Process Safety & Hazardous Materials
A Complete Professional Guide for HSE Practitioners
The Story Behind Process Safety – Why It Exists
Imagine a refinery where tons of flammable gases flow through pipes daily. One unnoticed leak, one failed
valve, or one poorly trained worker could trigger a chain of explosions. This is not fiction—it has happened
many times:
Bhopal Disaster, 1984 (India): Methyl isocyanate release → 15,000+ deaths.
Texas City Refinery Explosion, 2005 (USA): 15 dead, 170 injured due to poor safety systems.
Buncefield Fire, 2005 (UK): Fuel storage tank overflow → explosion → Europe’s biggest fire since
WWII.
These incidents shaped Process Safety Management (PSM)—a structured system designed to prevent
catastrophic accidents involving highly hazardous chemicals (HHCs).
1. Process Safety Management (PSM)
Definition & Purpose:
PSM is a structured approach to prevent catastrophic accidents such as fires, explosions, and toxic
releases from chemical processes.
It is required by OSHA (29 CFR 1910.119) and adopted worldwide with variations by ILO, HSE
(UK), EU Seveso Directive, and GCC/local safety laws.
Core Objectives of PSM:
1. Prevent major accidents in industries handling highly hazardous chemicals (HHCs).
2. Protect employees, the environment, communities, and company assets.
3. Ensure long-term operational reliability and compliance with regulations.
PSM Framework – OSHA’s 14 Elements:
1. Employee Participation – Involving workers in safety programs, hazard reviews, and decision-making.
2. Process Safety Information (PSI) – Complete documentation of chemicals, technology, and
equipment.
3. Process Hazard Analysis (PHA) – Methods like HAZOP, What-If, FMEA, Bowtie, LOPA.
4. Operating Procedures – Clear written instructions for startup, shutdown, emergencies, and normal
operation.
5. Training – Competency building for operators, engineers, contractors.
6. Contractor Management – Ensuring contractors work safely with chemicals
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