INDUSTRIAL CONSULTANTS

Process Safety Management Program

PSM Program Development

The major objective of process safety management (PSM) of highly hazardous chemicals is to prevent unwanted releases of hazardous chemicals. An effective process safety management program requires a systematic approach to evaluating the whole chemical process. Industrial Consultants provides customized Process Safety Management consultation, development and training services that will help you stay compliant within all 14 elements of PSM.

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Process Safety Management Program Consulting

As one of the largest ammonia-specific training and consulting company in North America, Industrial Consultants, LLC prides itself on the fact that we have helped thousands of companies with their PSM needs.

Industrial Consultants, LLC completes a turnkey basis PSM program for our clients. Each element of the program is tailored specifically to your facility. Or if your facility has an existing PSM program, we can provide a complete review of the elements. In addition to the review of the programs, Industrial Consultants, LLC also offers the following PSM services:
Develop your PSM program for you on a turnkey basis.
Assist you with the coordination or development of any phase or element.
Provide on-site supervision for your personnel.
Conduct training sessions for your personnel.

What is Process Safety Management?

Process Safety Management (PSM) is a program that was created by OSHA, then adopted by the EPA, for facilities that contain more than 10,000 pounds of ammonia on site. OSHA mandated facilities put in place the processes and procedures regarding how to “Manage the Process Safely”.

Many companies throughout the United States have chemicals in use at their respective facilities that can threaten employees and the communities surrounding them.  These chemicals pose a potential threat when part of the process that uses the chemicals has an engineering or administrative failure that will release the chemical into the surrounding area. 

The companies using these chemicals must anticipate an eventual failure that can release the chemical.  The causes are many, due to the complexity of the systems in place, to produce a product or sometimes a distribution of products to the general public.  One example of a process that can fail is an ammonia refrigeration system, which is used for refrigeration and product storage at the facilities.

Industrial Consultants PSM Inspection & Compliance
The OSHA Process Safety Management Program (PSM) and the EPA Risk Management Program (RMP) both have requirements that must be met or complied with to understand, maintain and operate the system safely.  The industries usually involved in this standard are the general and construction industries.  

The OSHA PSM program is CFR 1910.119 and the EPA RMP 40 CFR Part 68.  Both of these programs have requirements within the body of the regulations that your facility must be in compliance with or there may be consequences.  The consequences could include an injury, or even a fatality, which affects the safety of the operators and employees at the facility.

The 14 Elements of PSM

To manage this process safely, OSHA created 14 elements. These elements include:

Employee Participation (c)

This element includes a written plan of action of how employees will participate in the development of each of the aspects of the PSM program.  This will include evidence of employee participation including minutes of meetings, PHA participation/results, etc.

Process Safety Information (d)

This element contains the information about the refrigeration process.  This information must be gathered before the Process Hazard Analysis can be completed.  Some of the items included are draw block diagrams, Piping and Instrument Diagrams (P&IDs), relief valve design basis, materials of construction, standards used in the design and construction of the facility, Safety Data Sheets (SDS), electrical classification information, engineering/design files and equipment data sheets as well as U1 sheets for pressure vessels and heat exchangers.
This is where the entire ammonia refrigeration system is evaluated to determine if there are any hazards associated with how equipment, piping, etc. is currently situated, operated or maintained.  This should be done after the PSI is gathered and the drawings are verified.

Operating Procedures (f)

This includes the written procedures for all modes of operations, documentation of annual certifications and safe work practice procedures.
Training records for each employee involved in a covered process including qualification documents and training program guidance documents for your ongoing program are included in the element.

Contractors (h)

This covers how you manage your work with outside contractors as related to safety training, information transfer, specifications and codes, facility access, etc.

Pre-Startup Reviews (i)

This portion is the program for how and what must be done before starting a refrigeration system or component, after it has been modified or added.

Mechanical Integrity (j)

This element includes the typical PM procedures that are required to maintain the integrity of the process.  Also included in this element are the definitions and procedures for inspecting your ammonia system.  These include vibration analysis, alignment check, visual inspection and non-destructive testing.  Verification of the ventilation system is also included in this section.

Hot Work Permit (k)

This element covers the program description of what is involved in and how the program is administered for your hot work permit system.

Management of Change (l)

This element defines the procedures that must be followed when changes are made to the refrigeration system.  This can include additions, changes or modifications.

Incident Investigation (m)

This element defines the specific methods for investigation of incidents, accidents, and incidental smells or near accidents.

Emergency Planning and Response (n)

Your written Emergency Action Plan, Fire Prevention and Emergency Response Program all makeup this element.

Compliance Audits (o)

This defines how and when compliance audits will be conducted.  Also included is the description of the system to ensure that findings are addressed in a timely manner.

Trade Secrets (p)

This section covers how you would handle the disbursement of information concerning any trade secrets contained within you ammonia refrigeration system.  This usually does not apply to refrigeration systems.

Process Safety Management FAQs

What is the purpose of process safety management?
The major objective of process safety management (PSM) of highly hazardous
chemicals is to prevent unwanted releases of hazardous chemicals especially into locations that could expose employees and others to serious hazards.

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