Integripedia Topic
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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An explosion rocked South Africa’s second-largest crude oil refinery in Durban on Friday injuring seven people, local emergency services said.
A fire at Norway’s Tjeldbergodden industrial facility on Wednesday triggered an evacuation of staff and the shutdown of Europe’s largest methanol plant and a gas processing terminal.
U.S. Gulf operators have begun evacuating personnel and shutting down facilities in preparation for Tropical Storm Delta, which is expected to strengthen into a Category 3 hurricane as it moves into warmer waters.
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Offshore platforms and one refinery along the U.S. Gulf Coast shut down on Sunday as they prepared for a second hurricane strike in less than a month.
The U.S. Chemical Safety Board (CSB) said on Monday about 835 tons of a bleaching agent used in swimming pools was stored at the Louisiana plant where a chlorine chemical fire had erupted last week in the aftermath of Hurricane Laura.
The CSB has released a new "Safety Spotlight" highlighting the actions of Airgas, Inc. following the deadly 2016 nitrous oxide explosion at their facility in Cantonment, Florida.
Taiwan’s Formosa Petrochemical Corp has shut a residue desulphuriser (RDS) unit at its 540,000 barrels-per-day (bpd) Mailiao refinery after it was hit by a fire early on Wednesday, three sources close to the matter said.
Two people were killed on Thursday in an explosion at Astron Energy’s 100,000 barrel per day refinery in Cape Town.
Are you truly prepared for your next Turnaround? Effective work processes are required to successfully plan, manage, review and supervise plant turnarounds. Inspection planning and work scope selection are critical aspects of any turnaround...
As the United States faces this year's hurricane season, it is critical that the chemical industry understands and prepares for the potential safety hazards posed by extreme weather events.
TPC Group is accused of three willful violations and faces $514,692 in fines from OSHA after the agency concluded its investigation into the November 27, 2019 plant explosion in Port Neches, Texas.
PK Solutions announced the release of wilma™, an innovative, compact, and user-friendly monitoring assistant designed to assist trained safety professionals, operators, and technicians as an extension of your existing confined space entry...
API has released its 2019 Pipeline Safety Excellence Performance Report showing that liquid pipeline incidents have decreased significantly over the last 5 years, while pipeline mileage and barrels delivered have increased.
The CSB has released a new guidance document focused on the importance of the role of boards of directors and executives in ensuring that there are effective safety management systems in place to properly manage process safety risks.
Inspectioneering and API have teamed up to create the Mechanical Integrity Professional Initiative. The goal of this project is to raise the benchmark on industry knowledge and develop the next generation of SMEs. We believe that equipping MI...
ABB has developed an innovative augmenting technology aimed at digitalizing the field operator experience and improving interaction between field and control room operations.
An early morning explosion rocked Valero Energy Corp’s 125,000 barrel-per-day (bpd) Meraux, Louisiana, refinery on the east side of New Orleans
Lyondell Basell Industries said maintenance operations were staffed at its Houston refinery to assure safety and reliability.
PBF Energy said a fire that occurred at one operating unit at its Delaware City, Delaware, refinery on Wednesday has been extinguished and two employees are being treated for injuries.
South Korea’s Lotte Chemical has shut its naphtha cracker after an explosion at the plant in the southwestern city of Seosan, which injured 31 people, the company said on Wednesday.
Piping accounts for roughly 40% of “accidental releases” at major petroleum facilities. Modern robots can inspect every inch of piping while still in service, giving you a clear picture of your most concerning areas.
Shell has restarted a catalytic reformer at its 211,270 bpd refinery in Convent, Louisiana after repairing damage caused by a fire on February 16th.
Arkema and three executives are facing criminal charges in Texas stemming from the 2017 fires at the Arkema SA plant outside of Houston.
ExxonMobil is restarting several units at the company's 502,500 bpd Baton Rouge Refinery following a pipeline fire in early February.
A portion of Marathon Petroleum Corp’s 363,000 barrel-per-day Carson refinery in California has been shut following a fire, the company said on Wednesday.
A catalytic reformer was shut on Sunday night at Royal Dutch Shell Plc’s 211,270 barrel-per-day (bpd) refinery in Convent, Louisiana, after a brief fire, said sources familiar with plant operations.
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The CSB has approved a final rule on accidental release reporting that requires prompt reports from owners-operators of facilities that accidentally release a regulated substance resulting in a death, serious injury or substantial property damage.
U.S. refineries and petrochemical plants are cutting back on insurance because several years of severe accidents have driven up the cost of coverage, industry and insurance sources said.
