Safety Tip
Process Safety Management
Identify and Prevent Safety Risks
and Hazards
Today’s evolving digital transformation has many manufacturing facilities looking to update or migrate their legacy control systems. As part of the planning process, mitigating safety risks and hazards should be high on a facility’s priority list. The potential for an accidental release of highly hazardous chemicals can occur at any time if they are not properly controlled.
Process safety management (PSM) concerns the unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals. A PSM program must follow the Occupational Safety and Health Administration (OSHA) 29 CFR 1910.119 - Process Safety Management of Highly Hazardous Chemicals standard, which contains requirements for managing highly hazardous chemicals.
In a PSM covered area, manufacturing facilities must verify that they operate hazardous processes in a safe manner. They must validate the safety of their process, which requires performing a risk analysis of the process and associated safeguards to determine the probability of a dangerous event occurring.
For significant projects, such as a control system update or migration, process hazard analyses and other elements in a PSM standard should be included as part of the design and implementation plan. Also, manufacturers should request spare parts, storage/maintenance requirements related to the control systems hardware used in PSM covered processes.
To incorporate a safer work environment overall, how can you reduce risk and ensure your process operates at acceptable levels? The below steps will help get you started:
Safety starts from the top-down. Its importance is conveyed through a mix of communicating safety policies, strategies and initiatives; implementing process control safeguards and action plans; and investing in training and equipment repair and replacement. If the entire company regards safety as a top priority, appropriate resources will be allocated to ensure safe operations. With these elements in place, an effective corporate safety culture can be built to keep automation systems and people safe.
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