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About Process Safety Management
by Mary Beth Northrup
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Overview
About Process Safety Management
A wide variety of industrial processes uses hazardous chemicals. If not properly controlled, these processes pose a risk of chemical release, possibly even a catastrophic spill, fire or explosion. Process Safety Management is an Occupational Health and Safety Administration (OSHA) regulation that applies to facilities that handle certain types of highly hazardous materials. The regulation imposes a set of controls with the intent of preventing or minimizing catastrophic consequences from the release of those highly hazardous materials.
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History
An accident release of methyl isocyanate in 1984 in Bhopal India resulted in the tragic deaths of more than 2,000 people. This incident caused OSHA to re-examine workplace controls of United States methyl isocyanate producers and ultimately to re-evaluate workplace rules for the handling of all highly hazardous chemicals. One of the resulting new regulations was the 1992 OSHA Process Safety Management regulation. The requirements were phased in over a period of five years, between 1992 and 1997.
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Applicability
The regulation includes a list of highly hazardous chemicals. The requirements apply to processes that use over a threshold amount of the listed chemicals. That threshold amount varies from 100 pounds to 10,000 pounds, depending upon the chemical. In addition, the rule applies to any process involving more than 10,000 pounds of flammable liquids or gases and to explosives and pyrotechnics manufacturing.
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Exceptions
The regulation does not apply to retail facilities and to oil or gas drilling operations. It does not apply to fuels used for workplace consumption solely as a fuel. The rule does not apply to normally unoccupied remote sites.
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Requirements
Required program elements include a comprehensive hazard analysis, detailed operating procedures, pre-startup safety reviews and mechanical integrity checks. The facility is required to ensure that employees are involved in the development of safety procedures and that the employees receive proper training. The facility must develop emergency plans that describe actions to take in the event of an accidental chemical release. Employers must thoroughly investigate any incidents and follow through to implement identified corrective actions. Employers must conduct periodic compliance audits to assure effective implementation of all required program elements. Changes to the facility must be carefully planned and new process equipment constructed according to design specifications.
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Benefits
Handling highly hazardous and volatile materials is a risky business. Incidents can be catastrophic, resulting in significant damage and injury. The Process Safety Management regulation provides a systematic approach to the identification of hazards and establishment of mitigating controls. These controls greatly reduce the risk of catastrophic failures and losses to property, personnel and company reputation.
