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. 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 23 350 1990 ARCO Chemical 17 1990 BASF 2 1991 IMC 8 128 1991 Union Carbide 1 History
Behind PSM
6. 14-PSM ElementsBuilding 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. 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 1Employee 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 2Process Safety Information • 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 • 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:
10. Element 3Process Hazard Analysis (PHA or Hazop) • 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 • 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.
11. Element 4Operating 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 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:
12. Element 5Training Initial 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. Element 5Training 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 7Pre-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 7Pre-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 9Hot Work Permit 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 10Management of Change (MOC) Management Of Change • 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 11Incident Investigation 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