Process Safety News
Volume 19,
Understanding recently issued
OSHA PSM NEP
Process Safety Management of Highly Hazardous Chemicals
(29 CFR 1910.119)
By: Amy Theis, PE, Manager, Risk Management Services, Fauske & Associates, LLC (FAI) and
Timothy Cullina, PE, Safety Consulting Engineer, Fauske & Associates, LLC (FAI)
In late November 2011, OSHA released the National
Emphasis Program (NEP) for Process Safety
Management (PSM) officially replacing the limited-scope
2009 pilot NEP for PSM - covered chemical facilities. The
PSM requirements remain challenging, but essentially
unchanged. This article will focus on changes of the new
Chemical PSM NEP and how your facility can be prepared.
F
acilities Affected and Inspection Process
1) All federal and state-plan OSHA offices are
required to participate in the new Chemical PSM
NEP. Formerly, only regions I, VII and X (14 states) were
affected by the original pilot program. In addition,
each OSHA area office is required to complete 3 to 5
inspections per year.
2) As before, the target list includes the usual suspects
plus some new less common additions including:
• Facilities identified for maintaining greater than
threshold quantities of flammable liquids
• Facilities identified on the EPA’s Risk Management
Program database
• Facilities with NAICS codes that match the NAICS
codes of past PSM - offenders
3) Two categories will be used:
• Facilities using ammonia in refrigeration use as the
only highly hazardous chemical (HHC) ∼ 25% of
inspections
• Facilities using ammonia for other than refrigeration
or using HHCs other than ammonia ∼ 75% of
inspections
Winter 2012
Number 1
T he inspection process will include the use of
investigative questions that are designed to gather
facts related to requirements of the PSM standard which
include guidance for reviewing documents, interviewing
workers and verifying full implementation. An
emphasis is placed on the assessor evaluating effective
implementation of the PSM elements in addition to
sufficient program documentation. The questions will be
asked based on a dynamic list of questions that will not
be public domain.
C itation History
O SHA outreach efforts have provided summaries of
the pilot program results as measured by citations.
Table 1 on page 4 provides a summary of completed
inspection citations from the first 18 months of the pilot
program. If asked, most managers responsible for PSM
implementation may identify the more challenging
elements to be the same as OSHA’s list of most cited
elements. Roughly 75% of the citations came from
just 4 elements: Mechanical Integrity, Process Safety
Information, Process Hazard Analysis, and Operating
Procedures. Training and Management of Change
programs captured an additional 9%.
Continued on page 4
Upcoming Events
- FAI Spring 2012 Process Safety Training Courses, March 22-23,
2012 in Burr Ridge, IL (see pages 14 & 15 for more information)
- Visit FAI at booth #1352 at the
PTXi/Powder Bulk Solids
Conference, May 8-10, 2012 in Rosemont, IL
- FAI Relief Systems Design Course, May 21-22 in Burr Ridge, IL
(see page 11 for more information)
- FAI User Group Forum, May 23-25, 212 in Burr Ridge, IL (visit
www. fauske.com for more information)
 Process Safety News Winter 2012 Fauske.Com p. 4
Continued from page 1
Table 1
PSM Pilot NEP Citations as of December 21, 2010
OSHA Directorate of Enforcement, General Industry Enforcement
Hypothetical Citation Example
L o o k i n g a t t h e s p e c i f i e d c i t a t i o n s we c a n
s e e t h a t P S M e l e m e n t s fo r m i n te r re l a te d
re s p o n s i b i l i t i e s a s i l l u s t r a te d by t h e fo l l ow i n g
hy p o t h e t i c a l e x a m p l e.
D u r i n g a P S M N E P i n s p e c t i o n , t h e co m p l i a n ce
o f f i ce r c h e c k e d M e c h a n i c a l I n te gr i t y re co rd s
a n d n o te d t h a t m a i n te n a n ce c h a n g e d a
co m p o n e n t f ro m t h e o r i gi n a l s p e c i f i c a t i o n
( i t n o l o n g e r m e t t h e a p p l i c a b l e co d e ) to a n
u n s p e c i f i e d i te m . S i n ce t h e o l d co m p o n e n t i s
n o l o n g e r m a d e, a d i f fe re n t t y p e o f co m p o n e n t
n e e d e d to b e s e l e c te d a n d i n s t a l l e d. U n d e r
P S M , t h i s re p l a ce m e n t re q u i re d M a n a g e m e n t o f
C h a n g e p ro ce s s a p p rov a l. Th e i n s p e c to r c ro s s -
c h e c k e d t h e M O C l o g a n d fo u n d t h e c h a n g e
b o t h d o c u m e n te d a n d a p p rove d.
