Process Safety Management Program

Process Safety Management Program Services

OSHA PSM-Aligned Program Development, Gap Assessment, Implementation, and Compliance Support

HazBasis Process Safety provides professional Process Safety Management Program Services for facilities that handle highly hazardous chemicals, flammable materials, reactive chemicals, toxic substances, and high-consequence process hazards.

We help facility owners, plant managers, EHS leaders, process engineers, and corporate safety teams develop, improve, audit, and implement PSM programs aligned with OSHA 29 CFR 1910.119 expectations.

What Is a Process Safety Management Program?

A PSM program isn’t just a binder of procedures sitting on a shelf. It’s a management system built to prevent catastrophic releases, fires, explosions, toxic exposures, and serious process safety events, and it only works if operations, maintenance, engineering, and management can actually use it day to day.

HazBasis helps facilities strengthen PSM systems involving highly hazardous chemicals, flammable liquids and gases, toxic materials, reactive chemicals, combustible dust interface issues, batch and continuous chemical processes, pressure vessels and relief systems, storage tanks and transfer systems, process safety testing laboratories, and pilot plant or scale up operations. The goal isn’t a thicker binder. It’s identifying real gaps, improving documentation where it actually matters, and building systems your team will keep using after we leave.

When You Need PSM Program Services

You may need support if your facility is:

• Starting a new PSM covered process, or expanding chemical storage, processing, or production capacity
• Preparing for a PSM compliance audit
• Responding to OSHA, corporate, insurer, or customer findings
• Updating outdated PSM procedures
• Closing PHA, MOC, PSSR, or audit action items
• Improving process safety information
• Developing operating procedures and safe operating limits
• Strengthening mechanical integrity documentation
• Implementing a management of change system
• Investigating incidents or high potential near misses
• Preparing for startup after new construction or modification
• Building a more sustainable site level process safety program

OSHA PSM Aligned Support

HazBasis supports PSM program development and improvement aligned with the core elements of OSHA Process Safety Management: employee participation, process safety information, process hazard analysis, operating procedures, training, contractors, pre-startup safety review, mechanical integrity, hot work, management of change, incident investigation, emergency planning and response, compliance audits, and trade secret information management.

We help convert those requirements into clear procedures, practical workflows, defensible documentation, and tools your facility can actually implement, rather than a compliance document written to satisfy an auditor and nobody else.

Our PSM Support Process

Step 1: Initial Consultation. We discuss your facility, covered processes, chemicals, current program status, known gaps, and business objectives.

Step 2: Document and Program Review. We review available PSM procedures, PSI, PHA records, MOC files, PSSR records, MI documentation, incident reports, training records, and audit findings.

Step 3: Gap Identification. We identify missing, outdated, incomplete, or weak program elements and prioritize them based on risk, compliance importance, and implementation practicality.

Step 4: Program Improvement Plan. We develop a clear roadmap for documentation updates, technical studies, procedure development, training needs, and action item closure.

Step 5: Implementation Support. We help prepare documents, facilitate reviews, support meetings, close findings, and strengthen PSM workflows.

Step 6: Ongoing Support. We provide continuing technical support for PHA, MOC, PSSR, audits, incident investigations, and program updates as your program matures.

What We Deliver

PSM Program Gap Assessment 

We evaluate your existing program against OSHA PSM expectations and recognized process safety practices, reviewing PSM applicability, existing procedures, process safety information, PHA records and revalidation status, operating procedures, training records, contractor safety interface, PSSR documentation, mechanical integrity, MOC procedures, incident investigation reports, and open action item tracking. You get a prioritized action plan, not just a list of what’s wrong.

PSM Program Development 

For new or immature programs, we help build the structure from the ground up: policy and program manual, element specific procedures, roles and responsibilities, PSI templates, PHA workflow and revalidation schedule, operating procedure structure, training matrix, MOC procedure and forms, and an action item tracking system. The target is a program that’s clear and usable for the people running it, not just technically compliant on paper.

