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Process Safety Management Overview

Learning Objectives

  • Recognize the dangers associated with a catastrophic release of highly hazardous chemicals
  • Recall the purpose of Process Safety Management
  • Identify the possible causes of hazardous chemical releases
  • Identify Process Safety Management Program components

Available in English

6 Minutes

The goal of the lesson is make employees aware of the primary objective of process safety management: to prevent unwanted releases of highly hazardous chemicals into locations that expose employees and others to serious hazards, and to provide an overview of the standards and best practices necessary to achieve that objective.

According to the U.S, Chemical Safety Board, over 10,000 American workers are harmed by incidents involving chemicals each year.

Process safety management is a comprehensive approach to prevent chemical releases. An effective process safety management program includes an evaluation of the whole process including design and technology, and other elements that might impact the process. Chemical safety starts with a thorough examination of work operations to identify and control risk and potential hazards related to handling of chemicals.

Process safety management increases safety for the workforce. Now, small businesses with limited resources might use other ways to decrease the risks associated with hazardous chemicals in the workplace, but development of a process safety management program is the operating standard. An effective process safety management program requires employers to compile a written process information resource. This information enables workers to identify and understand the hazards posed by processes that involve highly hazardous chemicals.

Course Outline
  • Process Safety Management Overview
  • 29 CFR 1910. 119 – Process Safety Management of Highly Hazardous Chemicals
  • 29 CFR 1910. 119 – Appendices A, B, C, D
  • 1910.119 App A - List of Highly Hazardous Chemicals, Toxics and Reactives (Mandatory)
  • 1910.119 App B - Block Flow Diagram and Simplified Process Flow Diagram (Nonmandatory)
  • 1910.119 App C - Compliance Guidelines and Recommendations for Process Safety Management (Nonmandatory)
  • 1910.119 App D - Sources of Further Information (Nonmandatory)
  • 29 CFR 1910.120 – Hazardous Waste Operations and Emergency Response
  • 29 CFR 1910.38 – Emergency Action Plans
  • 29 CFR 1910 Subpart H – Hazardous Materials
  • 29 CFR 1910 Subpart I – Personal Protective Equipment
  • 29 CFR 1910.146 – Permit-required Confined Spaces
  • 29 CFR 1910.147 – Control of Hazardous Energy (Lockout/Tagout)
  • 29 CFR 1910.252 – General Requirements (Hot Work) – Welding, Cutting and Brazing
  • Guidelines for Risk Based Process Safety Management”, Center for Chemical Process Safety
  • Section 304 of the Clean Air Act Amendments (CAAA)
  • OSHA Letters of Interpretation on the PSM standard
  • OSHA PSM “Quick Card
  • OSHA “Process Safety Management Guidelines for Compliance
  • ANSI, API, and NFPA
  • Chemical Safety Board (CSB: incident investigations)
  • National Oceanic and Atmospheric Administration (NOAA: chemical reactivity and modeling software)