For companies that store, use or produce hazardous chemicals, proper management can be a matter of life and death.
The International Association of Oil & Gas Producers (IOGP) explains that Process Safety Management is a “disciplined framework for managing the integrity of operating systems and processes that handle hazardous substances,” and the goal is to prevent unplanned releases of hazardous materials or energy to prevent structural failure or loss of stability that could lead to a major incident.
The Core Pillars of Process Safety Management
While not officially categorized as three pillars, these elements are indeed fundamental to effective process safety: hazard identification, risk assessment, and risk management or control. We need to note that PSM is built on a larger set of principles or elements, such as those outlined by OSHA’s process safety management standards, the 14 Elements of Process Safety Management.
These pillars are important to implement because they proactively identify and evaluate potential hazards, assess the associated risks, and implement effective controls to prevent incidents. They act as a process safety framework that ensures the safety of workers, protects the environment, and maintains the integrity of processes involving hazardous materials.
The IOGP says there were 56 process safety events between 2007 and 2017 that led to 128 deaths due to an accident.
Take the West Fertilizer Company in West, Texas, for example. On April 17, 2013, emergency services personnel were responding to a fire at the fertilizer facility when the site exploded with the force of a magnitude-2.1 earthquake, killing 15 people and injuring nearly 200 others, according to a report from the U.S. Chemical Safety and Hazard Investigation Board. The blast, which destroyed schools, a nursing home and hundreds of homes, was named one of “the most destructive incidents ever investigated” by the CSB. The agency found the explosion could have been prevented with proper storage of the 40-60 tons of fertilizer-grade ammonium nitrate. In addition to the loss of life, the explosion led to about $230 million in insurance costs, plus $16 million in federal disaster assistance. Incidentally, an ammonium nitrate explosion was also the cause of the recent deadly incident at the Port of Beirut.
We can see that proper safety management can be a matter of life and death for organizations or companies that store, use, or produce hazardous chemicals.
What Is Process Safety Management?
The term Process Safety Management (PSM) became prominent because of an OSHA process safety management regulation that requires businesses to properly manage hazardous chemicals, with the goal of creating a safe workplace and preventing “unexpected releases of toxic, reactive, or flammable liquids and gases” that can cause accidents. Process Safety Management systems are usually a blend of technology platforms, specific procedures, and management frameworks.
Other versions of the PSM standard have since appeared as the implications were better understood. In the United States, the Center for Chemical Process Safety (CCPS) organization model includes 20 elements categorized into four pillars.
There are several other models that are used around the world. The Seveso III Directive (2012/18/EU), for example, has been implemented as a safety management system standard in the European Union to limit risks related to the storage and handling of hazardous chemicals.
It establishes measures to prevent major chemical accidents while prioritizing chemical safety through effective quality control and risk injury assessment tools. Additionally, the Directive promotes transparency by ensuring public access to safety reports and emergency plans, fostering trust and accountability.
Furthermore, the Directive emphasizes quality control and occupational health by requiring process safety management programs that protect workers and communities from potential risks. By mandating health risk assessments, the directive emphasizes the protection of workers and communities from potential hazards and injury.
Another PSM regulation that protects workers and minimizes the risk of catastrophic incidents is the CFR 1910,119, Process Safety Management of Highly Hazardous Chemicals.
In the United Kingdom, the Control of Major Accident Hazards (COMAH) Regulations 2015 cover PSM. In the Middle East several countries have opted for Safety Management Systems (SMS), which have PSM embedded. Within Australia, process safety is largely controlled through Occupational Health and Safety Acts and regulations pertaining to Dangerous Goods and Major Hazard Facilities. And the AICHE is helping Japan design such a safety management system there, too.
How Do Process and Occupational Safety Differ?
Process Safety Management is often confused with Occupational Safety Management, but the two systems can be distinguished by the scale of failure they seek to prevent, according to Oil Gas Facilities. They differ in their hazard identification and risk control assessment approaches.
