736 Introduction to Process Safety Management (PSM)

Glossary

A

Accident. An unplanned event that results in injury, illness, or damage to property, requiring investigation and corrective action to prevent recurrence.
Administrative controls. Policies, procedures, and practices implemented to reduce risk and ensure safety in the workplace, often involving training, supervision, and scheduling.
Atmospheric tank. A storage tank which has been designed to operate at pressures from atmospheric through 0.5 p.s.i.g. (pounds per square inch gauge, 3.45 Kpa).

B

Baseline. The initial set of data, configurations, or specifications used as a reference point for future comparison or analysis in the management of change process.
Baseline survey. An initial assessment conducted to establish a reference point for monitoring changes and improvements in process safety management.
Block flow diagram. A simplified diagram representing the major processes within a system, illustrating the flow of materials and key equipment.
Boiling point. The boiling point of a liquid at a pressure of 14.7 pounds per square inch absolute (p.s.i.a.) (760 mm). For the purposes of this section, where an accurate boiling point is unavailable for the material in question, or for mixtures which do not have a constant boiling point, the 10 percent point of a distillation performed in accordance with the Standard Method of Test for Distillation of Petroleum Products, ASTM D-86-62, which is incorporated by reference as specified in §1910.6, may be used as the boiling point of the liquid.

C

Catastrophic release. A major uncontrolled emission, fire, or explosion, involving one or more highly hazardous chemicals, that presents serious danger to employees in the workplace.
Change Management Plan. A document outlining the strategies, resources, and actions needed to implement and control changes within an organization, ensuring minimal disruption and maximum efficiency.
Change Request. A formal proposal submitted to modify a product, service, or process, detailing the nature, rationale, and potential impact of the change.
Checklist. A tool used to ensure all necessary steps and considerations are addressed during process safety management activities, promoting thoroughness and consistency.
Chemical stability data. Information on the stability of a chemical substance under various conditions, essential for safe storage and handling.
Compliance Audit. A systematic review conducted to ensure that a facility's process safety management practices comply with regulatory requirements and internal standards.
Configuration Management. A systematic approach to managing and tracking changes in software, hardware, and documentation to ensure consistency and control throughout the project lifecycle.
Consequences of deviation. The potential outcomes and impacts resulting from deviations from established operating procedures or process parameters.
Contract. A formal agreement between a company and a contractor detailing the scope of work, responsibilities, and safety requirements.
Contractor. An external individual or organization hired to perform specific tasks or services, required to adhere to the facility's safety standards and procedures.
Contractor Safety. Ensuring that contractors working on or near covered processes are aware of the potential hazards and adhere to safe work practices.
Corrosivity data. Information on the corrosive properties of a chemical, indicating its potential to degrade materials and cause damage to equipment.
Covered Process. Any process involving a highly hazardous chemical where the chemical is present in quantities at or above the specified threshold quantities listed in OSHA 1910.119.

D

Detection system. A system designed to identify the presence of hazardous conditions, such as gas leaks or fires, enabling timely response to prevent incidents.

E

Emergency action plan (EAP). A detailed plan outlining the actions to be taken by employees in response to various emergencies, ensuring their safety and well-being.
Emergency operations. Procedures and protocols for safely managing and responding to emergency situations within a facility.
Emergency Planning and Response. Procedures and protocols established to protect employees and the public in the event of an emergency involving hazardous chemicals.
Emergency response plan (ERP). A comprehensive plan detailing the strategies, resources, and actions required to effectively respond to and manage emergency situations.
Employee Participation. The involvement of employees in the development, implementation, and application of safety and health programs, including process hazard analyses and incident investigations.

F

Facility. The buildings, containers, or equipment which contain a process.
Facility citing. The process of selecting a suitable location for a facility, taking into account safety, environmental, and logistical considerations.
Failure mode and effects analysis (FMEA). A systematic method for identifying potential failure modes, their causes and effects, and prioritizing corrective actions to enhance reliability and safety.
Fault-tree analysis. A deductive technique used to analyze the causes of system failures by mapping out the logical relationships between faults and their contributing factors.