Fourteen U.S. states and Washington D.C. sued the Environmental Protection Agency on Wednesday to fight what they called the Trump administration’s effort to gut rules meant to improve safety at chemical plants and reduce the threat of accidents.
Early this morning, a large explosion at the Watson Grinding and Manufacturing facility in northwest Houston killed two people and damaged nearby homes.
On Monday at approximately 1:15 p.m. local time, an explosion and fire rocked a low-density polyethylene (LDPE) unit at Sasol's Lake Charles Chemical Project.
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The CSB released its final investigation report on two pressure vessel explosions that occurred at the MRR facility in Philippi, West Virginia. Two workers were fatally injured , and another was severely injured during the first incident.
A March fire at a petrochemical terminal that spread a blanket of black smoke across Houston began when part of a manifold, which includes a pump and motor, on one storage tank broke, according to a report by local and federal agencies.
Petrochemical maker TPC Group Inc will rebuild the Texas plant shut last week by devastating explosions that ignited fires that burned for six days, a spokeswoman said on Wednesday.
At least three employees were injured in a fire raging at TPC Group's chemical plant in Port Neches, Texas, early on Wednesday morning following a massive explosion felt 30 miles (48 kms) away from the plant.
The recent refinery fire that forced Philadelphia Energy Solutions to shutter its plant and file for bankruptcy has raised concerns about aging equipment at U.S. refineries.
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The U.S. Chemical Safety Board (CSB) said on Wednesday a fuel leak, possibly due to open valves and a running pump, set off the massive blaze at the ITC petrochemical storage facility along the Houston Ship Channel in March.
Marathon Petroleum reportedly experienced a small overnight fire at the company's 140,000 bpd Detroit Refinery.
The U.S. Chemical Safety Board (CSB) has released a factual update and preliminary animation detailing the events leading to the June 21, 2019, explosion and fire at the Philadelphia Energy Solutions (PES) Refinery in Philadelphia, PA.
Flames engulfed two ethanol holding tanks on Tuesday at a NuStar Energy petrochemical storage facility near San Francisco, prompting health authorities to urge residents of two adjacent towns to remain indoors for much of the day.
Saudi refiner SASREF, owned by state oil giant Saudi Aramco, said two contractors had died and two more were injured in “an incident” during maintenance work on Sunday, the company said in a statement on Tuesday.
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Brazilian state-controlled oil company Petrobras said a fire broke out at its Revap refinery, in the city of Sao Jose dos Campos, on Sunday afternoon.
PHMSA has transmitted three significant final rules to the Federal Register that will strengthen the safety of more than 500,000 miles of onshore gas transmission and hazardous liquid pipelines throughout the U.S.
Celanese experienced a fire at its Clear Lake facility in Pasadena, TX over the weekend. There were no injuries reported in the incident.
The CSB has issued a new safety digest on the value of worker participation to prevent chemical incidents. The digest notes that lack of worker participation was a factor in several major incidents investigated by the CSB.
The CSB has released its final investigation report into the 2014 methyl mercaptan release at the DuPont Plant in La Porte, TX, that killed four workers. The report includes key lessons learned from the incident.
In this interim report, Pinnacle analysts take data from the oil refining industry and dive into how that key sector is being affected by reliability today. Download your free copy!
Philadelphia Energy Solutions (PES) is expected to seek to permanently shut its oil refinery in the city after a massive fire caused substantial damage to the complex, two sources familiar with the plans said on Tuesday.
Massive explosions that engulfed a Philadelphia refinery in flames on Friday have renewed concerns about the oil industry’s use of hydrofluoric acid to make high-octane gasoline at plants in densely populated areas.
Firefighters are battling a massive fire at Philadelphia Energy Solutions’ refinery in Philadelphia that has resulted in several explosions but caused no significant injuries, the company said on Friday.
In a newly released 258-page report, California regulators say they now know the cause of the massive 2015 Aliso Canyon Gas Leak.
API has released the 2nd Edition of RP 755, the only refining and petrochemical industry guideline to improve worker safety by addressing fatigue as a risk factor.
How is reliability affecting your bottom line? Download our Economics of Reliability report, where Pinnacle analysts take data from the oil refining industry and dive into how that key sector is being affected by reliability today.
The CSB has called on the EPA to review its existing Hydrofluoric Acid study to determine the effectiveness of existing regulations, as well as the viability of utilizing inherently safer alkylation technologies in petroleum refineries.
