Chemical Process Safety Management: Definition, Techniques &

Example

Learn about techniques and methods used in chemical process safety management in this lesson. We will
discuss pressure relief valves, chemical compatibility, management of change, materials of construction, and
process flow diagrams.

Chemical Process Safety

Steve works at LynMorsi Chem, a chemical manufacturing facility, which makes and stores
flammable and reactive chemicals as well as process chemicals. Steve ensures the facility is
implementing chemical process safety management to prevent potential incidents.

Accidental releases of chemicals can occur at a facility without warning. A tragic industrial
accident occurred in 1984 in Bhopal, India where water reacted with methyl isocyanate (MIC).
The reaction caused a violent chemical reaction resulting in around 40 tons of MIC being
released. Hundreds of thousands of people were exposed. The gas killed over 3,700 people
initially, and the release is believed to have contributed to thousands of additional deaths and
tens of thousands of illnesses resulting from exposure.

Process Safety Management Standard

The Occupational Safety and Health Administration (OSHA) issued the Process Safety
Management of Highly Hazardous Chemicals standard in 1992 following the Bhopal disaster.
The standard is designed to minimize or prevent incidents and accidents from the release of
toxic, flammable, reactive or explosive chemicals.

The goal of process safety management is to minimize and prevent incidents resulting from the release of hazardous chemicals.

The process safety management (PSM) standard emphasizes employee participation. LynMorsi
needs to involve its employees in the implementation of its PSM program, and make
information regarding its program available to all employees.

LynMorsi collects and compiles written hazard information for process chemicals, equipment
and technologies. Chemical compatibility is an important issue in process safety. Some
chemicals may react violently if they come into contact with one another. If two chemicals are

able to be mixed without any adverse reactions, they are considered compatible. Chemical
compatibility must also be considered when designing a process system to avoid corrosion or
reaction with the materials in the process vessel, equipment and piping.

Process equipment and piping may be made of various materials such as steel, metal alloys, or
glass. Process flow diagrams need to be included in your written documentation. Process flow
diagrams visually depict the direction of chemical process flow streams and include process
vessels, equipment, piping and control valves and their place in the process. The flow diagram is
detailed and specific.

Process Hazard Analysis (PHA) is a comprehensive assessment of the process hazards.

Following the collection of process safety information, LynMorsi performs their analysis to
identify and evaluate process hazards, and determine appropriate controls for the hazards.

Written policies and procedures are created for implementing the PSM program, as well as
establishing process operating limits, and safe work practices. Employees receive training in
process safety management, with topics including chemical safety, job specific hazards,
emergency operations procedures and safe work practices. Steve makes sure they receive initial
training on safety topics and then a refresher course every three years.

When LynMorsi uses contractors for maintenance or operation of their process equipment, they
must be provided with process safety information and training. LynMorsi also obtains
information about the contractor's safety performance and their health and safety programs
prior to hiring.

A pre-start safety review must be performed prior to a new facility or chemical process unit
starting up, or if say, LynMorsi was modified substantially.

Inspections of all chemical process equipment are required on a regular basis to ensure they
are working properly and that mechanical integrity is being maintained. Steve has pressure
relief valves checked regularly, as they are designed to vent a vessel or system to prevent
overpressure to the system. The valve prevents a catastrophic failure from rupture or explosion.

A hot work permit is issued when hot work operations are being performed close to or on a
process covered by the standard. Anytime a change is made to processes, Steve evaluates how
this change will affect employee health and safety in a process called management of change
(MOC). Changes to process equipment, technology, chemicals, and procedures or facility
changes will require policies and procedures to be updated.

Any incident that has either resulted in a catastrophic release or could reasonably cause a
catastrophic release must be investigated no more than two days later. LynMorsi must develop
and implement an emergency action plan for the facility. Emergency response procedures to
handle small releases are required to be included.
LynMorsi must conduct a PSM compliance audit at least every three years. Once the audit is
complete, any deficiencies that have been found must be corrected. LynMorsi must provide all
necessary information to the individuals responsible for ensuring compliance with the PSM
standard regardless of whether the information contains trade secret information.

Lesson Summary
Chemical release incidents have caused property damage, injuries and deaths. The
Occupational Health and Safety Administration (OSHA) developed a process safety
management standard (PSM), which is designed to minimize or prevent incidents from the
release of toxic, flammable, reactive or explosive chemicals. The OSHA PSM standard elements
are:

Process Safety Information - a written collection of process hazard information.

Process Hazard Analysis (PHA) - a comprehensive assessment of the process hazards. Process flow
diagrams visually depict the direction of chemical process flow streams.

Employee participation.

Operating procedures and policies.

Employee training.

Contractor safety and safety preview pre-hire.

Mechanical integrity inspections.

Hot work permit - issued when hot work operations are being performed close to or on a process
covered by the standard.

Incident investigation.

Emergency planning and response.

Compliance audits.

Compliance even if revealing trade secrets is necessary.

Whenever there are changes to process equipment, technology, chemicals, procedures or

facility changes an evaluation is needed as to how the change affects health and safety. This is
called management of change (MOC). Update your policies and procedures as needed.

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