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Overview of Process Safety Management (PSM)
Process Safety Management (PSM) is a regulation issued by the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA). The regulation is designated as OSHA 1910.119, Process Safety Management of Highly Hazardous Chemicals. Its purpose is to prevent or minimize the consequences of releasing hazardous chemicals in a facility or the environment surrounding a facility. Hazardous chemicals are those that may be toxic, reactive, flammable, explosive, or a combination of these properties. Industries handling hazardous chemicals are required to develop an effective PSM program that protects employees, contractors, and visitors of the facility. These industries include: petrochemical, pharmaceutical, paints, adhesives and sealants, food processing, industrial organics and inorganics, and paper mills.
Elements of OSHA 1910.119 - PSM of Highly Hazardous Chemicals
How do companies know they are complying with the OSHA regulation when implementing a PSM program? To answer this question, companies should be familiar with the following 14 elements that are required for PSM program compliance. These elements are the minimum requirements extracted from OSHA 1910.119 [1]. All information (date, equipment, personnel, process safety information, and process hazard analyses) should be recorded and stored in the event that future audits need to refer back to historical information about the facility and equipment.
1. Employee Involvement
All employees that play a role in facility operations should be involved in a PSM program. Each of the following elements requires a competent and experienced team of individuals. Ideally, a team should include at least one person who specializes in the specific process being used.
2. Process Safety Information (PSI)
The PSI element requires that employers collect and document highly hazardous chemical (HHC) information before conducting a process hazard analysis. This information pertains to the chemicals, technology, and equipment used in the process. Furthermore, the information should be accessible to all employees in order to understand the HHC related risks they may face during the job.
3. Process Hazard Analysis (PHA)
A PHA is performed by a team of engineering and maintenance experts that are able to identify, evaluate, and control hazards. PHAs can be conducted using a number of techniques, including:
- "what-if" analyses
- checklist methods
- hazard and operability studies
- failure modes and effects analyses
- fault-tree analyses
Additionally, it’s important to make sure PHAs are performed in a timely manner as teams are expected to complete a certain amount of the analysis by specific deadlines. PHAs should be performed at least every 5 years [1].
4. Operating Procedures
Companies should document all operational procedures involving initial startup, normal operations, temporary operations, and emergency shutdowns. Operators should be aware of the operating limits of the process, the consequences if the process deviates from normal conditions, and be prepared to correct deviations when necessary.
5. Training
Employees should be trained on procedures, safety factors, and health hazards specific to the job task. Certification programs may help ensure that individuals are competent in specialized areas relative to their practices. Additionally, some practices require on-going training as methods and best practices continue to develop.
6. Contractor Safety
Companies should evaluate a contractor’s safety performance prior to starting a project (e.g. repair, turnaround, or renovation). Once a contractor passes clearance requirements, it is the responsibility of the company to inform the contractor of potential risks and health hazards related to the contractor’s project. The contractor’s responsibility is to inform the incoming contracted team of risks and health hazards and to ensure contracted employees have received and understood necessary training.
7. Pre-Start Up Process Safety Review
Companies are required to perform a safety review before new or modified facilities begin production. The pre-start up safety review confirms that an initial PHA has been performed and that all safety, operating, maintenance, and emergency procedures meet the requirements of codes, standards, and specifications [1].
8. Mechanical Integrity
Routine inspections are required for major process units and equipment, such as pressure vessels, storage tanks, piping systems, relief and vent systems, emergency shutdown systems, control systems (e.g. monitoring devices and sensors), and pumps to ensure the mechanical integrity of the component meets requirements. All inspections and tests need to be well-documented and must follow recognized and generally accepted good engineering practices (RAGAGEP).
9. Hot Work Permit
This mandate requires that employers issue hot work permits for personnel performing high-temperature operations on equipment (e.g. welding).
10. Management of Change
A company needs to have an organized and efficient process for managing procedural changes regarding process chemicals, technology, and/or equipment. Under the OSHA 1910.119 standard, each change requires that the following considerations be addressed:
- The technical basis for the proposed change
- The impact of change on safety and health
- Modifications to operating procedures
- Necessary time period for the change
- Authorization requirements for the proposed change [1]
11. Incident Investigation
Investigations should be performed on incidents that resulted in (or could have resulted in) catastrophic HHC release. Incident investigations should report:
- The date of the incident
- The date of the investigation
- The description of the incident
- The root causes that contributed to the incident
- Any recommendations or solutions resulting from the investigation
12. Emergency Planning and Response
Companies are required to develop and implement emergency action plans for the entire facility. Emergency plans include procedures for mitigating large and small releases of HHCs.
13. Compliance Audits
Individuals should recertify their credentials at least every three years to keep up-to-date with evolving practices and technology. This element also states that companies should retain the 2 most recent compliance audit reports.
14. Trade Secrets
This mandate ensures that employees involved in elements 2-13 have access to the information about the process and health risks they may encounter during the job.
