Process Safety Management (PSM)
Refineries, chemical plants and other facilities that handle large amounts of highly hazardous chemicals must follow OSHA’s Process Safety Management standard. Its goal is to prevent catastrophic fires, explosions and toxic releases, the kind of incidents that kill many people at once.
- General Industry
- Refineries & Chemical Plants
Who it covers
PSM applies to processes with more than a threshold quantity of a listed highly hazardous chemical, such as chlorine or ammonia, or 10,000 pounds or more of a flammable liquid or gas, with some exceptions (for example, retail facilities and some fuels used only for heating). Besides refineries and chemical plants, covered sites can include ammonia refrigeration in food plants, water treatment with chlorine, and pulp and paper mills. EPA’s Risk Management Program has similar rules to protect the surrounding community.
The 14 elements of PSM
| Element | In plain language |
|---|---|
| Employee participation | Workers help with hazard analyses and can see PSM information. |
| Process safety information | Written data on the chemicals, technology and equipment. |
| Process hazard analysis (PHA) | A team study of what could go wrong, redone at least every 5 years. |
| Operating procedures | Written steps for startup, normal operation, shutdown and emergencies. |
| Training | Operators are trained and refreshed at least every 3 years. |
| Contractors | Screening, training and safety performance of contract companies. |
| Pre-startup safety review | A check before new or changed equipment starts up. |
| Mechanical integrity | Inspection, testing and maintenance of vessels, piping, relief systems and controls. |
| Hot work permits | Permits for welding and cutting on or near covered processes. |
| Management of change (MOC) | Review before any change to chemicals, equipment or procedures. |
| Incident investigation | Investigating incidents and near misses, starting within 48 hours. |
| Emergency planning and response | A plan for releases, alarms and evacuation. |
| Compliance audits | Audits at least every 3 years. |
| Trade secrets | Needed information is shared with those who need it, even if confidential. |
What it means for contract workers
- You must be trained on the hazards of the process you work near, and on the plant’s emergency action plan.
- Know the alarms, muster points and evacuation routes before starting work.
- Follow plant permits exactly. See Permit-to-Work Systems.
- Report unusual conditions immediately: leaks, odors, alarms, unexpected pressures.
- Never change equipment, valves or procedures without approval through management of change.
- Report injuries and near misses; the host employer must keep an injury log for contractor work.
First day at a PSM site
- Site orientation and contractor safety training completed
- Know the hazards of the chemicals in my work area
- Know the emergency alarm sounds and my muster point
- Know how to get a work permit and who signs it
- Gas monitor and required PPE (often flame-resistant clothing) issued
- Know who to tell about a leak or abnormal condition
Standards & references
- 29 CFR 1910.119: Process safety management of highly hazardous chemicals
- OSHA: Process safety management
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