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Process Safety Management: Protecting People and Operations in Industries Handling Highly Hazardous Chemicals
Process Safety Management (PSM) is a comprehensive management system that is designed to prevent the release of hazardous chemicals or energy and mitigate the impact of such releases when they occur.
PSM is not only essential for maintaining the safety of workers but also for protecting the environment and surrounding communities. According to the Occupational Safety and Health Administration (OSHA), PSM “focuses on the process and the equipment used to produce chemical products and seeks to identify potential hazards and reduce the likelihood of an accident.”
OSHA Process Safety Management Standard
The PSM standard (OSHA 29 CFR 1910.119) requires employers to develop and implement a PSM program for covered processes that includes the following elements:
- Employee participation
- Process safety information
- Process hazard analysis
- Operating procedures
- Training
- Contractors
- Pre-startup safety review
- Mechanical integrity
- Hot work Permits
- Management of change
- Incident investigation
- Emergency planning and response
- Compliance Audits
- Trade Secrets
What is OSHA process safety management (PSM)?
Process Safety Management (PSM) is a systematic approach to managing the hazards associated with highly hazardous chemicals used in industrial processes. PSM is designed to prevent catastrophic incidents, such as fires, explosions, and toxic releases, by identifying, evaluating, and controlling potential hazards. It involves a comprehensive set of policies, procedures, and practices aimed at ensuring the safe design, operation, and maintenance of industrial processes that use hazardous chemicals.
When is Process safety management required?
Process safety management (PSM) is required by the Occupational Safety and Health Administration (OSHA) in the United States for any employer with a process that involves highly hazardous chemicals in quantities at or above the specified threshold quantities. Threshold quantities are defined for specific chemicals in OSHA’s list of highly hazardous chemicals and is set at 10,000 lbs for flammable liquids or gases.
Who is required to have a process safety management program?
Employers who have processes that involve highly hazardous chemicals (HHCs) above specified threshold quantities are required to have a process safety management (PSM) program in place. This requirement is established by the Occupational Safety and Health Administration (OSHA) in the United States, under the PSM Standard (29 CFR 1910.119).
Examples of industries that commonly use highly hazardous chemicals and may be required to have a PSM program include chemical, refining, petrochemical, and pharmaceutical.
What is the purpose of Process safety management?
The purpose of Process Safety Management (PSM) is to prevent catastrophic incidents, such as fires, explosions, and toxic releases, that can occur as a result of the handling, storage, and processing of highly hazardous chemicals (HHCs) used in industrial processes.
The objectives of PSM include identifying and assessing potential hazards, implementing controls to prevent or mitigate those hazards, training workers to safely operate and maintain equipment and processes, and continuously improving the effectiveness of the PSM program.
OSHA PSM Applicability
Appendix A of the OSHA Process Safety Management standard (29 CFR 1910.119) provides a list of highly hazard chemicals (HHCs) covered under the OSHA PSM standard and the threshold quantity for each. PSM requirements apply to processes that contain HHCs above their listed threshold quantities. Additionally, processes containing over 10,000 lbs of flammables are required to follow PSM standards.
In addition to avoiding regulatory action, compliance offers benefits such as:
- Reduction in potential injuries and fatalities
- Reduction in the likelihood and severity of releases, fires, and explosions
- Reduction in potential environmental impacts
- Increase in process operability
Laboratory Testing
Laboratory testing is an important component of process safety management, as it helps to identify potential hazards, evaluate the effectiveness of process controls, and ensure the safe operation of equipment and processes. Some of the common laboratory testing methods used in process safety management include:
- Chemical Analysis – Chemical analysis involves the testing of materials and substances used in the process to identify potential hazards, such as the presence of toxic or reactive chemicals.
- Chemical Reaction Hazards Testing & Analysis – Reactive chemical testing is used to measure potential reactivity of raw materials and finished products. This testing may uncover undesired reaction hazards.
- Thermal Stability Testing – Thermal stability testing involves the evaluation of the potential for chemical reactions to occur due to temperature changes in the process. This testing helps to identify potential runaway reactions, which can lead to fires, explosions, or other safety hazards.
- Corrosion Testing: Corrosion testing is used to evaluate the corrosive properties of chemicals and materials used in the process. This testing helps to identify potential failures in equipment and piping, which can lead to leaks, spills, and other safety hazards.
- Mechanical Testing: Mechanical testing involves the evaluation of the strength and durability of equipment and materials used in the process. This testing helps to identify potential failures in equipment, which can lead to accidents and other safety hazards.
- Pressure Testing: Pressure testing is used to evaluate the ability of equipment and piping to withstand the pressures and temperatures associated with the process. This testing helps to identify potential failures in equipment, which can lead to leaks, spills, and other safety hazards.
Process Safety Management Consulting Services
Process Safety Management consulting services can assist organizations in meeting their regulatory requirements under PSM and reducing their risk of handling highly hazardous materials. These services include:
- PSM program development (overall or individual element support)
- Leading process hazard analyses (HAZOPS, Checklists)
- Writing operating procedures
- Conducting employee training
- Leading process safety audits
- Providing subject matter expertise for handling reactive or flammable materials
Sigma-HSE is well-equipped to provide top-notch services thanks to our team of highly qualified engineers. Contact us to discuss your process safety needs.
