Process safety management

0:00 Intro

Process safety management, for the CSP exam. Every rule and number here is cited to its primary source, on screen.

0:10 Learning objectives

In this lesson, you'll learn to: state what triggers PSM coverage and what is exempt, list the process safety information and the PHA rules, apply management of change, pre-startup review and mechanical integrity, and recall the time limits for audits, training and investigations.

0:32 What the standard covers

PSM applies to a process in two ways. One: a chemical at or above the appendix A threshold quantity. Two: a Category 1 flammable gas, or flammable liquid with a flashpoint below 100 °F, on site in one location at 10,000 pounds or more. Atmospheric-tank or transferred liquids kept below normal boiling point without chilling or refrigeration are excepted. Exempt: retail, well drilling or servicing, and normally unoccupied remote facilities. Separately, the flammables trigger excepts fuel used solely for workplace consumption, like comfort-heating propane, only if not part of a process with another covered chemical.

1:23 Process safety information

Compile written process safety information before conducting any process hazard analysis. Chemical hazards: toxicity, PELs, reactivity. Technology: flow diagram, chemistry, maximum intended inventory, safe limits. Equipment: P&IDs, electrical classification, relief system design basis, safety systems.

1:52 Process hazard analysis

The PHA identifies, evaluates and controls process hazards. Here is the team and the cycle. The team needs engineering and process operations expertise, at least one employee with process-specific experience, and one member who knows the method. At least every 5 years, a qualifying team updates and revalidates it.

2:24 Management of change

Keep PHAs, updates and documented resolutions for the life of the process. Written MOC procedures cover changes to chemicals, technology, equipment, procedures and facilities affecting a covered process. Replacements in kind are excluded. Before any change, address its technical basis and its impact on safety and health. Also address procedure changes, the time needed, and authorization requirements.

2:56 Pre-startup and integrity

Affected employees and contractors are informed and trained before start-up. Two often-confused elements. First, the pre-startup safety review. Pre-startup review: new facilities. Modified facilities need it only when the modification requires a change in the process safety information. It confirms readiness, including completed training, before chemicals are introduced. Mechanical integrity covers pressure vessels, tanks, piping, relief and vent systems, shutdown systems, controls and pumps.

3:42 Numbers to memorize

Equipment outside acceptable limits is corrected before further use, or in a safe and timely manner once necessary means assure safe operation. The most testable numbers. PHA revalidation: at least every 5 years. Compliance audit: at least every 3 years. Refresher training: at least every 3 years, and more often if necessary.

4:13 Incidents and audits

Operating procedures: certified annually. Investigations start no later than 48 hours. Reports are kept 5 years. Keep the two most recent audit reports. Investigate each incident that resulted in, or could reasonably have resulted in, a catastrophic release. Near misses count. The clock: start as promptly as possible, no later than 48 hours. The team needs at least one person knowledgeable in the process, plus a contract employee if contractor work was involved.

4:51 Common exam traps

Audits are certified at least every 3 years, by at least one person knowledgeable in the process. Findings get a documented response, and deficiencies are documented as corrected. Now, six traps that catch people on exam day. One: replacements in kind are excluded from management of change. Two: a pre-startup review for modified facilities is only needed if the PSI must change. Three: PHA revalidation is at least every 5 years. Audits and refresher training are at least every 3, and refresher training more often if necessary.

5:38 Recap quiz

Four: near misses with catastrophic potential must be investigated too. Five: contractors giving incidental services that don't influence process safety are excluded. Six: keep the two most recent audit reports; incident reports, 5 years. Question 1. How often must a PHA be updated and revalidated? A: every year. B: at least every 3 years. C: at least every 5 years. D: every 10 years. C. At least every 5 years, by a team meeting the (e)(4) requirements. Question 2. A pump is replaced with an identical unit meeting the design specification. What does PSM require? A: full MOC review. B: a new PHA. C: nothing under MOC. D: a pre-startup review. C. A replacement in kind satisfies the design specification and is excluded from MOC. Question 3. A near miss could reasonably have caused a catastrophic release. When must the investigation begin? A: within 24 hours. B: as promptly as possible, within 48 hours. C: within 5 days. D: only if injured. B. As promptly as possible, but not later than 48 hours. Want to see where you stand on every CSP domain? com.

25 questions, free, no card. You get a readiness score for each CSP domain.