H

Hazard Analysis. The identification and evaluation of potential hazards associated with processes and equipment to prevent accidents and ensure safety.
Hazard and operability study (HAZOP). A structured and systematic examination of a process or operation to identify and evaluate potential hazards and operational issues.
Hazard elimination. The process of completely removing a hazard from the workplace to ensure the highest level of safety.
Hazard substitution. The practice of replacing a hazardous substance or process with a less hazardous one to reduce risk.
Hierarchy of controls (HOC). A framework used to minimize or eliminate exposure to hazards, prioritizing controls from most effective (elimination) to least effective (PPE).
Highly hazardous chemical. A substance possessing toxic, reactive, flammable, or explosive properties and specified by paragraph (a)(1) of this section.
Hot work. Work involving electric or gas welding, cutting, brazing, or similar flame or spark-producing operations.
Hot Work Permit. A written authorization required to perform operations that involve open flames or heat, which could ignite flammable materials in the work area.
Human factors. The study of how people interact with their work environment, equipment, and processes to improve safety, performance, and well-being.

I

Impact Analysis. The process of assessing the potential consequences of a proposed change, including effects on resources, processes, and stakeholders.
Implementation Plan. A detailed schedule outlining the steps, resources, and timeline required to successfully execute a change within an organization.
Incident Investigation. A procedure to investigate incidents that resulted in, or could have resulted in, a catastrophic release of hazardous chemicals.
Interlock. A safety mechanism designed to prevent dangerous conditions by ensuring that certain conditions are met before a process can proceed.

L

Lower explosive level (LEL). The lowest concentration of a gas or vapor in air capable of producing a fire or explosion.
Lower flammability level (LFL). The minimum concentration of a vapor in air below which a flame cannot propagate, similar to LEL.

M

Management of Change (MOC). A formal process for managing changes to process chemicals, technology, equipment, procedures, and facilities to ensure that safety and health are not compromised.
Manifest. A detailed record or document listing the contents, destination, and other pertinent information about a shipment or cargo, ensuring accountability and traceability during transportation.
Mechanical Integrity. Ensuring that critical process equipment is designed, installed, operated, and maintained to prevent failures and accidental releases of hazardous chemicals.
Modification. Any change to equipment, procedures, raw materials, or processes that could impact safety, requiring evaluation and management through change control processes.

N

Near-miss. An event that could have resulted in an accident, injury, or damage but did not, providing an opportunity for learning and prevention.
Normally unoccupied remote facility. A facility which is operated, maintained, or serviced by employees who visit the facility only periodically to check its operation and to perform necessary operating or maintenance tasks. No employees are permanently stationed at the facility. Facilities meeting this definition are not contiguous with, and must be geographically remote from all other buildings, processes, or persons.
Normal operations. The routine activities and procedures carried out to maintain process stability and achieve production goals under standard conditions.

O

Operating Procedures. Clear instructions for safely conducting activities involved in each covered process consistent with the process safety information.

P

Physical data. Information on the physical properties of a chemical, such as boiling point, melting point, and vapor pressure, essential for safe handling and storage.
Pre-startup safety review (PSSR). A thorough check conducted before starting up new or modified equipment or processes to ensure that all safety requirements are met.
Pre-Startup Safety Review (PSSR). A review conducted to confirm that new or modified facilities meet safety and operational requirements before startup.
Process. Any activity involving a highly hazardous chemical including any use, storage, manufacturing, handling, or the on-site movement of such chemicals, or combination of these activities. For purposes of this definition, any group of vessels which are interconnected and separate vessels which are located such that a highly hazardous chemical could be involved in a potential release shall be considered a single process.
Process chemistry. The study of the chemical reactions and conditions involved in a process, crucial for understanding and controlling potential hazards.
Process equipment. The machinery, piping, vessels, and other components used in a process, requiring proper design, maintenance, and operation to ensure safety.
Process flow diagram. A detailed diagram illustrating the flow of materials and energy through a process, showing equipment, pipelines, and control systems.
Process Hazard Analysis (PHA). A thorough, orderly, and systematic approach for identifying, evaluating, and controlling the hazards of processes involving highly hazardous chemicals.
Process Safety Information (PSI). Comprehensive information pertaining to the highly hazardous chemicals used or produced by the process, information concerning the technology of the process, and information concerning the equipment in the process.
Process Safety Management (PSM). A regulatory standard aimed at preventing the release of highly hazardous chemicals, especially into locations that could expose employees and others to serious hazards.
Properties of chemical hazards. Characteristics of chemicals that determine their potential to cause harm, including toxicity, flammability, and reactivity.