Process Safety Management standard aims to prevent large-scale disasters, like explosions. Occupational Safety Management, on the other hand, aims to prevent more individual-level safety incidents, like falls. A safety management system is crucial for both.
Occupational Safety hazards are more common, but can often be addressed by smaller scale interventions, while process Safety hazards generally require higher level solutions. The simple explanation is that process safety relates to what you are doing, and occupational safety relates to how you do it.
To address Process Safety Management, there are several risk studies that come into play, such as Hazard and Operability studies (HAZOPs), Layers of Protection Analysis (LOPA), Failure Mode and Effects Analysis (FMEA), Process Hazard Analysis (PHA), and Security and Vulnerability Analysis (SVA).
How to Implement Process Safety Management
Implementing PSM is needed to ensure the safety of workers and the environment in industries where hazardous materials and processes are involved. The foundation of process safety management relies on recognizing potential hazards, setting up clear operational procedures, and continuously training employees to handle risks confidently.
So, the first step in implementing PSM is conducting a detailed risk analysis. This means taking a closer look at hazardous materials, identifying weak points within the processes, and evaluating what could go wrong in the event of a failure. By understanding these factors, companies can be better prepared for emergencies and minimize the likelihood of incidents.
After identifying the risks, organizations should create practical and easy-to-follow procedures that reduce those risks. This includes routine maintenance schedules, well-defined emergency response plans, and safety measures specifically designed to prevent accidents. Consistency in applying these procedures ensures a safer environment for everyone involved.
Equally important is ongoing employee training. Workers must know how to spot hazards, follow safety guidelines, and respond quickly during emergencies. Regular audits and assessments help identify areas for improvement, ensuring that safety processes evolve to meet new challenges.
By making process safety management an integral part of daily operations, organizations can create a culture of safety. This commitment not only reduces risks but also builds trust and resilience, helping prevent incidents that could have severe consequences.
How to Implement Process Safety Management
PSM is complex and requires a multidimensional approach that blends technology and management solutions. According to OSHA PSM, every Process Safety Management program should include 14 basic elements, according to OSHA. Here is a brief overview:
- Process safety information: Staff should have access to basic information about the hazards of the chemicals and tools they are using on the job.
- Process hazard analysis: This helps organizations evaluate their processes and operations to identify potential threats and safety issues. Still, organizations can’t manage safety and hazards until they know what hazards are actually in their facilities.
- Operating procedures: Work should follow consistent, well-established safety protocol.
- Hot work permit: Work with fire or other sources of ignition requires a systematic process for authorization and oversight.
- Emergency preparedness and response: Organizations should have a response plan if something goes wrong.
- Mechanical integrity: Businesses are required to track and evaluate the evolving safety risks of equipment.
- Pre-startup safety review: Businesses are required to thoroughly assess new or modified facilities before hazardous substances are introduced into the workplace.
- Training management: Employees should be properly trained on all safety procedures and have access to ongoing refresher training.
- Management of change: This is a form of risk management practice. When processes change, businesses should conduct a systematic review of how the changes will affect risk throughout their facility.
- Incident investigation: When incidents and near-misses occur, businesses need a systematic process to record, track, investigate, report and analyze what happened.
- Contractor safety management: The safety of contractors and subcontractors should be covered by process safety management systems.
- Compliance audits: Organizations should conduct regular internal PSM audits to ensure regulatory compliance with their procedures and processes.
- Employee involvement: Employees should be able to access, acknowledge and sign-off on policy documents.
- Trade secrets: Employees must be provided thorough documentation of materials and processes, even those that are trade secrets, to ensure health and safety.
It is worth noting that PSM focuses on events that have perhaps occurred very infrequently in the past. Perhaps, they might never have occurred at all. But, if they do occur, they are often catastrophic. While it can be complex and expensive to understand these low-probability events, the outcomes that result when they do occur are orders of magnitude more severe.
