Process Safety Management (PSM) Done Right: Keeping People, Plants, and Profits Safe

Picture this: a small chemical leak goes undetected. Within moments, it escalates into a serious process safety event. Sirens wail, production stops, and your people are at risk. The financial cost is significant, but the damage to trust, compliance, and lives is even greater.

That’s why effective Process Safety Management (PSM) is not just a regulatory obligation under OSHA 29 CFR 1910.119 — it’s a business imperative. At Stonehouse Process Safety, we help companies transform their approach to PSM into a competitive advantage that protects people, assets, and profits.

What is Process Safety Management (PSM)?

Process Safety Management (PSM) is a structured, OSHA-mandated system focused on managing hazards associated with highly hazardous chemicals. The goal is to prevent process-related incidents like fires, explosions, and toxic releases.

The core of PSM is the 14-element framework defined in OSHA’s PSM standard (29 CFR 1910.119), which sets best practices for chemical safety, equipment reliability, hazard analysis, and emergency planning.

Whether you operate a large-scale chemical facility or a small manufacturing plant, PSM helps improve operational reliability, reduce risk, and maintain compliance.

Why PSM Matters: Beyond Regulatory Compliance

Many companies view PSM as a box-ticking exercise. But a well-executed PSM program delivers real, measurable value:

• Prevents catastrophic incidents and loss of life.
• Minimizes costly downtime and regulatory fines.
• Builds a strong process safety culture across teams.
• Improves insurance positioning and reduces long-term liabilities

PSM isn’t just for large operations. Small businesses can implement practical, risk-based process safety programs with simplified documentation, focused training, and smart outsourcing.

The 14 Elements of OSHA’s PSM Standard

• Employee Participation: Empower your workforce to be active participants in your safety program. Engaged employees identify risks early and keep programs alive, not just on paper.
• Process Safety Information (PSI): Up-to-date, accurate chemical and equipment data form the foundation of every PSM decision. Think of this as your facility’s “process safety library.”
• Process Hazard Analysis (PHA): Using HAZOP, What-If, and other techniques, identify what could go wrong and how to prevent it. This is the detective work!
• Operating Procedures: Clear, step-by-step instructions reduce reliance on memory and help standardize safe operations. Clear, written instructions for how to run process safely – no guesswork, no shortcuts.
• Training: Customized, hands-on training helps your people understand hazards and apply procedures instinctively. People are only as safe as what they know. Training turns procedures into muscle memory.
• Contractor Safety: Ensure that third-party workers meet your safety expectations through orientation, training, and oversight. Everyone should play by the same rules.
• Pre-Startup Safety Review (PSSR): Before bringing new or modified systems online, verify everything is ready and safe to operate. Think of it as a ‘preflight ‘checklist for your process.
• Mechanical Integrity: Support robust inspection, testing, and maintenance programs to ensure critical equipment remains safe and reliable. Pumps, valves, tanks, relief devices – if it moves, spins, or holds pressure, it needs inspection, testing, and maintenance. No shortcuts.
• Hot Work Permits: Help implement effective hot work controls to prevent ignition in hazardous areas. Welding, cutting, grinding, brazing, soldering, open flame tools….; it’s all covered.
• Management of Change (MOC): Small changes or tweaks to processes can cause big trouble. MOC systems ensure changes are reviewed for safety impact before implementation.
• Incident Investigation: It’s important to uncover root causes—turning near misses and failures into actionable lessons.
• Emergency Planning and Response: Develop, test, and improve plans that keep people safe when the unexpected occurs.
• Compliance Audits: Perform detailed audits that identify gaps, validate compliance, and recommend improvements. Should be a three-yearly check-up.
• Trade Secrets: Balance proprietary information protection (required by workers and contractors to do their jobs) with necessary access to safety-critical data.

How Stonehouse Supports Your PSM Journey

With decades of chemical industry experience, Stonehouse Process Safety offers end-to-end PSM solutions tailored to your needs:

• PSM Consulting – We assess your current systems and help build compliant, practical solutions.
• PSM Training – Our interactive, expert-led training builds confidence and capability across your team.
• PSM Auditing – Independent evaluations help uncover blind spots, improve safety culture, and prepare for regulatory inspections.

Build Operational Resilience Through PSM

An effective PSM system goes far beyond compliance. It boosts operational continuity, builds staff confidence, and protects your brand.

By investing in process safety, you’re investing in long-term performance. Stonehouse can help you get there.

Start Your PSM Program with Stonehouse Today

Ready to take the next step? Our process safety experts are here to support you—from compliance reviews to complete program design.

Contact Stonehouse Process Safety to book your free initial consultation.

Frequently Asked Questions about PSM

• Q: What is OSHA PSM compliance?

A: OSHA PSM compliance refers to meeting the requirements of the Process Safety Management standard (29 CFR 1910.119).

• Q: Who needs a PSM program?

A: According to regulation, facilities that use or store quantities of highly hazardous chemicals above the OSHA thresholds (quantity and concentration) are required to implement a PSM program.

That said, even facilities that are below the threshold quantity and concentration, as well as facilities outside the OSHA jurisdiction, should consider a PSM program to keep the system safe and reliable.

• Q: Can small companies implement PSM?

A: Yes, through a simplified, risk-based approach with practical implementation.

• Q: How often should a PSM audit be conducted?

A: At least every three years, with more frequent internal reviews recommended.

• Q: What services does Stonehouse offer for PSM?

A: We provide consulting, training, auditing, and complete program development.