This guide offers an overview of Process Safety Management (PSM), an essential system for preventing uncontrolled hazardous material releases. PSM relies on safety in design, engineering controls, and disciplined operating practices. The guide outlines PSM's 14 elements — from process safety information to trade secret protection. According to the Occupational Safety and Health Administration, PSM is about identifying and controlling hazards to prevent accidents. A successful PSM framework includes cultivating a safety culture, identifying and assessing risks, and managing these risks. Two key process safety models include the Swiss Cheese Model and the Risk-Based Model by the Center for Chemical Process Safety. Implementing PSM involves selecting a suitable model (Standards-Based, Compliance-Based, Continuous Improvement-Based, or Risk-Based), fostering a safety culture, and establishing a risk management system. PSM is vital for safeguarding employees, the environment, and communities.

1. c 2023 SynergenOG Sdn. Bhd.
Process Safety Management -
A Comprehensive Guide
How to implement an effective PSM system

2. Process Safety Management (PSM) is a critical
part of making your business safer.
It can help prevent accidents, safeguarding your
employees, business, and the environment.
Introduction

3. Definition of Process Safety
Not limited to chemical plants and oil refineries, Process Safety applies wherever
there's a potential for harm.
Example: In a bakery, incorrect mixture of yeast, flour, and water could
lead to an explosion—hence, the importance of PSM.
It deals with the prevention of uncontrolled releases of hazardous materials
and energy.

4. Process Safety,
a relatively new field,
was born from industrial
accidents at Bhopal,
India (1984), and
Piper Alpha (1988).
The History of Process Safety
These incidents
highlighted the necessity
of better management of
process safety risks.

5. Three Key Aspects of Process Safety
01
Inherently
Safer Design
Designing products and processes to minimize their
potential to fail or release hazardous materials.
Managing hazards associated with processes and
materials, includes process isolation, process
automation, and emergency shutdown systems.
Ensuring that processes are operated safely and
within their design parameters.
Engineering
Controls
Disciplined
Operating
Practices
02
03

6. PSM is about proactively preventing accidents and incidents.
It is essential to managing risks associated with using hazardous materials
and energy.
It also protects the environment and the community.
Purpose of Process Safety Management (PSM)

7. Elements of PSM (Part 1)
Process Safety
Information
Process Hazard
Analysis
Operating
Procedure
Employee
Participation

8. Elements of PSM (Part 2)
Process Safety
Management
Training
Contractor
Training
Pre-Startup
Safety Review
Mechanical
Integrity

9. Elements of PSM (Part 3)
Hot Work
Permits
Management
of Change
Process
Incident
Investigation/
Accident
Investigation
Emergency
Planning and
Emergency
Response

10. Elements of PSM (Part 4)
Safety
Compliance
Audits
Trade Secret
Protection

11. OSHA Standards on Process Safety Management
The Occupational Safety and Health Administration (OSHA) protects workers from
exposure to dangerous conditions and sets standards for safety, including PSM.
OSHA's PSM includes procedures and practices for the safe handling of hazardous
materials, as well as an emergency response plan.

12. Conclusion
Implementing a comprehensive Process Safety Management system is vital to
ensure the safety of employees, the public, and the environment.
Consistent, system-wide commitment is the key to successful PSM—a healthy
business must prioritize safety.

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