Process Safety Management (PSM) is a systematic approach to identifying, evaluating, and controlling hazards associated with industrial processes involving highly hazardous chemicals. An effective PSM program helps prevent catastrophic incidents, protect personnel and facilities, and maintain compliance with applicable regulations.
Stonehouse Process Safety provides specialized PSM consulting services to help organizations develop, evaluate, and strengthen their process safety programs. Our experienced consultants assist with OSHA PSM compliance audits, gap assessments, Process Hazard Analyses (PHAs), program development, and the implementation of practical risk-reduction measures.
With decades of experience across a broad range of industries, our team combines technical expertise with a pragmatic approach to help clients achieve regulatory compliance and improve process safety performance.
What Is Process Safety Management (PSM)?
Process Safety Management (PSM) is a systematic approach to preventing fires, explosions, and hazardous chemical releases that could threaten personnel, facilities, and the environment.
PSM integrates key elements of process safety, including hazard identification, risk assessment, operating procedures, training, and incident investigation, into a comprehensive safety management program.
In the United States, OSHA 29 CFR 1910.119 establishes PSM requirements for facilities handling certain highly hazardous chemicals. However, PSM principles can benefit a broad range of manufacturing and processing operations, even when regulatory compliance is not required.
Who Is Required to Comply with OSHA PSM?
OSHA’s Process Safety Management standard, 29 CFR 1910.119, applies to certain facilities that handle highly hazardous chemicals at or above specified threshold quantities.
The standard generally applies to processes involving:
- Highly hazardous chemicals listed in Appendix A of OSHA 29 CFR 1910.119 at or above their designated threshold quantities.
- Category 1 flammable gases or flammable liquids with flashpoints below 100°F (37.8°C) in quantities of 10,000 pounds or more, subject to specific exemptions.
PSM applicability depends on several factors, including chemical inventories, process configurations, storage conditions, and the relationship between interconnected equipment and operations.
Facilities that do not meet OSHA’s applicability thresholds may still benefit from implementing process safety management principles to reduce the risk of fires, explosions, and hazardous chemical releases.
Stonehouse can assist organizations in evaluating PSM applicability and understanding the requirements relevant to their operations.
Our Process Safety Management Consulting Services
Stonehouse Process Safety provides comprehensive PSM consulting services to help organizations establish, maintain, and improve their process safety programs. Our specialists support facilities with regulatory compliance, hazard identification, risk management, and the development of effective process safety systems.
PSM Compliance Audits
Stonehouse conducts independent PSM compliance audits to evaluate facility programs against applicable requirements of OSHA 29 CFR 1910.119. Our assessments examine the adequacy and implementation of PSM procedures, documentation, and practices, identifying areas of noncompliance and opportunities for improvement.
PSM Gap Assessments
Our PSM gap assessments help organizations understand the current state of their process safety programs and identify deficiencies relative to regulatory requirements and recognized industry practices. These evaluations provide a practical foundation for prioritizing improvements and strengthening program effectiveness.
PSM Program Development and Implementation
Whether establishing a new PSM program or improving an existing system, Stonehouse assists with the development of policies, procedures, and supporting documentation. Our consultants work with facility personnel to develop practical programs tailored to their operations, hazards, and organizational needs.
Process Hazard Analysis (PHA) and Revalidation
Stonehouse conducts and facilitates Process Hazard Analyses using established methodologies, including HAZOP, What-If, and FMEA. Our specialists also support periodic PHA revalidations to evaluate changes in processes, equipment, and safeguards.
Process Safety Information (PSI) Development and Review
We assist clients with compiling, reviewing, and evaluating Process Safety Information, including chemical hazard data, process documentation, and equipment information. Our specialized laboratory capabilities can also support the characterization of flammability, explosion, and chemical reactivity hazards.
Management of Change (MOC) and Pre-Startup Safety Reviews (PSSR)
Our consultants assist organizations in developing and evaluating procedures for managing process changes and reviewing safety requirements before introducing new or modified equipment and operations.
Incident Investigation and Root Cause Analysis
Stonehouse provides specialized support for investigating industrial fires, explosions, chemical releases, and other process safety incidents. Our consultants help identify contributing factors and recommend practical measures to prevent recurrence.