Process Safety Information Support 

Accurate PSI is the foundation everything else in a PSM program rests on. We help compile, review, or improve documentation on chemical hazards, toxicity, reactivity, flammability, and explosibility data, thermal and chemical stability, hazardous effects of inadvertent mixing, process technology, safe operating limits, maximum intended inventory, equipment design basis, materials of construction, electrical classification, and relief system design basis. Better PSI leads directly to stronger PHAs, better operating procedures, and better MOC decisions downstream.

PHA, HAZOP, and Revalidation Support 

We support PHA preparation, HAZOP facilitation, what-if and checklist reviews, PHA revalidation, node and scenario development, safeguard evaluation, and recommendation development through to report preparation and action item closure. The focus is making sure the PHA actually captures credible hazards, including fire, explosion, toxic release, overpressure, chemical reactivity, static ignition, equipment failure, human factors, and loss of containment scenarios, not just the obvious ones.

Management of Change Support 

A weak MOC system is one of the most common sources of process safety risk we see. We help develop or improve MOC workflows covering changes to chemicals, process conditions, equipment, piping and instrumentation, control logic, relief systems, operating procedures, facility layout, staffing, raw materials or suppliers, batch size, and both temporary and emergency changes, so that changes get reviewed before implementation instead of after something goes wrong.

Pre-Startup Safety Review Support 

We support PSSR activities before startup of new, modified, or recommissioned processes, reviewing construction and installation status, P&ID field verification, safety systems and interlocks, relief devices, operating procedures, training completion, PHA and MOC action item closure, mechanical integrity readiness, and startup authorization documentation. A strong PSSR is what confirms the process is actually ready before hazardous materials show up.

Mechanical Integrity Program Support 

Mechanical integrity is what prevents loss of containment and equipment failure before it happens. We help review or improve MI documentation for pressure vessels, storage tanks, piping systems, relief devices, emergency shutdown systems, controls and interlocks, rotating equipment, inspection and test procedures, preventive maintenance programs, and deficiency management, connecting that documentation back to the real process hazards it’s supposed to address.

Incident Investigation and Corrective Action Support 

We support investigation and recurrence prevention for fires, explosions, chemical releases, toxic exposure potential, overpressure events, relief valve lifts, static ignition, reactive chemical events, combustible dust events, and near misses with catastrophic potential, helping identify causal factors, failed safeguards, root causes, and corrective actions that actually strengthen the system rather than just closing the incident report.

Compliance Audit and Action Item Closure 

Audits and internal reviews generate findings that need technical interpretation, not just a checkbox. We help with audit preparation, document review, finding classification, corrective action planning, PHA and MOC recommendation resolution, PSI updates, PSSR closeout, and management review packages, with the goal of turning findings into real improvements instead of a growing pile of unresolved paperwork.

Common Questions We Help Answer

• Does this process fall under OSHA PSM?
• What PSM elements are missing or weak?
• Is our process safety information complete?
• Are our PHAs current and technically defensible?
• Are PHA recommendations being closed properly?
• Does our MOC system actually capture process safety risk?
• Are our operating procedures adequate, and do our safe operating limits need improvement?
• Is our PSSR process strong enough before startup?
• Is our mechanical integrity program properly documented?
• Are relief system design bases available?
• Are incident investigations identifying real root causes?
• Are compliance audit findings being resolved effectively?

Why Choose HazBasis

HazBasis combines process safety management expertise with deep technical experience in fire and explosion hazards, chemical reaction hazards, flammable liquids, combustible dust, hazardous area classification, electrostatic hazards, pressure relief systems, and incident investigation.

Our PSM program work is:

• OSHA PSM aligned and technically defensible
• Practical for facility implementation
• Clear for EHS, operations, engineering, and management alike
• Suitable for audit, PHA, MOC, PSSR, and incident investigation support
• Focused on catastrophic incident prevention, not paperwork for its own sake

We don’t treat PSM as a compliance exercise to check off. We connect procedures, equipment, chemicals, safeguards, people, and management systems into a program that actually functions when it’s tested.

FAQ