Th e t y p e o f co m p o n e n t s e l e c te d m a n d a t e d
d i f fe re n t s te p s fo r t h e o p e r a to r s (O p e r a t i n g
Pro ce d u re s ) w h o re q u i re d t r a i n i n g a n d
ve r i f i c a t i o n i n t h e n e w p ro ce d u re s ( Tr a i n i n g ) .
Th e O S H A i n s p e c to r fo u n d u p d a te d p ro ce d u re s
i n u s e a n d d o c u m e n te d t r a i n i n g. Th e r a t i o n a l e
fo r s e l e c t i n g t h e co m p o n e n t w a s cove re d i n
t h e t r a i n i n g a n d m a d e av a i l a b l e fo r re v i e w by
e m p l oye e s a n d t h e i r re p re s e n t a t i ve s ( E m p l oye e
Pa r t i c i p a t i o n ) . N o c i t a t i o n s we re i s s u e d.
W h e n t h e n e w co m p o n e n t w a s i n s t a l l e d by
t h e s u p p l i e r (Co n t r a c to r s ) , i t i nvo l ve d s h u t t i n g
d ow n p a r t o f t h e p ro ce s s ( Pre - s t a r t u p S a fe t y
R e v i e w ) a s we l l a s b r a z i n g s o m e o f t h e l i n e s
( H o t Wo r k Pe r m i t ) . Th e e m p l oye r re v i e we d
t h e re s p o n s e p l a n ( E m e rg e n c y P l a n n i n g ) t o
e n s u re t h a t p ro ce d u re s we re a d e q u a te fo r t h e
i n s t a l l a t i o n h a z a rd s. Wo r k e r s co m p l e te d t h e
h o t wo r k p e r m i t a n d a co py re m a i n e d i n t h e
re co rd s. N o re co rd s we re av a i l a b l e to i n d i c a t e
h ow t h e co n t r a c to r i n te r a c te d w i t h t h e f a c i l i t y
w h e n wo r k i n g o n a P S M cove re d p ro ce s s.
S e ve r a l c i t a t i o n s co u l d b e i s s u e d u n d e r 1 1 9 ( h ) .
Pro p o s e d f i n e s co u l d e xce e d $ 7 , 0 0 0 .
A l t h o u g h M a n a g e m e n t o f C h a n g e p rov i s i o n s
cove re d i n te r i m c h a n g e s, w h e n t h e n e w
co m p o n e n t w a s p l a ce d i n s e r v i ce t h e Pro ce s s
S a fe t y I n fo r m a t i o n w a s n o t u p d a te d. Th e
Pro ce s s H a z a rd A n a l ys i s w a s re v a l i d a te d, b u t
t h e re co rd s co u l d n o t a cco u n t fo r p o te n t i a l
h a z a rd s a s s o c i a te d w i t h t h e n e w co m p o n e n t .
Fo r t u n a te l y, i n s p e c t i o n a n d m a i n te n a n ce
p ro ce d u re s a n d t r a i n i n g we re u p d a te d
( M e c h a n i c a l I n te gr i t y ) . M u l t i p l e c i t a t i o n s
co u l d b e i s s u e d u n d e r 1 1 9 ( d ) ( 3 ) ( i ) fo r t h e P & I D s
a n d o t h e r P S I t h a t we re n o t u p d a te d a n d 1 1 9 ( e )
( 3 ) ( i ) fo r n o t e v a l u a t i n g t h e p ro ce s s h a z a rd o f
t h e n e w co m p o n e n t d u r i n g t h e P H A . Ag a i n ,
p ro p o s e d f i n e s co u l d e xce e d $ 7 , 0 0 0 . I n f a c t ,
t h e ave r a g e f i n a n c i a l p e n a l t i e s p e r i n s p e c t i o n
u n d e r t h e p i l o t p ro gr a m e xce e d e d $ 2 5 , 0 0 0 .
H owe ve r, s i n g l e c i t a t i o n s f ro m t wo re ce n t P S M
i n s p e c t i o n s d re w v i o l a t i o n p e n a l t i e s o f $ 2 5 , 0 0 0
e a c h fo r f a i l u re to c a l i b r a te a d e v i ce u s e d fo r
v i b r a t i o n a n a l ys i s i n o n e c a s e a n d fo r f a i l u re t o
fo l l ow t h e f l a n g e b o l t to rq u e s p e c i f i c a t i o n i n
t h e o t h e r.
A s i l l u s t r a te d, 1 1 P S M e l e m e n t s c a n b e a f fe c t e d
by c h a n gi n g o n e co m p o n e n t . Th e N E P i n s t r u c t s
t h e O S H A i n s p e c to r to c h e c k a re p re s e n t a t i ve
n u m b e r o f t h e e l e m e n t s to co n f i r m t h a t t h e
re q u i re d fo l l ow - u p a c t i v i t i e s h ave b e e n
i m p l e m e n te d a c ro s s t h e s p e c t r u m o f P S M
e l e m e n t s fo r t h e n e w co m p o n e n t .