References
- 29 CFR 1910.119, Process Safety Management of Highly Hazardous Chemicals, OSHA.
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Our company invents and manufactures technologies that address some of the world’s most critical challenges around energy, safety, security, productivity and global urbanization.
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Published on May 24, 2018The U.S. Chemical Safety Board (CSB) has released a new 13 minute video detailing the events leading up to the August 31, 2017 fire at the Arkema chemical plant in Crosby, Texas. The incident led to all employees and more than 200 nearby residents being evacuated for a week. Twenty-one people sought medical attention from reported exposures to the fumes and smoke released into the air.
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Published on July 5, 2014U.S. Chemical Safety Board safety video discussing the 2010 Macondo tragedy where a failed blowout preventer caused a sudden explosion and fire on the Deepwater Horizon oil rig, resulting in the deaths of 11 workers and causing a massive oil spill into the Gulf of Mexico.
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Published on November 14, 2013U.S. Chemical Safety Board safety video covering the 2009 explosion at NDK Crystal in Belvidere, Illinois, which fatally injured a truck driver at a nearby gas station. The CSB found that the catastrophic pressure vessel explosion resulted from stress corrosion cracking and that the operator not only failed to inspect or test the vessels, but they failed to heed 3rd party warnings about risk to the public.
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Published on November 5, 2013CSB video excerpts from Dr. Trevor Kletz, a world renowned expert in chemical process safety, who died October 31, 2013.
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Published on February 14, 2013U.S. Chemical Safety Board safety video: “Inherently Safer: The Future of Risk Reduction”
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Published on April 20, 2012U.S. Chemical Safety Board safety video detailing a 2010 hot work accident at DuPont Buffalo.
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Published on September 22, 2011U.S. Chemical Safety Board safety video covering three accidents that occurred over a 33-hour period in 2010 at the Dupont plant in Belle, WV.
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Published on January 7, 2009As temperatures continue to drop, it's important for process plants to be prepared for the unique safety challenges of subfreezing weather, according to U.S. Chemical Safety Board Chairman John Bresland.
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Published on December 19, 2008Refineries and chemical plants are facing serious economic difficulties but still need to maintain their focus on process safety, according to U.S. Chemical Safety Board Chairman John Bresland.
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Published on March 21, 2008U.S. Chemical Safety Board safety video depicts the massive explosion that killed 15 and injured 180 at the BP Texas City refinery in 2005.
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Hosted By: Clarion Technical Conferences
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NewsSunHerald, October 17, 2018
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NewsABC Eyewitness News, April 10, 2018
A fire at the TPC Group chemical plant in southeast Houston kept firefighters at work for more than an hour last week.
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Partner Content
Offshore platforms are exposed to some of the roughest conditions on earth and require regular attention to ensure they are structurally sound and safe for continued operation. With so many components and major joints at elevated locations, it is clear why a well-trained rope access technician can be an invaluable resource for offshore operators.
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NewsReuters, March 23, 2018
An explosion killed six people at a refinery in the Czech Republic on Thursday, rescue officials said. Two other people were taken to hospital with serious injuries.
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Partner Content
LOTIS utilizes laser profilometry to conduct internal steam reformer tube inspections. The data captured by LOTIS is exceptionally powerful when combined with our LifeQuest™ remaining life assessment capabilities, providing an integrated solution set for the process and syngas industries.
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NewsCBS DFW, March 20, 2018
Five days after an explosion rocked the Tri-Chem Industries plant in Cresson, there is still an active search for one worker.
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Partner Content
InVista is a lightweight, hand-held ultrasonic in-line inspection tool (intelligent pig) capable of detecting pipeline wall loss and corrosion in unpiggable or difficult-to-inspect pipelines. The pipeline geometry inspection data captured by the InVista tool is exceptionally powerful when combined with the LifeQuest™ Pipeline fitness-for-service capabilities, providing an integrated solution set for the pipeline industry.
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NewsHindustan Times, January 22, 2018
An explosion at a chemical plant in India on Sunday has killed at least four workers and injured nine others.
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NewsIndia TV News, January 22, 2018
An explosion occurred in a boiler of Indian Oil's 300,000 bpd Panipat Refinery on Monday, reportedly killing two workers and injuring at lease six others.
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NewsBeaumont Enterprise, December 18, 2017
The fire that shut down a crude unit at Exxon Mobil's Beaumont refinery was started by an open valve, the company's investigation found.
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NewsReuters, December 14, 2017
Tuesday’s blast at Austria’s Baumgarten gas hub, which killed one person and disrupted European gas flows, was most likely caused by a loose seal on a filter cap, operator Gas Connect Austria (GCA) said.
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NewsReuters, December 7, 2017
An explosion at a Petroperu crude oil tank killed two men who had been performing maintenance work on Wednesday, the state-owned oil company said.
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NewsReuters, December 4, 2017
A female contract worker was fatally injured on Friday while working on a construction project at ExxonMobil Corp’s refinery in Beaumont, Texas.