PinnacleART and Metegrity, Inc. have formed a strategic partnership to improve the mechanical integrity program of a natural gas service provider’s operations in the southwest region of the United States.
The U.S. Chemical Safety Board has released its final report on the June 27, 2016 investigation of an explosion and fire at the Enterprise Products Pascagoula Gas Plant in Pascagoula, MS.
The U.S. Chemical Safety Board (CSB) recently released a Factual Investigative Update regarding their investigation of the April 26, 2018 explosion and fire at Husky Energy's 50,000 bpd Superior Refinery. According to the CSB, evidence collected to...
Today, the U.S. Chemical Safety Board (CSB), as part of its investigation into the May 2017 Didion Mill explosion, issued “Call to Action: Combustible Dust” to gather comments on the management and control of combustible dust from companies,...
Download Pinnacle's Economics of Reliability Report - Refining to see how reliability is affecting profitability.
On Thursday, the U.S. Chemical Safety Board said the April 26 explosion at Husky Energy’s Superior, Wisconsin, refinery was probably triggered by air leaking around a slide valve into the gasoline-producing unit that blew up.
The 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...
The U.S. Chemical Safety Board (CSB) has released an animation detailing the events leading up to the February 8, 2017 explosion at the Packaging Corporation of America's DeRidder, Louisiana, pulp and paper mill. The incident killed three contract...
Last October, we saw the State of California implement its “PSM for Refineries” standard and now the State of Washington’s Division of Occupational Safety and Health (DOSH) appears to be following suit, releasing draft language to adopt a...
The U.S. Chemical Safety Board (CSB) has released a new 11-minute safety video and final report describing the events leading up to the October 21, 2016 toxic chemical release at the MGPI Processing plant in Atchison, Kansas. The video, titled...
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The U.S. Chemical Safety Board (CSB) released a preliminary animation of the events surrounding the 2017 fire at Arkema's chemical plant in Crosby, Texas.
The U.S. Chemical Safety Board (CSB) has released a new 8-minute safety video describing the events leading to the November 22, 2016 fire at ExxonMobil's Baton Rouge refinery, which severely burned four workers. The video, entitled "Fire in Baton...
The U.S. Chemical Safety Board has released a new safety bulletin covering the November 22, 2016 fire that severely burned four workers at the ExxonMobil refinery in Baton Rouge, Louisiana.
OSHA recently released a new guide to help petroleum refiners comply with its Process Safety Management (PSM) standard (1910.119). The guide presents lessons learned from the petroleum refinery Process Safety Management National Emphasis Program.
The U.S. Chemical Safety and Hazard Investigation Board (CSB) today issued a Safety Alert urging oil and chemical facilities to take special precautions when restarting in the wake of shutdowns due to Hurricane Harvey.
Gecko's TOKA Flex robot is designed to give unprecedented access to piping systems with a robust ultrasonic data-collection capability. The Flex, our most advanced RUG robot, is equipped to find and collect the critical inspection data you need....
California state agencies recently announced final approval of new regulations to strengthen workplace and environmental safety at oil refineries across the state.
The U.S. Chemical Safety Board (CSB) has released a 3-minute animation describing the events leading to the November 22, 2016 fire at ExxonMobil's Baton Rouge refinery, which severely burned four workers.
Cal/OSHA and Chevron have reached a settlement agreement for a comprehensive plan that will improve safety at the Chevron Richmond refinery and for surrounding communities. The agreement meets and exceeds California’s landmark regulation to reduce...
The U.S. Occupational Safety and Health Administration (OSHA) has issued two reports on the safe management of hazards by small businesses and storage facilities that use highly hazardous chemicals in business processes.
The U.S. Chemical Safety Board (CSB) has released its findings and a safety bulletin entitled "Key Lessons for Preventing Incidents when Preparing Process Equipment for Maintenance" resulting from the 2015 hydrocarbon release and fire that injured...
Superior inspection results, a best-in-class user interface, great ergonomics and rugged design, unrivaled connectivity options, and much more. The Krautkrämer USM 100 is a revolutionary ultrasonic flaw detector that uncomplicates your...
Today, the U.S. Chemical Safety Board (CSB) released its final report into the February 18, 2015, explosion at the ExxonMobil refinery in Torrance, California. The blast caused serious property damage to the refinery and scattered catalyst dust up...
The U.S. Chemical Safety Board (CSB) has released its final report into the August 28, 2016, nitrous oxide explosion at the Airgas manufacturing facility in Cantonment, Florida. The blast killed the only Airgas employee working at the facility that...
