’re not just checking a regulatory box but embedding a culture of risk awareness and operational discipline that sustains long-term performance.