Co n t i n u e d o n p a g e 5
 Process Safety News Winter 2012 Fauske.Com p. 5
Continued from page 4
What to Expect
W h e n O S H A v i s i t s, t h e f a c i l i t y m a n a g e m e n t
s h o u l d e x p e c t to b e a s k e d fo r t h e i r O S H A 3 0 0
l o g s, t y p i c a l l y fo r t h e l a s t t h re e ye a r s. W h e n t h e
O S H A I n s p e c to r v i s i t s a P S M cove re d f a c i l i t y,
e x p e c t t h e s a m e a n d m o re. Th e O S H A I n s p e c to r s
w i l l a t te m p t to i d e n t i f y t h e m o s t h a z a rd o u s
p ro ce s s fo r i n s p e c t i o n u n d e r t h e C h e m i c a l
NEP based on the quantity of chemicals in
t h e p ro ce s s, t h e a g e o f t h e p ro ce s s u n i t ,
m a i n te n a n ce a c t i v i t i e s a n d l o g s, p re v i o u s a u d i t
f i n d i n g s, e m p l oye e i n p u t a n d i n j u r y a n d i n c i d e n t
l o g s.
A m o n g t h e f i r s t i n s p e c t i o n to p i c s cove re d
w i l l b e p e r s o n a l p ro te c t i ve e q u i p m e n t ( P P E )
d e te r m i n a t i o n s a n d h a z a rd o u s l o c a t i o n
c l a s s i f i c a t i o n s. Th o u g h n o t s p e c i f i c a l l y
P S M - re l a te d, P P E a n d l o c a t i o n c l a s s i f i c a t i o n s
a p p l y to m u l t i p l e P S M e l e m e n t s. Th e i n s p e c to r s
w i l l re q u e s t t h a t yo u p rov i d e a n ove r v i e w o f t h e
f a c i l i t y ’s P S M p ro gr a m i n c l u d i n g i d e n t i f i c a t i o n
o f k e y re s p o n s i b l e p e r s o n n e l a n d d e s c r i p t i o n s
o f re co rd s c re a te d fo r P S M m a n a g e m e n t a n d
co m p l i a n ce d e m o n s t r a t i o n . Th e y w i l l a s k to
s e e a l i s t o f P S M c h e m i c a l s, t h e i r q u a n t i t i e s o n
s i te, p ro ce s s e s u s e d a n d p ro ce s s d e s c r i p t i o n s.
Pro ce s s a n d s a fe t y s ys te m d e s c r i p t i o n s s h o u l d
i n c l u d e s a fe u p p e r a n d l owe r o p e r a t i n g l i m i t s,
d e s i gn co d e s a n d s t a n d a rd s fo r t h e s e l e c te d
u n i t ( s ) P F D s, P & I D s a n d P l o t P l a n s w i l l b e
re q u i re d. Th i s i n fo r m a t i o n s h o u l d b e av a i l a b l e
a s p a r t o f t h e Pro ce s s S a fe t y I n fo r m a t i o n ( P S I )
f i l e. I n a d d i t i o n , t h e i n s p e c to r w i l l re q u e s t to
re v i e w t h e m o s t re ce n t Pro ce s s H a z a rd A n a l ys i s
( P H A) o r re v a l i d a t i o n co m p l e te w i t h t h e P S I . A l l
o f t h i s c a n b e e x p e c te d to h a p p e n b e fo re a n
i n i t i a l w a l k a ro u n d. Prov i d i n g a d e q u a te a n d
co m p l e te i n fo r m a t i o n to t h e i nve s t i g a to r w i l l
m a k e a g o o d f i r s t i m p re s s i o n .
O S H A i n s p e c to r s w i l l l o o k fo r e v i d e n ce o f
p ro gr a m i m p l e m e n t a t i o n i n t h e m a i n te n a n ce
d e p a r t m e n t , a t t h e o p e r a to r ’s p o s i t i o n s a n d
i n t h e f i e l d, r a t h e r t h a n j u s t a cce p t i n g w h a t i s
w r i t te n i n P S M p ro gr a m p l a n s. Th e N E P e q u i p s
i n s p e c to r s w i t h q u e s t i o n s a n d g u i d a n ce to
n av i g a te f ro m w r i t te n p ro gr a m s to re q u i re d
re co rd s. Th e N E P a l s o d i re c t s Co m p l i a n ce S a fe t y
a n d H e a l t h O f f i ce r s (C S H O s ) to re v i e w p a s t P S M -
re l a te d c i t a t i o n s i s s u e d to t h e s a m e e m p l oye r
( n o t j u s t t h e s a m e f a c i l i t y ) g o i n g b a c k 6 ye a r s
a n d i d e n t i f y p o te n t i a l f a i l u re s to a b a te a n d
p o s s i b l y re p e a t w i l l f u l v i o l a t i o n s.
