Process Safety Management (PSM) is a disciplined framework for preventing unplanned releases of hazardous chemicals, loss of stability, and structural failure during chemical processing. In fact, between 2007 and 2017, 56 process safety events resulted in 128 deaths. Proper management of a process can mean the difference between life and death for a chemical company. If a company does not have a process safety management program, it may not be meeting legal requirements for operating and maintaining its process.
Process safety management
A PSM system is a comprehensive program to reduce workplace injuries and fatalities and to improve efficiency in a manufacturing or other industrial environment. Process safety management focuses on a number of key areas, such as the use of PPE and proper breaks for employees. It also incorporates physical locks to prevent employees from entering hazardous areas or engaging machines until safety checks have been completed. The PSM program also helps organizations reduce incident costs by ensuring that all employees, operational equipment, and technology are in compliance with the principles of process safety management.
Implementing a PSM program requires an employer to document its risk assessment procedures and provide these documents to all workers. This includes a written operating procedure that details the steps that must be taken at each operating phase, the limits of each process, and any safety systems used. These documents must be easily accessible to all employees, and they must be updated and certified annually. Moreover, they should cover any special circumstances and provide employees with relevant technical data.
Proper management of chemicals and hazardous materials can be a matter of life or death for a company. Process safety management is a disciplined framework that prevents unexpected releases of hazardous chemicals, structural failure, and loss of stability. Between 2007 and 2017, there were 56 cases of process safety events resulting in 128 fatalities. While the exact cause of each case remains unclear, the right process safety program can help prevent such incidents. By taking the necessary steps, a process safety management program can prevent accidents and protect the environment, employees, and community.
Process safety management focuses on technology, facilities, and personnel in a way that minimizes risks and incidents associated with highly hazardous chemicals. The goal of PSM is to prevent chemical accidents, thereby minimizing injuries and fatalities. It also reduces the risk of environmental damage and helps companies comply with the standards of OSHA and other regulatory bodies. However, non-compliance can have serious financial and legal consequences. Process safety management can also be used to improve the efficiency of a company’s processes.
Pre-startup safety review
A Pre-startup Safety Review (PSSR) is a formal inspection conducted before the start-up of a new or modified processing facility. This review is an excellent way to ensure that the installations comply with the original design while catching potential hazards that may have occurred during the detailed engineering phase. The PSSR covers a number of areas, including process safety, quality assurance, and personnel safety. Read on to learn more about the various types of PSSRs and how to conduct one for your process plant.
PSSRs are essential for large projects. A pre-startup safety review will allow your company to refuse responsibility for equipment that does not meet all safety standards. It will also give plant operators the authority to refuse responsibility for unsafe equipment. Once this review is complete, your plant will be ready for operations. You’ll want to ensure that all equipment is functioning properly, and that all procedures have been followed to train your staff. If you’re not sure how to conduct a PSSR, Wiley provides a PDF that you can download for free.
The process safety review is required for any new facility or substantially modified facility. The review must address any changes to the process safety information. If the modification will make the process more hazardous, a PSSR is still required. Management must approve the change prior to the start-up, but may be exempt if the change will only reduce the amount of hazards. During the review, workers should be trained on process hazards and any new equipment.
The PSSR can include a third party. For instance, it may include contractors who know the equipment and can provide the needed technical know-how. Besides, the PSSR process safety review is essential in ensuring the safe operation of covered process equipment. As part of the PSSR, documentation is key, which means it is essential for the process safety management system. Make sure to provide all of the necessary documents to the PSSR team prior to startup.
Compliance audits
Process safety management is a system that identifies potential risk scenarios, provides adequate controls, and maintains compliance throughout the operational life of a process. A company’s operating teams should be trained in the various scenarios and have well-documented operating procedures. Compliance auditing checks individual activities to ensure that they meet regulatory requirements. The results of these audits should be incorporated into company policies and procedures, and can serve as a guide for future audits.
The process safety management (PSM) standard includes 14 elements that companies must follow in order to avoid risk. One of these elements is the process safety management (PSM) compliance audit. An effective audit will include cross-trained personnel, audit checklists, and self-assessments. Compliance audits are an essential component of PSM programs and are essential to achieving compliance. In addition to being an essential part of the program, compliance audits can be an important tool in identifying the areas that need improvement in a company’s safety and environmental performance.
The audit team should consist of knowledgeable professionals with relevant experience in the PSM standard. An audit team may consist of five to six people and last for a week or two. It may consist of internal personnel, consultants, and other plants. The responsible manager should sign the audit report and make it official certification. Ultimately, however, an outside auditor will need to certify compliance. So who should conduct these audits? And why?
While some aspects of the limits table may seem easy, they can be difficult to document and maintain if your process has hundreds of critical variables. These critical variables may include pressure, temperature, flow rates, and levels. For older processes, developing critical variables can be challenging due to limited PSI availability. Process safety audits often reveal opportunities for compliance, such as regulatory direction changes, or changing equipment designs. A thorough process safety audit will help you meet the requirements.
OSHA requires that facilities with covered processes perform compliance audits every three years. Since the first compliance audit, facilities that were in existence at the time the OSHA regulation was promulgated have performed seven to nine. The audit findings reveal common shortcomings, including failure to define safe limits and operating conditions. Process safety management information is also important. The audit findings of recent audits highlight the importance of process safety information and safe operating limits.
Refresher training
If your employees are not keeping up with the latest regulations and industry standards, it may be time for a refresher training program. Such trainings often last five to ten minutes each, and can be a great way to remind your staff of the latest skills they need to keep their work safe. But when should you consider getting your employees re-trained? Consider the following tips. You will need refresher training if your employees regularly make common mistakes.
Refresher training is essential to maintain employee confidence. Lack of confidence makes employees less productive and is a major reason why many of them quit their jobs. A refresher course can also help you identify any knowledge gaps and training needs. In addition to reducing mistakes, refresher training can improve memory retention. Herman Ebbinghaus, the author of the famous Forgetting Curve, discovered that after one week of not practicing, memories begin to deteriorate.
Refresher trainings are designed to help workers improve their knowledge of important process safety topics. Refresher trainings focus on key areas of process safety management and include industry-specific content. Participants can choose topics of interest to focus on. This is an excellent option for companies that have many contractors. Refresher training can help improve safety among contractor workforces and mitigate the risks associated with poor adherence to safety standards. A refresher course can help your workforce stay up-to-date on the latest regulations, industry standards, and safety regulations.
Refresher trainings should be conducted frequently. Employees should be updated on the latest health and safety regulations and procedures as soon as possible. Additionally, refresher trainings should be conducted after any changes to processes or new equipment. These trainings should take into account the risk assessment and explain how to use the new equipment safely. This way, you can ensure that your employees are properly trained, and your organization will reap the benefits.
Refresher trainings are also valuable for employees who already know the material. By incorporating feedback from learners, you can determine which topics need to be included and when they should be taught. The more precise your knowledge gaps, the more effective your refresher trainings will be. You can use these feedbacks to improve next year’s course. So, why not take the plunge? Take the first step to refresh your process safety trainings today?