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Partner Content
It is difficult to cover all inspection applications with basic inspection procedures like radiography, ultrasonics, magnetic particle testing, and dye penetrant inspection. Owner-operators are finding that advanced NDE services such as guided-wave ultrasonics, AUT corrosion mapping, and eddy current testing are essential tools to keep their facilities operating safely and efficiently.
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NewsReuters, February 14, 2017
Russia's top oil producer Rosneft will have to spend up to $100 million to improve standards at aging refineries it bought last year
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NewsReuters, January 16, 2017
Abu Dhabi National Oil Company (ADNOC) has shut half the capacity at its 800,000 barrels-per-day Ruwais refinery after a fire there last week...
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NewsReuters, January 13, 2017
An accident at the Ciudad Madero refinery of Mexican state-owned oil firm Pemex killed one worker on Thursday.
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Partner Content
Industrial Rope Access is a proven method of achieving a safe work position at elevated heights or areas that are difficult to access. When combined with advanced NDE technologies, rope access technicians can substantially reduce the cost of inspections and maintenance activities by virtually eliminating the need for fixed scaffolding.
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NewsReuters, October 21, 2016
Saudi Aramco said on Thursday that two workers died of injuries sustained in a fire that broke out at its Wasea crude oil plant in central Saudi Arabia.
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NewsReuters, October 20, 2016
Divers on Wednesday retrieved a body from the harbor at German chemical group BASF's flagship production site at Ludwigshafen, believed to be the third victim in a deadly blast and subsequent fire that occurred on Monday.
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NewsReuters, August 16, 2016
Malaysia's Petronas Chemicals Group Bhd said on Tuesday that an ammonia leak at one of its plants in the eastern state of Sabah killed two employees and injured three.
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NewsU.S. Occupational Safety & Health Administration, August 5, 2016
The U.S. Department of Labor's Occupational Safety and Health Administration has found three repeat and eight serious safety violations at Solvay Specialty Polymers' chemical facility in West Deptford, New Jersey.
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NewsU.S. Chemical Safety Board, January 13, 2016
An ongoing investigation by the U.S. Chemical Safety Board (CSB) of the February 18, 2015 explosion at the ExxonMobil Refinery in Torrance, California, has uncovered multiple process safety management deficiencies that led to the accident and a serious near miss.
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NewsU.S. Chemical Safety Board, September 21, 2015
The U.S. Chemical Safety Board (CSB) will convene a public meeting on Wednesday, September 30, 2015, in Houston, Texas, at The Hilton Americas – Houston Hotel from 6 to 9 p.m. CDT to hear and vote on investigators’ findings and safety recommendations from the November 2014 chemical release at the DuPont La Porte facility that killed four workers.
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NewsU.S. Chemical Safety Board, June 30, 2015
The U.S. Chemical Safety Board (CSB) has recently voted unanimously to update the status of fifteen safety recommendations resulting from nine accident investigations, including...
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NewsOSHA, May 14, 2015
Four workers killed by a lethal gas in November 2014 would be alive today had their employer, DuPont, taken steps to protect them, a U.S. Department of Labor investigation found.
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NewsUS Chemical Safety Board, December 1, 2014
Today the U.S. Chemical Safety Board (CSB) formally announced that to “Modernize U.S. Process Safety Management Regulations” is the Board’s newest Most Wanted Safety Improvement, concluding that implementation of key federal and state CSB safety recommendations will result in significant improvement of Process Safety Management (PSM) regulations in the United States.
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NewsUS Chemical Safety Board, November 11, 2014
In its final Regulatory Report entitled "Regulatory Report: Chevron Richmond Refinery Pipe Rupture and Fire,” the U.S. Chemical Safety Board (CSB) proposes recommendations for substantial changes to the way refineries are regulated in California. The CSB calls on California to enhance its process safety management (PSM) regulations for petroleum refineries to ensure a more robust and adaptive regulatory regime.
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NewsUS Chemical Safety Board, October 28, 2014
Today the U.S. Chemical Safety Board (CSB) released a safety video into the fatal April 2, 2010, explosion and fire at the Tesoro refinery in Anacortes, Washington.
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CSB Releases Safety Message Highlighting Important Role of Recommendations Program in Agency MissionNewsUS Chemical Safety Board, October 9, 2014
The U.S. Chemical Safety Board today released a video safety message discussing the role that the CSB recommendations program plays in ensuring that the Board’s accident investigations have a lasting impact on industrial safety.
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NewsMay 7, 2014
The Ocean Energy Safety Institute will hold a Forum entitled, Risk Awareness, Risk Perception and using the Awareness and Perception in Making Operational Decisions on a Continuing Basis in Oil and Gas Operations, in Houston, TX, May 12-13.
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NewsUnited States Chemical Safety Board, November 6, 2013
CSB board members and staff are saddened to learn of the death of the one of the world’s greatest authorities on chemical process safety, Dr. Trevor Kletz.
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