Process Safety Management System became prominent because of an OSHA regulation that requires companies to properly manage hazardous chemicals, with the goal of creating safe workplaces and preventing unexpected releases of toxic, reactive, or flammable liquids and gases that can cause disasters. Process Safety Management systems are usually a blend of technology platforms, specific procedures and management frameworks.
What is Process Safety Management?
Process Safety Management (PSM) refers to a comprehensive set of practices and procedures implemented in process industries to ensure the safe operation of facilities that handle hazardous materials. It involves identifying, assessing, and controlling potential risks and hazards associated with handling and processing chemicals and implementing measures to prevent accidents, protect workers, and minimize environmental impacts.
Elements of Process Safety Management System
Process Safety Management System is complex and requires a multidimensional approach that blends technology and management solutions. Every Process Safety Management program should include 14 basic elements, according to OSHA. Here is a brief overview.
1. Process Safety Information
Collect and document process safety information (PSI) regarding hazards, technology, and equipment. Hazard information should cover toxicity, exposure limits, physical and chemical properties, reactivity, stability, and risks of mixing materials. If safety data sheets comply with OSHA standards, hazard information is considered met. Technology information should include diagrams, chemistry details, inventory limits, and consequences of deviations. Equipment information entails construction materials, diagrams, safety systems, and design standards.
2. Operating Procedures
Develop and implement operating procedures on how to safely proceed with the activities and tasks involved in the process. Operating procedures should be aligned with PSI and address the steps for each operating phase, operating limits, safety and health considerations, and safety systems and their functions.
Aside from PSI on hazards, other safety and health considerations are the precautions necessary to prevent exposure, control measures in case of exposure, quality control for raw materials, and control of hazardous chemical inventory levels.
3. Process Hazard Analysis
A process hazard analysis (PHA) evaluates process hazards, considering past incidents, control measures, and potential consequences of failures. It requires a specialized team comprising experts in engineering, process operations, and PHA methodologies. Such methodologies include PHA checklists, what-if scenarios, , HAZOP, FMEA, and fault tree analysis. PHAs, a vital part of process safety management, must be updated and revalidated every five years.
4. Employee Participation
Before proceeding with the other elements, process safety managers will need to develop a plan of action on implementing employee participation in the PSM program. Additionally, process safety managers must consult with employees on how to proceed with each element as well as provide access to information relevant to the program.
5. Training
Aside from participating in the PSM program, employees should receive adequate training on the process, operating procedures, emergency operations, specific safety and health hazards, and safe work practices. Chemical safety managers should also conduct refresher training at least every 3 years, or more often if necessary.
All training must be documented and include the identity of the employee, the date of training, and verification that the employee understands the subject matter of the training.
6. Contractors
This PSM element applies to contractors performing maintenance or repair, turnaround, major renovation, and specialty work. Chemical safety managers should review the contractor’s safety performance and programs before selecting them.
After selection, chemical safety managers must periodically evaluate the performance of the chosen contractor. They should also consider giving the contractor’s employees a site induction to brief them on the potential hazards related to the work, process, or site.
7. Mechanical Integrity
Ensure the mechanical integrity of process equipment, including pressure vessels, storage tanks, piping systems, pumps, and monitoring systems. Document inspections and tests conducted, rectifying any deficiencies beyond acceptable limits before further use. Utilize tracking tools or software to monitor equipment status, promptly addressing any issues to prevent accidents.
8. Incident Investigation
A PSM incident involves or could potentially result in a catastrophic release of a hazardous chemical. Chemical safety managers must begin an incident investigation within 48 hours of such an incident, identifying its primary cause and contributing factors, along with recommendations for prevention. Prompt action should follow to address findings and implement corrective measures from the investigation report. Once resolved, all affected parties should review the report thoroughly to determine the need for further investigation.
9. Management of Change
Before making any changes to chemicals, technology, equipment, or facilities, prepare a management of change (MOC) procedure. It should address the technical basis for the proposed change, its impact on safety and health, modifications to operating procedures, and the authorization requirements and time period needed for the proposed change.
10. Pre-Startup Safety Review
For new and modified facilities, chemical safety managers must perform a pre-startup safety review. The PSSR should confirm that construction and equipment are in accordance with design specifications, operating procedures have been established, and all employee training is complete. Additionally, there must be a MOC procedure for modified facilities and a PHA has to be performed for new facilities.
11. Emergency Planning and Response
Develop an emergency action plan (EAP) for the entire site. It should meet the requirements of the EAP OSHA standard and include procedures for handling small releases of HHCs. If the site is under the Hazardous Waste Operations and Emergency Response (HAZWOPER) OSHA standard, ensure that the EAP meets the requirements of that standard as well.
12. Hot Work Permit
A hot work permit is issued whenever hot work operations are conducted on or near a process. Before requesting or issuing a hot work permit, chemical safety managers must ensure that the fire prevention and protection requirements of the Welding, Cutting, and Brazing OSHA standard have been implemented. The hot work permit will verify this and also specify the date/s authorized for hot work and the object/s on which hot work is to be performed.
The permit to work (PTW) system should ensure that authorized and competent people have thought about foreseeable risks and that such risks are avoided by using precautions.
13. Compliance Audits
Chemical safety managers must conduct compliance audits at least every 3 years to check if the site’s PSM program adheres to all of the elements. They will also need to determine and document an appropriate response to each of the findings in the compliance audit reports. Organizations are required by the PSM standard to keep the two most recent compliance audit reports.
14. Trade Secrets
Without regard to possible trade secret status, all information necessary to comply with the PSM standard should be made available to those involved in the PSM program. However, organizations are allowed to require such persons to enter into confidentiality agreements not to disclose any trade secret information.
Conclusion
Process safety management is a critical framework that protects human lives, the environment, and valuable assets in industrial operations. By adhering to the 14 elements of process safety management and fostering a culture of safety, organizations can mitigate risks and minimize the potential for accidents and incidents. Implementing and enhancing PSM is not just a regulatory requirement but a moral and financial imperative, ensuring that industries operate safely and responsibly. It is a commitment to safety that should be at the core of every industrial organization’s mission.
Process safety management training is necessary to ensure that employees, especially those working with dangerous machinery or chemicals, develop competence in process safety management concepts, practices, and procedures.
For more information and help on your PSM system or even a tailor-made training for you or your organization please don’t hesitate to contact us.
Call us: +234 9115687051. Email us: training@primeliftsafetyng.com
