1. Process Safety Management
Are You Involved In PSM?
Process Safety Management
Employee Involvement
29 CFR
5189 Title 8

3. What is PSM?
The regulations contain requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive, flammable or explosive chemicals.
The establishment of process safety management regulations are intended to eliminate to a substantial degree, the risks to which employees are exposed in petroleum refineries, chemical plants and other similar facilities.

4. What is the purpose of PSM?
To protect our employees and the community
To protect the environment
The right way to do business
It increases employee involvement and awareness
Provides sustainable systems through on-going requirements
And it’s the Law!

5. History Behind PSM
1980s and early 1990s witnessed an alarming number of industrial accidents
OSHA/EPA driven to prevent the unexpected releases of toxic, reactive, or flammable liquids and gases
Trade unions seeking greater protection for represented employees
Communities demanding protection for themselves and the environment
Industry is supportive of OSHA/EPA’s movement to protect communities, employees, and surrounding environment
Year
Location
Deaths
Injuries
1984
Bhopal
2000+
1988
PEPCON 2
350
1989
Phillips 23
1990
ARCO Chemical 17
BASF
1991
IMC 8
128
Union Carbide 1

6. 14-PSM Elements Building Blocks for Reducing Risks
Employee Participation
Process Safety Information
Process Hazard Analysis
Operating Procedures
Training
Contractor Program
Pre-Startup Safety Review
Mechanical Integrity
Hot Work Permit
Management of Change
Incident Investigation
Emergency Planning
Compliance Audits
Trade Secrets

7. Will not be covering the following PSM Elements:
What is PSM?
Will not be covering the following PSM Elements:
Element 6: Contractors
Element 8: Mechanical Integrity
Element 12: Emergency Planning & Response
Element 13: Compliance Audits
Element 14: Trade Secrets

8. Element 1 Employee Participation
Operating Procedures
Procedure Review
Development of procedures
Incident Investigation team members
Hazardous Energy Control (LOTO)
Maintaining LOTO Logs (documentation)
Employees participate in Hazops
Employee Participation is not limited to the items above.
A pro-active facility will involve their employees in the other PSM elements as well.

9. Element 2 Process Safety Information
Written information is compiled and available to allow employees to understand the hazards posed by the process which shall include, but is not limited to the following:
Hazards of the chemicals
Process Technology
Process Equipment
MSDS
Pressure Safety Valve Design
P&ID’s
Design Standards
Electrical Classification
Equipment Records
Safe Operating Limits

10. Element 3 Process Hazard Analysis (PHA or Hazop)
A detailed study of each process unit to ensure the fundamental design adequately addresses the process hazards and identifies the safeguards to prevent accidental releases.
The study is conducted by a team including engineering and operations expertise and trained PHA facilitator.
Hazards of the process
Previous incidents
Engineering controls for hazards
Administrative controls for hazards
Consequences of control failures
Facility siting
Human factors
Effect of failure on employees

11. Element 4 Operating Procedures
Objective
Develop, implement, and maintain clearly written detailed procedures for safely operating and maintaining a process during all operating modes.
Required content in operating procedures:
Operating Limits
Consequence of deviation
Steps to correct or avoid deviations (Trouble Shooting)
Safety and Health Measures
Precautions to prevent over exposure
Action to take if exposure occurs
Hazards
Safety Systems
Lockout / tagout
Confined space entry
Opening process equip
Annual Certification
Current and accurate

12. Initial training Element 5 Training
Each employee presently involved in operating or maintaining a process, and each employee before working in a newly assigned process, shall be trained in an overview of the process and in the operating procedures.
The training shall include emphasis on the specific safety and health hazards, procedures, and safe practices applicable to the employee's job tasks.

13. Refresher and supplemental training
Element 5 Training
Refresher and supplemental training
At least every three years, and more often if necessary, refresher and supplemental training shall be provided to each maintenance or operating employee and other workers necessary to ensure safe operation of the facility.

14. Element 7 Pre-Startup Safety Review (PSSR)
The pre-start up safety review shall confirm that prior to the introduction of acutely hazardous, flammable and explosive materials to a process:
Construction and/or equipment are in accordance with design specifications;
Safety, operating, maintenance, and emergency procedures are in place and are adequate;
For new facilities, a process hazard analysis has been performed and recommendations have been resolved or implemented before start-up; and modified facilities

15. Element 7 Pre-Startup Safety Review (PSSR)
Training of each operating employee and maintenance worker has been completed.
The Pre-Start Up Safety Review shall involve employees with expertise in process operations and engineering.

16. Element 9 Hot Work Permit
Shall develop and implement a written procedure for the issuance of "hot work" permits.
The permit shall certify that the applicable portions of the fire prevention and protection requirements have been implemented prior to beginning the hot work operations;
Indicate the date(s) authorized for hot work
Identify the equipment or facility on which hot work is to be done.
The permit shall be kept on file until completion of the hot work operations.

17. Element 10 Management of Change (MOC)
Shall establish and implement written procedures to manage changes (except for "replacement in kind") to process chemicals, technology, and equipment, and changes to facilities.
Employees involved in the process shall be informed of, and trained in, the change in the process as early as practicable prior to its start up.

18. Element 11 Incident Investigation
Shall establish a written procedure for prompt reporting and investigating every incident which results in or could reasonably have resulted in a major accident.
Incident investigations shall be initiated no later than 48 hours following the incident.
An incident investigation team shall be established and consist of persons knowledgeable in the process involved including a contract employee if the incident involved work of the contractor, and other persons who are qualified to thoroughly investigate and analyze the incident.
Shall prepare a report and either provide a copy of the report or communicate the contents of the report to all employees and other personnel whose work assignments are within the facility, where the incident occurred at the time the incident occurred