PSM Training and Organizational Competency
We provide process safety training and competency development programs tailored to facility personnel, engineers, managers, and PSM coordinators. Our programs help organizations strengthen their understanding of regulatory requirements and effective process safety practices.
Additional Process Safety Support
Stonehouse also assists with facility siting, emergency planning evaluations, mechanical integrity program reviews, fire and building code assessments, and specialized technical evaluations of process safety systems.
PSM Compliance Audits vs. PSM Gap Assessments
Although both services evaluate the effectiveness of a facility’s Process Safety Management program, they serve different purposes.
PSM Compliance Audits provide a formal evaluation of a facility’s compliance with applicable regulatory requirements. Under OSHA 29 CFR 1910.119, covered facilities must conduct compliance audits at least every three years to verify that established procedures and practices are adequate and being followed.
PSM Gap Assessments help organizations identify missing, incomplete, or ineffective elements of their existing process safety programs. These evaluations can be particularly valuable when establishing a new PSM program, preparing for an upcoming compliance audit, or implementing improvements following organizational or operational changes.
Stonehouse provides both services, helping clients identify deficiencies, prioritize corrective actions, and strengthen their process safety programs.
Why Choose Stonehouse for Process Safety Management?
Stonehouse Process Safety brings decades of specialized experience in process safety engineering, hazard assessment, and regulatory compliance. Our consultants have supported hundreds of projects worldwide, helping organizations identify process hazards, strengthen safety programs, and develop practical risk-reduction strategies.
Our expertise spans the technical and management aspects of process safety, including Process Hazard Analysis, fire and explosion prevention, electrostatic hazards, chemical reactivity, and safety systems evaluation. Combined with our in-house laboratory testing capabilities, this allows us to provide technical insight into complex process hazards that may require more detailed investigation.
Whether conducting a PSM compliance audit, developing a new program, or supporting the implementation of corrective actions, Stonehouse delivers independent, technically sound recommendations tailored to each facility’s operations and regulatory requirements.
Frequently Asked Questions about Process Safety Management
What is the difference between PSM and PHA?
Process Safety Management (PSM) is a comprehensive framework for managing hazards associated with industrial processes. A Process Hazard Analysis (PHA) is one component of a PSM program, focused on systematically identifying, evaluating, and controlling process hazards. OSHA’s PSM standard includes 14 elements, of which PHA is one.
How often is a PSM compliance audit required?
OSHA 29 CFR 1910.119 requires covered facilities to conduct and certify PSM compliance audits at least every three years. These audits evaluate whether established procedures and practices are adequate and being followed. Facilities must document audit findings, corrective actions, and the resolution of identified deficiencies.
How often must a Process Hazard Analysis be revalidated?
Under OSHA PSM, covered facilities must update and revalidate their Process Hazard Analyses at least every five years. Revalidations consider changes to processes, equipment, operating conditions, and safeguards to ensure the assessment remains accurate and relevant.
What is included in a PSM compliance audit?
A PSM compliance audit generally includes a review of process safety documentation, operating procedures, training records, hazard assessments, mechanical integrity programs, management of change procedures, incident investigations, and other applicable PSM elements. Audits typically involve document reviews, interviews with facility personnel, and on-site evaluations, followed by a report documenting findings and identified deficiencies.
How long does a PSM compliance audit take?
The duration of a PSM audit depends on the facility’s size, process complexity, number of covered processes, documentation quality, and scope of the evaluation. Stonehouse develops customized project scopes and timelines based on the characteristics and requirements of each facility.
Can Stonehouse help implement PSM audit recommendations?
Yes. In addition to identifying potential deficiencies, Stonehouse can assist with developing corrective action plans, improving process safety documentation, evaluating safeguards, and implementing risk-reduction recommendations. Our consultants work with facility personnel to develop practical solutions tailored to their operations.
Looking for PSM Consulting?
Stonehouse can help with all your PSM needs, from PSM Compliance Audits to PSM Gap Assessments. To talk to our experts about your specific operations, reach out today.
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