Today, the CSB released a “Business Case for Safety,” summarizing four major accident investigations from the last 15 years and detailing why safety is good for business and ultimately a company’s bottom line.
The U.S. Chemical Safety Board (CSB) has released preliminary findings from its ongoing investigation of the toxic chemical release that occurred at the MGPI Processing plant in Atchison, Kansas, on October 21, 2016. The CSB’s investigation into...
The U.S. Chemical Safety Board’s (CSB) three-person investigation team arrived onsite at the Loy-Lange Box Company to begin its assessment on Thursday April 6th. Since arriving on site the following activities and analysis have been conducted
A three-person investigative team from the U.S. Chemical Safety Board (CSB) is deploying to the scene of an incident that killed three people and injured four others on Monday, April 3 at the Loy-Lange Box Company in Saint Louis, Missouri.
Vanessa Sutherland, Chairperson of the U.S. Chemical Safety Board, released a statement on Thursday, the 12th anniversary of the BP Texas City disaster that killed 15 workers and injured 180 others.
The U.S. Chemical Safety Board (CSB) has released a video demonstrating the agency's positive safety impact in 2016. The video was posted just days after President Trump proposed his "America First" budget plan, which calls for the elimination of...
A three-person investigative team from the U.S. Chemical Safety Board (CSB) is deploying to the scene of an incident that killed three workers and reportedly injured seven on Wednesday, February 8 at the Packaging Corporation of America (PCA) plant...
The U.S. Chemical Safety Board (CSB) has released a safety video detailing its investigation of the June 13, 2013 explosion and fire at the Williams Olefins Plant in Geismar, Louisiana, which killed two workers and injured an additional 167. The...
The U.S. Environmental Protection Agency (EPA) has finalized a rule amending its Risk Management Program (RMP) regulations to reduce the likelihood of accidental releases at chemical facilities and improve emergency response activities when those...
A three person investigative team from the U.S. Chemical Safety Board (CSB) has been deployed to the scene of an incident that injured six workers – including four critically – on Tuesday, November 22 at the ExxonMobil Refinery in Baton Rouge,...
Federal investigators found multiple safety violations at a South Dakota ethanol refinery expansion project after a pipefitter suffered fatal burns when ethanol spilled from a process pipe and was ignited by flames from nearby welding operations.
An investigative team from the U.S. Chemical Safety Board (CSB) has deployed to the scene of a chemical release that led to a shelter-in-place order for thousands of residents and at least 85 members of the public seeking medical attention in...
The U.S. Chemical Safety Board (CSB) today released its 2017–2021 Strategic Plan, including an updated mission and vision statement, which will guide the activities and objectives of the CSB.
The U.S. Chemical Safety Board (CSB) has released its final report into the June 13, 2013, explosion and fire at the Williams Olefins Plant in Geismar, Louisiana, concluding that process safety management program deficiencies during the 12 years...
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.
U.S. Chemical Safety Board (CSB) report finds that offshore regulatory changes made thus far do not do enough to place the onus on industry to reduce risk, nor do they sufficiently empower the regulator to proactively oversee industry’s efforts to...
The U.S. Environmental Protection Agency (EPA) is proposing to revise its Risk Management Program (RMP) regulations to improve chemical process safety, assist local emergency authorities in planning for and responding to accidents, and improve...
Today the U.S. Chemical Safety Board (CSB) released a safety video into the fatal April 17, 2013, fire and explosion at the West Fertilizer Company in West, Texas, which resulted in 15 fatalities, more than 260 injuries, and widespread community...
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...
The U.S. Chemical Safety Board has approved the final investigation report and video from the 2009 explosion and fire at caribbean petroleum terminal facility in Puerto Rico.
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...
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...
The U.S. Chemical Safety Board (CSB) has recently voted to update the status of sixteen recommendations resulting from twelve accident investigations including key safety improvements resulting from the 2006 CAI/Arnel fire and explosion in Danvers,...
Today the U.S.Chemical Safety Board (CSB) released a safety message to commemorate the tenth anniversary of the accident at the BP refinery in Texas City, Texas, that killed 15 workers and injured 180 others. In the message Chairperson Rafael...
On Thursday, the U.S. Chemical Safety Board (CSB) revealed the initial findings from their investigation into the deadly gas leak that took the lives of four workers at Dupont's chemical plant in LaPorte, TX
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...
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...
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.
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.
CSB Will Hold July 16 Public Meeting in Charleston, WV to Release Investigation into 2010 Fatal Accident in New Cumberland, WV and Update the Public on Ongoing Investigation into Chemical Leak at Freedom Industries.
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