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Process Safety Management Training: Not Just a Box to Check!

May 8th, 2023 by Tad Goetcheus

PSM safety is complex compared to general OSHA General Industry Workplace Employee Safety.  Basically, process safety is a blend of engineering and management skills, and its objective is to prevent explosions, fires, equipment failure, and toxic releases associated with loss of or containment of energy or dangerous substances. PSM training also helps employees understand the importance of following safety protocols.  By understanding the risks associated with hazardous materials and processes, employees can better recognize when safety protocols are not being followed, and this can help reduce the risk of accidents and injuries in the workplace. Dedicated and effective training will create an environment where safety is a priority and employees are more likely to follow safety protocols.

Training can take place in a classroom or workplace and should be conducted by those considered a subject matter expert or in the process of becoming a subject matter expert. At HRP the client project manager routinely conducts the training sessions by incorporating forms, procedures, and design drawings, as well as plant equipment reviews in the Covered Process area themselves.

Every element of PSM has a close link with training elements including Process Safety Information (PSI), Process Hazard Analysis (PHA), Mechanical Integrity (MI), Audit, Pre-Startup Safety Review (PSSR), Incident Investigation (II), Standard Operating Procedures (SOPs), Hot or Hazardous Work Permit, Employee Participation, Management of Change (MoC), Emergency Response Planning, and Contractor Management.

Imparting training just on PSM awareness to the employees will not be enough.  There are actions emerging out of every other PSM element and those must be carefully attended to.  As such HRP when working with clients often provides two levels of training to our client’s employees: (1) PSM Awareness and (2) Detailed PSM Training. Following are some, but not a complete list, of items included in a PSM Detailed level training:

• Maintenance persons must be trained in maintenance procedures within the covered process area, calibration of safety systems, calibration of emergency equipment, including but not limited to emergency sensors and ventilation systems.
• Operating and Maintenance persons must be trained in unit specific and job specific hazards and control measure.
• Every person handling a hot or hazardous work permit must be trained in the hot or hazardous work permit system from start to finish.
• For emergency response and planning in the covered process area, as well as for plant wide response, tabletop exercises should be carried out. Personnel should be trained in the proper response to emergency situations, such as fires, spills, and other hazardous events.
• Training should cover the proper storage and handling of hazardous materials, and the proper disposal of hazardous waste. 
• Training should also include instruction on the proper use of safety equipment, such as respirators, protective clothing, and safety glasses.  Personnel should also be trained in the proper use of safety signs and labels, as well as the proper use of safety equipment in hazardous areas. 
• Team members conducting PSSR, PHA and MOC must be thoroughly trained on specific procedures with relevant examples. An effective way for training is to complete beta exercises of the actual covered process.
• Personnel doing II must be trained on the immediate causes, finding root causes, and how to provide solutions or corrective actions to root causes.
• Each employee involved in operating equipment within the covered process needs to have detailed training of the process and the operating procedures associated with it, including steps for each operating phase. 
  • Initial startup
  • Normal operations
  • Temporary operations
  • Emergency shutdown
  • Emergency operations
  • Normal shutdown, and
  • Startup following a turnaround or emergency shutdown.
• Operating limits
  • Consequences of deviations and steps required to avoid deviations.
• Safety and health considerations
  • Properties and hazards of chemicals used and precautions for preventing exposure.
• Safety systems and their functions

Technology can be used to create interactive and engaging training material.  For example, multimedia presentations can be used to illustrate the principles of PSM in a way that is more engaging than traditional methods such as lectures and handouts.  Additionally, interactive simulations can be used to give employees a hands-on experience of how to identify and address potential hazards.  This can help to ensure that employees understand the importance of PSM and are better prepared to recognize and respond to potential hazards. 

Per regulation, PSM training must be conducted every 3 years from the date of initial training, OR when the changes to the cover process changes (NOTE- a MOC typically triggers updated training is required!) The benefits of PSM training activity planning, documentation and recording in PSM includes:

1. Improved safety:  by planning and recording training activities, employers can ensure that all workers are adequately trained in the safety procedures and protocols associated with their work.  This helps to reduce the risk of accidents and injuries, as workers are more likely to be aware of the potential hazards and how to handle them.
2. Increased efficiency:  by having a plan for training activities, employers can ensure that all workers are trained in the same way and that the training is up to date.  This helps to reduce the amount of time spent on training, as workers are more likely to be familiar with the safety procedures and protocols.
3. Improved compliance:  by planning and recording training activities, employers can ensure that they are meeting all the requirements of PSM.  This helps to reduce the risk of fines or other penalties for non-compliance, as employers can demonstrate that they are taking the necessary steps to ensure the safety of their workers.
4. Improved morale:  by providing adequate training to their workers, employers can demonstrate that they value their workers and are committed to their safety.  This can help to improve morale and increase employee engagement, as workers feel more secure in their work environment.

In conclusion, whether you are training one employee or 2,500 employees at a facility with a PSM covered process, concentrated focus and detail on process and procedure is paramount. Don’t just check a box to indicate you met the requirement---there’s too much at risk to take PSM training lightly.

Tad A. Goetcheus, PE is the COO/President of HRP Associates Inc. Mr. Goetcheus has been involved with all aspects of safety engineering consulting regarding PSM and has successfully participated or managed HRP’s PSM technically trained at over 100 client sites with covered processes in several US States and internationally. Please reach out to Mr. Goetcheus, or HRP’s staff at 800-246-9021 for assistance with your PSM project.

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Tad A. Goetcheus, PE, COO/President at HRP Associates, Inc.