Following regulatory standards is an important part of working safely, but it’s not the only step. Safe work starts with an organized, analytical approach to your workplace’s safety needs and potential hazards called Process Safety Management (PSM). This systematic approach of evaluating your industrial processes is required by the Occupational Health and Safety Administration (OSHA) in facilities that use hazardous substances, but following these 14 PSM protocols to evaluate and implement your safety standards will help you avoid incidents, reduce costs, and keep workers safe.

1. Process Safety Information

Any safety management program is built on thorough, accurate information. Better understanding of your systems, equipment, and potential hazards comes from access to written safety information on process technology, equipment design, safe operating limits, and hazardous chemicals. This information may come from material safety data sheets (MSDS), equipment design specifications, piping and instrumentation diagrams (P&ID), and process flow diagrams.

2. Process Hazard Analysis

To safeguard against hazards, you first have to identify hazards. A process hazard analysis (PHA) is a total examination of industrial processes to identify and control hazards. Most often done for chemical processes, performing a PHA means examining equipment, instrumentation, utilities, human error, and potential failure scenarios. This is a necessary step to implement safety controls and risk prevention measures.

3. Operating Procedures

These are detailed, written protocols for working safely, especially with hazardous chemicals.

4. Emergency Planning and Response

Operating procedures should include protocol for responding to emergencies, as well as preparing for emergency situations. This includes establishing evacuation plans, having emergency equipment on hand, coordinating with local emergency services, and putting together and training emergency response teams. Regular emergency training and drills are beneficial to all employees, as well.

5. Incident Investigation

Whenever an accident, near-miss, or any other potentially harmful incident occurs, a thorough investigation must be undertaken to find its acute and systemic causes. This can lead to revision of current procedures if an unexpected failure point is found.

6. Compliance Audits

Your PSM program should be evaluated periodically to ensure that your workplace is following regulatory standards and best practices, and that your program is being implemented effectively.

7. Management of Change

When new processes, equipment, or materials are introduced, they must be evaluated to ensure that they’re safe and do not interact with existing processes in a hazardous way. A stringent review process, risk assessments, and updated training should take place.

8. Employee Training

All employees must be trained in process safety information, operating procedures, safe practices, and emergency response plans. Training sessions should be refreshed periodically and revised alongside new procedures, processes, or equipment.

9. Employee Participation

Employee feedback and reporting are vital elements of safe operations. With their understanding of workplace conditions, workers can spot potential hazards. Giving them the power to report freely strengthens safety culture.

10. Pre-Startup Safety Review

Before new facilities, processes, or equipment can be put into operation, a safety evaluation called a pre-startup safety review (PSSR) must occur to identify any potential hazards before work begins.

11. Mechanical Integrity and Maintenance Programs

Critical equipment must be kept in optimal condition and operate safely. This requires regular inspections, preventative maintenance, and replacing infrastructure that has aged out.

12. Hot Work Permits

A hot work permit must be written and authorized before any work that involves ignition sources like open flames or sparks in areas where flammable or combustible materials may be present. This helps identify fire hazards and ensure appropriate precautions and monitoring when those hazards exist.

13. Contractor Safety Management

The presence of contractors can introduce new or greater risks or challenges into your work. They should be provided with process safety information and oversight to ensure they follow your facility’s safety procedures. 

14. Trade Secrets

Process safety management standards recognize a need to protect trade secrets, but relevant safety information must be available to team members, contractors, and regulatory bodies. Procedures for maintaining trade secrets while still providing necessary PSM information must be established.