PSM - Process Safety Management

3 Parts to Process Safety

Process Safety Management (PSM) meet the requirements of OSHA Standard Process Safety Management of Highly Hazardous Substances.
Process Safety Information is the technical information on the process and equipment in the system. This information allows for accurate analysis.
Process Hazard Analysis and maintaining information on the system for operator training and reference.

PSM Program Required Elements

Employee Participation
Process Hazard Analysis
Process Safety Information
Operating Procedures
Pre-Startup Review
Hot Work
Mechanical Integrity
Emergency Planning
Management of Change
Planned Maintenance

Although OSHA believes process safety management will have a positive effect on the safety of employees and will offer other potential benefits to employers, such as increased productivity, smaller businesses that may have limited resources to them at this time, might consider alternative avenues of decreasing the risks associated with highly hazardous chemicals at their workplaces. One method that might be considered is reducing inventory of the highly hazardous chemical. This reduction in inventory will result in reducing the risk or potential for a catastrophic incident. Also, employers, including small employers, may establish more efficient inventory control by reducing, to below the established threshold, the quantities of highly hazardous chemicals onsite. This reduction can be accomplished by ordering smaller shipments and maintaining the minimum inventory necessary for efficient and safe operation. When reduced inventory is not feasible, the employer might consider dispersing inventory to several locations onsite. Dispersing storage into locations so that a release in one location will not cause a release in another location is also a practical way to reduce the risk or potential for catastrophic incidents.

The various lines of defense that have been incorporated into the design and operation of the process to prevent or mitigate the release of hazardous chemicals need to be evaluated and strengthened to ensure their effectiveness at each level. Process safety management is the proactive identification, evaluation and mitigation or prevention of chemical releases that could occur as a result of failures in processes, procedures, or equipment.

The process safety management standard targets highly hazardous chemicals that have the potential to cause a catastrophic incident. The purpose of the standard as a whole is to aid employers in their efforts to prevent or mitigate episodic chemical releases that could lead to a catastrophe in the workplace and possibly in the surrounding community.

To control these types of hazards, employers need to develop the necessary expertise, experience, judgment, and initiative within their work force to properly implement and maintain an effective process safety management program as envisioned in the Occupational Safety and Health Administration (OSHA) standard.

Process Safety Management

Unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals have been reported for many years in various industries that use chemicals with such properties. Regardless of the industry that uses these highly hazardous chemicals, there is a potential for an accidental release any time they are not properly controlled, creating the possibility of disaster. An effective Process Safety Management program can help prevent releases and prepare for emergency response in the event of a chemical release.g.

To help ensure safe and healthful workplaces, OSHA has issued the Process Safety Management of Highly Hazardous Chemicals standard which contains requirements for the management of hazards associated with processes using highly hazardous chemicals.

Process Safety Management is intended to prevent an incident like the 1984 Bhopal Disaster. A process is any activity or combination of activities including any use, storage, manufacturing, handling or the on-site movement of Highly Hazardous Chemicals (HHCs). A process includes any group of vessels which are interconnected or separate and contain HHC's which could be involved in a potential release. A process safety management incident is the "Unexpected release of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals. Incidents continue to occur in various industries that use highly hazardous chemicals which exhibit toxic, reactive, flammable, or even explosive properties, or may exhibit a combination of these properties. Regardless of the industry that uses these highly hazardous chemicals, there is a potential for an accidental release any time they are not properly controlled by a properly designed Process Safety Management Program. This, in turn, creates the possibility of disaster.

A great many industrial facilities must comply with OSHA's Process Safety Management (PSM) regulations as well as the quite similar United States Environmental Protection Agency‎ (EPA) Risk Management Program (RMP) regulations. The Center for Chemical Process Safety Management (CCPS) of the American Institute of Chemical Engineers (AIChE) has published a widely used book that explains various methods for identifying hazards in industrial facilities and quantifying their potential severity.

Hazardous chemical releases pose a significant threat to workers. The key provision of process safety management (PSM) is process hazard analysis (PHA), a careful review of what could go wrong and what safeguards must be implemented to prevent releases of hazardous chemicals. The following references

All materials in the members area for this topic index

Program Material

Programs (written)
 PSM Contractor   Download  MS-WORD
 PSM Emergency   Download  MS-WORD
 PSM Employee Participation   Download  MS-WORD
 PSM Hotwork   Download  MS-WORD
 PSM Introduction   Download  MS-WORD
 PSM Investigations   Download  MS-WORD
 PSM Mech Integrity   Download  MS-WORD
 PSM Moc   Download  MS-WORD
 PSM Op Procedures   Download  MS-WORD
 PSM Pha   Download  MS-WORD
 PSM Pm   Download  MS-WORD
 PSM Psi Req   Download  MS-WORD
 PSM Startup   Download  MS-WORD
 PSM Training   Download  MS-WORD
Fact Sheets
 PSM 1910 0119 App A   Download  MS-WORD
 PSM 1910 0119 App C   Download  MS-WORD
 PSM 1910 0119 App D   Download  MS-WORD
 PSM 1910 0119   Download  MS-WORD

Forms & Documents

 PSM Amonia Refrigeration Checklist   Download  MS-WORD
 PSM Block   Download  MS-WORD
 PSM Crit Dev Form   Download  MS-WORD
 PSM Entry Permit   Download  MS-WORD
 PSM Equip List Form   Download  MS-WORD
 PSM Line Break Form   Download  MS-WORD
 PSM Maint Schedule   Download  MS-WORD
 PSM Process Dia   Download  MS-WORD
 PSM Psi Info   Download  MS-WORD
 PSM Trg Ori Eng   Download  MS-WORD

Training Material

 Conversation A Management Safety Tool Safety Article   Download  MS-WORD
 Process Safety Management Overview PowerPoint   Download  MS-PPT
 Reactive Chemical Hazards   Download  OnLine


Case Histories
 PSM Moc Case Summary   Download  MS-WORD
 PSM Moc Case1   Download  MS-WORD
 PSM Moc Case2   Download  MS-WORD



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