The document outlines the key elements of Process Safety Management (PSM) as defined by OSHA guidelines. It discusses the importance of process safety in preventing fires, explosions, and toxic releases. The main components of an effective PSM system include process safety information, process hazard analysis, operating procedures, training programs, management of change procedures, incident investigation, and emergency response planning. Implementing PSM helps create a safer workplace, reduces business risks and losses, and ensures compliance with industry and regulatory standards. Failure to establish proper process safety controls could lead to accidents or incidents that threaten employees, the environment and local communities.

1. PROCESS SAFETY
MANAGEMENT

2. CONTENTS
• What is Process Safety?
• What are OSHA guidelines ?
• Did we have Process Safety Incidents ?
• What are the content of PSM ?
• Benefits of the PSM.
• Quick 4 Steps for PSM.
• What may happen if we don’t act ? --------

3. WHAT IS PROCESS SAFETY?
• A process is a series of steps which added together make a
product.
• Process safety is making sure each step is safe.
• Process safety looks mainly at fires, explosions, toxic releases.
• Two Dimensions of Safety
• 1. Workplace Safety
• 2. Process Safety

4. CONTENTS IN WORK PLACE SAFETY AND PROCESS
SAFETY
Workplace Safety
• Safety Procedures
• Work Permit System
• PPEs
• Safety Audits
• Work area monitoring
• Risk assessments
• Incident Investigation
•
. Process Safety
• Process Design
• Engineering Design
• SOP (BCS)
• Process Hazards analysis
• Change Control
• Emergency Response
• Process Safety Audits
•

5. WHAT ARE OSHA GUIDELINES ?
• The Process Safety Management (PSM) of Highly Hazardous
Chemicals standard, 29 CFR 1910.119 is intended to prevent
or minimize the consequences of a catastrophic release of
toxic, reactive, flammable or explosive Hazardous Chemicals
from a process.
• A process is any activity or combination of activities including
any use, storage, manufacturing, handling or the on-site
movement of Hazardous Chemicals
• The OSHA Process Safety Management (PSM) standard (29 CFR
1910.119) was published in the Federal Register on February
24, 1992.

6. OSHA - PROCESS SAFETY MANAGEMENT
• Process Safety Information
• Process Hazard Analysis
• Operating Procedures
• Employee Participation
• Training
• Contractors
• Pre-Startup Safety Review
• Mechanical Integrity
• Management of Change
• Incident Investigation
• Emergency Planning and Response
• Compliance Audits

7. PROCESS SAFETY INFORMATION
• Toxicity,
• Permissible exposure limits,
• Physical data,
• Reactivity data,
• Corrosivity data, and
• Thermal and chemical stability data, and hazardous effects
of inadvertent mixing of different materials.

8. Information on the technology of the process must include
at least the following
• A block flow diagram or simplified process flow diagram
• Process chemistry
• Maximum intended inventory
• Safe upper and lower limits for such items as temperatures, pressures, flows or
compositions
• An evaluation of the consequences of deviations, including those affecting the
safety and health of employees.

9. Information on the equipment in the process must include
the following
• Materials of construction
• Piping and instrument diagrams (P&IDs)
• Electrical classification
• Relief system design and design basis
• Ventilation system design
• Design codes and standards employed
• Material and energy balances for processes
• Safety systems (e.g., interlocks, detection, or

10. PROCESS HAZARD ANALYSIS (PHA)-HAZOP
• The process hazard analysis is a thorough, orderly, systematic
approach for identifying, evaluating, and controlling the
hazards of processes involving hazardous chemicals.
• Process hazard analysis must address the following:
• • The hazards of the process;
• Special hazard,
• Reactivity hazards,
• Static electricity,
• Material separation chemistry etc.

11. The important features of the study are :
• Design Intent
• Deviation
• Causes
• Consequences
• Severity
• Safeguards
• Action item & Follow up
• Process hazard analysis is best performed by a team with
expertise in engineering and process operations
• A team is made comprising process, project, safety and
whenever required additional assistance shall be obtained
from the concerned Department (Mechanical, Electrical,
Instrument and Civil etc.)

12. All process hazard analyses must be updated and
revalidated, based on their completion date, at least every
five years
Risk assessment is also conducted through 3 x 3 matrix.
SOP for identification of OHS hazard and risk assessment
and determining of control is prepared.
PHA should be recommended for any basic change and new
process/project. The method for the risk assessment should
be finalized during EQHS review.