Q

Qualitative analysis. A non-numerical examination of data to identify patterns, trends, and potential hazards, often used in initial hazard assessments.
Quantitative analysis. A numerical assessment of data to measure and evaluate risks, often involving statistical methods and mathematical modeling.
Quality control. The process of ensuring products and processes meet specified standards and requirements, essential for maintaining safety and performance.

R

Reactivity data. Information on the chemical reactivity of a substance, including its potential to undergo hazardous reactions under certain conditions.
Relief system. A safety mechanism designed to release excess pressure or material from a process to prevent equipment failure or catastrophic events.
Replacement in kind. A replacement which satisfies the design specification.
Risk Assessment. The systematic identification and evaluation of potential risks associated with a proposed change, aiming to mitigate negative impacts on the organization.

S

Safety data sheet (SDS). A document that provides detailed information on the properties, hazards, handling, and emergency measures related to a chemical substance.
Safety Instrumented Systems (SIS). Automated systems designed to prevent or mitigate hazardous events by taking corrective action when a process parameter exceeds its safe limit.
Safety system. An integrated set of controls and equipment designed to ensure the safe operation of processes, including alarms, interlocks, and emergency shutdown systems.
Shutdown. The process of safely stopping a process or operation, typically for maintenance, inspection, or emergency situations.
Stakeholder Analysis. The process of identifying and evaluating the interests, influence, and impact of individuals or groups that may be affected by or have an interest in a proposed change.
Suppression system. A system designed to control or extinguish fires, such as sprinklers or gas-based suppression systems, to protect people and property.

T

Technical Review. An in-depth examination of the technical aspects of a proposed change to ensure feasibility, safety, and compliance with standards and regulations.
Thermal data. Information on the thermal properties of a substance, including its heat capacity, thermal conductivity, and stability, important for process safety.
Toxicity. The degree to which a substance can cause harm to living organisms, critical for assessing the health risks associated with chemical exposure.
Trade secret. Any confidential formula, pattern, process, device, information, or compilation of information that is used in an employer's business, and that gives the employer an opportunity to obtain an advantage over competitors who do not know or use it. See Appendix E to �1910.1200 � Definition of a Trade Secret (which sets out the criteria to be used in evaluating trade secrets).
Training Program. A structured plan to educate and qualify employees on the safe operation and maintenance of processes, ensuring they understand and adhere to process safety management practices.

U

Upper explosive level (UEL). The highest concentration of a gas or vapor in air capable of producing a fire or explosion.
Upper flammability level (UFL). The maximum concentration of a vapor in air above which a flame cannot propagate, similar to UEL.

V

Ventilation system. A system designed to control the indoor air quality by diluting and removing hazardous substances from the air, ensuring a safe working environment.
Verification. The process of checking and confirming that a change has been correctly implemented according to the specified requirements and plans.

W

Warning controls. Visual, audible, or other signals used to alert personnel to the presence of hazards, prompting immediate action to mitigate risk.
What-if analysis. A brainstorming technique used to identify potential hazards and evaluate their consequences by asking "what if" scenarios.
Work-practice controls. Methods that modify the way tasks are performed to reduce exposure to hazards, including job rotation, safe work procedures, and training.