Develop an Action Plan
I t i s h e l p f u l to e v a l u a te yo u r P S M p ro gr a m' s
e f fe c t i ve n e s s by e x a m i n i n g s u cce s s f u l
i m p l e m e n t a t i o n o f t h e to p 4 c i te d e l e m e n t s :
M e c h a n i c a l I n te gr i t y, Pro ce s s S a fe t y
I n fo r m a t i o n , Pro ce s s H a z a rd A n a l ys i s a n d
O p e r a t i n g Pro ce d u re s. Th i s w i l l gi ve a g o o d
i n d i c a t i o n o f w h e t h e r yo u r P S M p ro gr a m n e e d s
i m p rove m e n t to b e co m p l i a n t . A n o t h e r k e y
e l e m e n t i s M a n a g e m e n t o f C h a n g e, w h i c h
t r i g g e r s a c t i o n s i n e a c h o f t h e p re v i o u s l y
m e n t i o n e d e l e m e n t s. I f p ro ce d u re s a re n o t i n
p l a ce o r p ro p e r l y co m p l e te d, t h e re co u l d b e a
d o m i n o e f fe c t re s u l t i n g i n m u l t i p l e c i t a t i o n s.
A g a p a n a l ys i s i s u s e f u l to d e te r m i n e a re a s o f
highest risk.
Conclusion
M a ny n e w f a c i l i t i e s w i l l b e i n c l u d e d i n t h e
t a rg e t l i s t , w h i c h we re n o t a f fe c te d by t h e
p re v i o u s p i l o t p ro gr a m i n 2 0 0 9 . Th e N E P w i l l
co n d u c t p ro gr a m m e d i n s p e c t i o n s fo r t h o s e
co m p a n i e s w i t h k n ow n r i s k s a n d e n co u r a g e
u n p ro gr a m m e d i n s p e c t i o n s fo r t y p i c a l l y l ow -
p ro f i l e P S M - cove re d f a c i l i t i e s. O S H A w i l l
e v a l u a te co m p l i a n ce u s i n g s p e c i a l l y d e ve l o p e d
“d y n a m i c i n s p e c t i o n l i s t s” t h a t a re re - g e n e r a t e d
o n a re g u l a r b a s i s.
F A I e n gi n e e r s a re f a m i l i a r w i t h O S H A a u d i t i n g
te c h n i q u e s a n d c a n h e l p yo u r f a c i l i t y p re p a re fo r
a n O S H A P S M N E P i n s p e c t i o n . We c a n p e r fo r m a
P S M g a p a n a l ys i s to i d e n t i f y p r i o r i t y e l e m e n t s
n e e d i n g a t te n t i o n . FA I c a n a l s o p rov i d e
a s s i s t a n ce w i t h P S M p ro gr a m d e ve l o p m e n t
i n c l u d i n g E m e rg e n c y R e s p o n s e Pro ce d u re s a n d
Pro ce s s S a fe t y I n fo r m a t i o n ( p ro p e r ve n t s i z i n g,
p ro ce s s c h e m i s t r y a n d s a fe o p e r a t i n g l i m i t s ) .
Co n t a c t M r. J e f f G r i f f i n a t ( 6 3 0 ) 8 8 7 - 5 2 7 8
o r v i a e m a i l a t gr i f f i n @ f a u s k e. co m fo r m o re
i n fo r m a t i o n re g a rd i n g h ow FA I c a n s u p p o r t yo u r
f a c i l i t y i n p re p a r a t i o n fo r a n O S H A P S M N E P
inspection.
R e fe re n ce s
O cc u p a t i o n a l S a fe t y a n d H e a l t h Ad m i n i s t r a t i o n , D i re c t i ve N u m b e r :
C P L 0 3 - 0 0 - 0 1 4 , P S M Cove re d C h e m i c a l Fa c i l i t i e s N a t i o n a l
E m p h a s i s Pro gr a m , N ove m b e r 2 9 , 2 0 1 1 .
L . Lo n g, M . M a r s h a l l  a n d J. L ay, U p d a t e o n O S H A’s P S M N a t i o n a l
E m p h a s i s Pro gr a m s, Pro ce s s S a fe t y Pro gre s s, Vo l. 3 0 , N o. 4 ,
D e ce m b e r 2 0 1 1 .
Amy Theis, Risk Management Services Manager at FAI, will
be a featured presenter at the
AIChE Global Congress on Process Safety,
Loss Prevention Symposium
April 3rd, in Houston, Texas