13. OPERATING PROCEDURE
• Following procedure must be required for various operating phase:
• Standard Operating procedure - Batch Control Sheet (BCS)
• Operation control procedure (OCP)
• Safe Operating procedure (SOP)
• Safety systems (e.g., interlocks, detection or suppression systems) and their
functions.
• Precautions necessary to prevent exposure,
• including engineering controls,
• administrative controls, and
• personal protective equipment;
• Operating limits:
• Consequences of deviation, and
• Steps required to correct or avoid deviation.
• Emergency procedure, Safe partial shutdown, Safe complete shutdown

14. EMPLOYEE PARTICIPATION
• Employees Understand the Process
• Employees Understand the Risk
• Employees Know What Can Go Wrong
• Following various forums are being utilized for employee
participation,
• Safety Committee
• Bi-weekly Safety meeting
• Shift EHS Briefings
• Risk assessment (PHA or 3 x 3 matrix)
• Management of change review meeting
•
•

15. • Incident reporting and Investigation
• House Keeping Inspection
• Training programs
• Contractor safety committee meetings.
• Safe partial shutdown, safe complete shutdown, table top
exercise and Mock drills.
• Safety Communication Board.

16. TRAINING
• Initial Training
• Implementation of an effective training program is one of the most
important steps to enhance employee safety.
• PSM requires that each employee presently involved in operating a process
or a newly assigned process must be trained in an overview of the process
and in its operating procedures. The training must include emphasis on the
specific safety and health hazards of the process, emergency operations
including shutdown, and other safe work practices that apply to the
employee’s job tasks.
• Refresher Training
• Refresher training must be provided at least every two years, or more often
if necessary, to each employee involved in operating a process to ensure
that the employee understands and adheres to the current operating
procedures of the process

17. PRE STARTUP EHS REVIEW
• Pre startup EHS review must be performed for any new
process/project installation and for modified process/project
installation.
• Pre startup EHS review should be performed by the team
consist of Plant/area incharged, Plant engineer & safety officer
etc.
• Pre startup EHS review needs to be done.

18. MECHANICAL INTEGRITY
• It is important to maintain the mechanical integrity of critical
process equipment to ensure it is designed and installed
correctly and operates properly. PSM mechanical integrity
requirements apply to the following equipment:
• Pressure vessels and storage tanks;
• Piping systems (including piping components such as valves);
• Relief and vent systems and devices;
• Emergency shutdown systems;
• Controls (including monitoring devices and sensors, alarms,
and
• interlocks); and
• Pumps.

19. • PMSM procedure & checklist are prepared & implemented to maintain the
ongoing integrity of process equipment.
• Each inspection and test on process equipment must be documented,
identifying the date of the inspection or test, the name of the person who
performed the inspection or test
• Appropriate checks and inspections must be performed to ensure that
equipment is installed properly and is consistent with design specifications
and the manufacturer’s instructions and also ensure that maintenance
materials, spare parts, and equipment are suitable for the process
application for which they will be used

20. MANAGEMENT OF CHANGE
• Every changes to a process must be thoroughly evaluated to fully assess
their impact on employee safety and health and to determine needed
changes to operating procedures.
• SOP for Management of change (MOC) is prepared.
• Type of change :
• Identical replacement
• Replacement in kind
• Basic change
• New process / project
• Initial review
• EQHS review
• Action plan
• All Action Items Are Tracked to completion

21. INCIDENT REPORTING & INVESTIGATION
• A crucial part of the process safety management program is a
thorough investigation of process incidents to identify the chain of
events and causes so that corrective measures can be developed and
implemented.
• SOP for Incident reporting & investigation is prepared
• Multiple Cause
• Fishbone
• Why-why
• Follow-up to completion
• Sharing of Information
•

22. EMERGENCY PLANNING & RESPONSE
• If, despite the best planning, an incident occurs,
• it is essential that emergency pre- planning and training make
employees aware of, and able to execute, proper actions.
• For his reason, an emergency action plan for the entire plant
must be developed and implemented in accordance with the
provisions of factory inspectorate guidelines.
• Planned responses to an emergency covers:
• fires / explosion
• spills / releases
• emergency shutdowns
• evacuations
• other incidents

23. BENEFITS OF PROCESS SAFETY MANAGEMENT
• Proactive managent system focuses on avoiding incident.
• Safer work place for employee.
• Reduce risk of adverse environment impact.
• Compliance with industry codes, standards and practices.
• Reduce downtime and losses.
• Reduces risk to nearby communities.
• Is viewed favourably by external interested parties like Factory
Inspectorate and Pollution Control Boards.
• Implementation based on World Class OSHA’s(Occupational
safety and Health Administration,USA) standards CFR
1910.119,which is mandatory in the USA.
• Total employee involvement in implementation of system
makes the system sustainable.

24. WHAT MAY HAPPEN IF WE DON’T ACT ? ------