Process Safety & Risk Management

The primary objective of Process Safety Management (PSM) and Risk Management Plan (RMP) is to prevent unwanted releases of highly hazardous chemicals (regulated substances), especially into the location that could expose employees, community and/or environment to serious hazards.

The PSM program aims to protect the employees and workplace, while the RMP program aims to protect the community and environment.

Many small and large businesses currently do not have the knowledge base or time necessary to create and implement effective PSM and RMP programs. Although many companies establish safety as their highest priority, there can still be a gap in implementation which can result in fines, asset damages, or injuries.

Design Group professionals bring industry expertise to assist our clients in developing the necessary elements of these programs. We support our clients in the areas where we have an extensive experience and can engage and manage additional specialists to provide a comprehensive solution.

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Process Safety Management (PSM)

PSM applies to companies that deal with any of more than 130 specific toxic and reactive chemicals over the listed threshold quantities; it also includes flammable chemicals in quantities of 10,000 pounds (4,535.9 Kg) or more.

Risk Management Plan (RMP)

RMP applies to companies holding more than a threshold quantity of a regulated substance in a process. The regulations require owners or operators of covered facilities to implement a risk management program and to submit an RMP to EPA at least every five years. These regulated substances are also subject to the requirements of the general duty clause.

OSHA's PSM vs. EPA's RMP

Different chemical list and Threshold Quantities (TQ) for some chemicals
RMP contents dictated by three level program structure
RMP requires off-site consequence analysis
PHAs for RMP must consider off-site impacts
RMP Emergency Response Plan must be integrated with community response plan

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Our Programs

Staff of experienced PSM/RMP specialists to provide industry expertise, program management, and facilitation services
Help clients achieve control over their PSM/RMP program
Comply with regulatory requirements
Develop the necessary PSM/RMP elements to operate safer plants, optimize the process and save cost
Customize the scope to deliver comprehensive and efficient solutions based on the facility’s need

Design Group PSM/RMP Program Support

1. Study the chemical inventory, and process to analyze the PSM/RMP applicability
2. Analyze current standing of all applicable elements and sections in accordance with the PSM/RMP standard
3. Develop all necessary Process Safety Information documents
Block flow/process flow diagrams Process chemistry Maximum intended inventory Safe upper and lower operational limits Piping and instrumentation diagrams	Electrical area classification drawings Relief system design and design basis Material and energy balances Ventilation system design Safety systems - interlocks, detection, or suppression systems
4. Review and develop Operating Procedure
Initial startup Normal startup Temporary operations	Emergency shutdown Normal shutdown Startup post-turnaround or emergency shutdown
5. Organize Process Hazards Analysis (third party to facilitate) and track all action items post PHA to completion
6. Review five-year accident history
7. Develop incident investigation program to track and record all incidents
8. Develop management of change program and document all changes
9. Organize periodic employee training
10. Involve third party for Mechanical Integrity program
11. Develop Pre-startup Safety Review (PSSR) process
12. Develop hot work permit and process
13. Develop contractor management program
14. Develop emergency planning and response
15. Worst case/alternate release analysis
16. Management system
17. Coordinate third-party for the compliance audit

Note: Design Group will involve client employees as required (Employee Participation) throughout the process.