The Definition of Process Safety Management (PSM)

Definition of Process Safety Management (PSM)

Process safety management (PSM) is a management system for preventing catastrophic releases of highly hazardous chemicals, which can cause fires, explosions and toxic exposures. In the U.S., OSHA's Process Safety Management of Highly Hazardous Chemicals standard, 29 CFR 1910.119, was issued in 1992 after disasters such as Bhopal and the Phillips 66 Pasadena explosion. It applies to processes that involve listed chemicals above threshold quantities, or 10,000 pounds or more of a flammable liquid or gas, with some exceptions.

PSM focuses on major accident hazards, which are different from everyday occupational injuries. A site can have a low injury rate and still be at risk of a catastrophic process incident, so PSM uses its own controls and metrics.

Key Facts About Process Safety Management

• OSHA PSM has 14 elements, including employee participation, process safety information, process hazard analysis, operating procedures, training, contractors, pre-startup safety review, mechanical integrity, hot work permits, management of change, incident investigation, emergency planning, compliance audits and trade secrets.
• Compliance audits are required at least every three years.
• EPA's Risk Management Program (RMP) rule complements PSM for offsite consequences.
• Retail facilities, oil and gas well drilling and servicing, and normally unoccupied remote facilities are exempt.
• OSHA has discussed updating the 1992 standard for years, but the core rule remains unchanged.

Example of Process Safety Management

A chemical plant plans to raise a reactor's operating temperature to boost output. Under its PSM program, the change goes through MOC, the PHA is updated, operating procedures are revised, operators are trained and a PSSR is completed before the new conditions are used.

How to Build a PSM Program

1. Determine which processes are covered based on chemicals and quantities.
2. Compile complete process safety information.
3. Perform PHAs and resolve recommendations.
4. Implement procedures, training, mechanical integrity, MOC and contractor controls.
5. Audit compliance, investigate incidents and track process safety indicators.

Related Terms

• Process Hazard Analysis (PHA)
• Management of Change (MOC)
• Pre-Startup Safety Review (PSSR)
• Explosion Hazard
• Incident Investigation

Frequently Asked Questions: Process Safety Management

What is the difference between process safety and occupational safety?

Occupational safety focuses on individual injuries such as slips, cuts and strains. Process safety focuses on preventing low-frequency, high-consequence events such as explosions and toxic releases.

Which facilities are covered by OSHA PSM?

Facilities with processes involving chemicals listed in Appendix A above threshold quantities, or 10,000 pounds or more of flammable liquids or gases, unless an exemption applies.

How often must PSM be audited?

Employers must certify a compliance audit at least every three years.