Process Safety Management (PSM)

Process Safety Management


Leading companies know that process safety is key to their risk management. MMG offers a full range of safety services. With a focus on higher order risks, MMG’s expert consultants advise on both the management and technical evaluation of risks.

Let the leader in Process Safety Management (PSM) consulting assess your PSM programs or help you develop and implement PSM programs. The intent of OSHA’s PSM or EPA’s Risk Management Plan (RMP) program is to prevent an unexpected release of highly hazardous chemicals with toxic, reactive, or flammable properties which could cause significant harm to employees, the public, or the environment. There are 14 elements to the PSM program, including:

  • Hot work permit/safe work
  • Employee participation
  • Process safety information
  • Training
  • Contractors
  • Process hazard analysis
  • Management of change
  • Operating Procedures
  • Mechanical integrity
  • Pre-startup safety review
  • Emergency planning and response
  • Incident investigation
  • Compliance auditing
  • Trade secret

MMG staff are expert at effective implementation of all parts of PSM. We have helped develop some of the best management of change (MOC), Incident Investigation, pre-startup safety review (PSSR), operating procedures, mechanical integrity, employee participation, and other programs in the industry. And, we can help you develop and implement key performance indicators (most importantly, leading indicators) so that you can track the progress of PSM at your site/affiliate on a week-by week and month-by-month basis. These efforts will help your plant get the most out of implementing PSM and will help ensure that you have minimal issues at audit time.

In addition, MMG staff will address elements of PSM  that are typically missing from PSM systems including: Facility Siting, Project Risk Management, Senior Leadership & Accountability, and most notably Human Factors.

Process Safety Management

“A polyethylene reactor at the Phillips. Texas neat the Houston Ship Channel on October 23, 1989, high-density polyethylene plastics plant released flammable vapors and exploded, killing 23 people and injuring 130 others. The magnitude of the explosion was equivalent to an earthquake registering 3.5 on the Richter scale, and debris was thrown as far as six miles away.

A safety system interlock in the Formosa plastics plant, Illinois is overridden on April 23, 2004 . Five were killed and two were injured. The company had a second major explosion 18 months later.


These are just a few of the incidents that have occurred during the course of history. But what do all of these events have in common? They were all lacking adequate process safety management.

So what do we mean by “process safety management?” Process safety management, or PSM, is a disciplined framework for managing the integrity of operating systems and processes that handle hazardous materials. This management system has been widely credited for reductions in major accidents and improved process industry performance.

By applying good design, engineering, and operating principles we are better able to prevent and control the release of hazardous materials and energy. Through better controls we are able to avoid the fires, explosions, and toxic releases that result in serious injuries, property damage, lost production, and environmental impacts.

These types of events, however, can only be prevented or mitigated if proper process safety management practices are employed, and in many cases they are not.

The major objective of process safety management (PSM) is to prevent unwanted releases of hazardous chemicals, particularly in areas that could expose workers and the public to serious hazards.  An effective PSM programme requires a systematic approach to identifying, evaluating and managing process hazards.

SEN consultants are industry experts in PSM to share their practical experience and knowledge to provide clients with a pragmatic approach to PSM compliance.