Process Safety Management - Tips for the Little Guy

What Is Process Safety Management  Process Safety Management is the application of management principles and systems to the identification, understanding, and control of process hazards to protect employees, facility assets and the environment.

What Is Process Safety Management 14 Elements  Application  Employee Participation  Process Safety Information  Process Hazard Analysis  Operating Procedures  Employee Training  Contractors  Pre-Start up Safety Review  Mechanical Integrity  Hot Work (Non-routine Work Authorizations)  Management of Change  Incident Investigation  Emergency Planning and Response  Compliance Audits

(a) Application  Appendix A of 29 CFR contains a listing of toxic and reactive highly hazardous chemicals which present a potential for a catastrophic event at or above the threshold quantities listed.  To adequately address this section, identify what brings you into coverage by the standard, specifying which processes at the facility are covered and why.

(a) Application cont. Consider what you can do to get out of the situation  Reduce inventories of highly hazardous chemicals  Receive smaller shipments  Enhance inventory control  Break up storage locations within the plant to reduce the amounts on hand to below the threshold quantity (TQ)  Substitute listed with non-listed

May 25, 2004 Conyers GA

(c) Employee Participation  Employees are required to be an active part of the process and your written programs need to document what roles employees play, their involvement in the development of the programs, and continuing participation in the process.  An OSHA inspector (CSHO) will attempt to verify participation by interviewing employees at random.

(c) Employee Participation cont.  Consultation / participation with training and supervision to determine the frequency and content of initial and refresher training.  Consultation / participation to develop and review operating and maintenance procedures.  Consultation / participation in incident investigations regarding the covered process.

(d) Process Safety Information  Material Safety Data Sheets (MSDS)  Piping and instrumentation diagrams (PINDs)  Block flow diagrams  Material and energy balance calculations  Relevant consensus standards  Materials of construction

(d) Process Safety Information cont.  Available to all affected employees [requirement of (c) Employee Participation]  Available for Process Hazard Analysis and revalidations [requirement of (e) Process Hazard Analysis]  So auditors and CSHOs can find everything!

(e) Process Hazard Analysis

 OSHA has suggested formats  Don’t start until all information is gathered  Use a software tool to guide, record, manage process

“Catastrophic release means a major uncontrolled emission, fire, or explosion involving one or more highly hazardous chemicals, that presents serious danger to employees in the workplace.” (b) (e) Process Hazard Analysis

(f) Operating Procedures  Standard Operating Procedures  Do in tandem with Job Hazard Analysis (JHAs)  Mesh with training program  Partner with Quality Team (ISO 9001) to create training matrix and managed documents

(g) Employee Training  The employer shall prepare a record:  Identity of employee.  Date of training.  Means to verify that employee understood training  At a minimum, refresher training shall be provided at least every three years and more often if necessary to each employee involved in operating a process.

(h) Contractors  Absolute Requirements  Employer Documentation:  Contract employee injury and illness logs related to work in covered process areas.  Contract Employer Documentation:  Records showing employees received training in and understands safe work practices related to the process on or near where they will be working so they perform their jobs safely.

(i) Pre-Start up Safety Review  Check, double check, and review any changes, modifications, additions made in a PSM covered area – before you flip the switch.

(j) Mechanical Integrity  The employer shall develop and maintain a master list of all equipment specifically covered by the standard, and equipment that is important to safety of the process.  Pressure vessels and storage tanks.  Piping systems including valves and other piping components.  Relief and vent systems and devices.  Emergency shutdown systems.  Controls (including monitoring devices and sensors, alarms, and interlocks).

(j) Mechanical Integrity cont.  Pumps.  Rotating equipment.  Heat exchange equipment.  Electrical generation and distribution equipment.  Un-interruptable power supplies.  Emergency power supply equipment.  Fire protection equipment.

(k) Hot Work (a.k.a. Non- routine Work Authorizations)  Welding, cutting, braising – make sure only trained personnel perform these functions  Have trained fire watchers (align with fire extinguisher / fire response training)

(l) Management of Change  Create formalized system to review all changes to process areas including:  Raw material changes / substitutions  Personnel changes  Process parameters  Facility changes (HVAC / roof / fire protection / ……..)

(l) Management of Change cont.  PSI  Mechanical Integrity  PINDs  Hot Work  Contractor Safety  Employee Training  PSSR  Operating Procedures

(m) Incident Investigation

(n) Emergency Planning and Response  Call in all resources and make plan comprehensive:  Information Technology (IT) Disaster Recovery Plan  Business Continuity Plan (session 4:30)  Security  Communications / Public Relations  Employee Assistance

(o) Compliance Audits  Ask for the audit protocol ahead of time  Have a system in place to identify the location of all PSM documentation  Identify what's in or out of audit scope  Ask for money to correct audit items before the audit is conducted  Prepare management for report

Resources  OSHA web site (  CPL – Process Safety Management of Highly Hazardous Chemicals – Compliance Guidelines and Enforcement Procedures – 78 pages of gold!  Appendix C to § Compliance Guidelines and Recommendations for Process Safety Management (Nonmandatory)  OSHA training institute  Safety and Health – Chemical Process Industry – course #330A. PSM ‘boot camp’ – five days of fun and a three ring binder!  AIChE / CCPs

Please Visit! Booth # 1312 Booth # 1310