A local client has requested another 40-hr Process Safety Management course and we have scheduled it for the first week of April 2018.  The course will be at:

Sugar Creek Packing Company

2600 N James H McGee Blvd

Dayton, OH 45417

NOTE: this is the same location that held the "Safety for PSM/RMP Managers" course.

Time:  8:00 - 4:00 p.m.

Cost:  $1,200.00 (Three or more from the same company gets a 25% reduction)

Lunch provided


As you can see from the agenda below, this course allows me time to get into some RAGAGEPs like piping installations, pressure vessels, relief systems, etc.  As well, we will dip our toes into the International Fire Code (IFC), International Building Code (IMC), and the International Building Code (IBC) as "building blocks" to process safety and just good old fashion hazardous materials management.

I teach this course using the PREVENT-PROTECT-MITIGATE methodology as well as “layers of protection” using our Hierarchy of Controls (Engineering, Administrative, and PPE.  Using OSHA's and EPA's process safety standards as our guide, we will discuss applicability and means/methods to DEVELOP, IMPLEMENT, and MANAGE a functioning process safety management system for each requirement.

Here is the course agenda:





  • OSHA's Process Safety Management (29 CFR 1910.119)
    • "Process" and "Co-Location" discussion
    • Ways to manage inventories
  • EPA's Risk Management Plan (40 CFR Part 68)
  • OSHA's Exceptions:
    • Retail facilities
    • Oil or gas well drilling or servicing operations
    • Normally unoccupied remote facilities
  • EPA's Three (3) Program Levels
  • Difference in OSHA's List of Substances and EPA's List of Substances and their thresholds (Flammables, Toxics, and Thresholds)
  • EPA's Programs Process eligibility requirements
    • Program 1 eligibility requirements
    • Program 2 eligibility requirements
    • Program 3 eligibility requirements
  • EPA's Off-Site Consequence Analysis (WCS & ARS)
  • PROPOSED changes by EPA and OSHA and their impacts


Key Definitions


Employee Participation

  • Application
  • Written Plan/Program
  • Employers "consulting" with employees and/or representatives
  • Access to PSM/RMP information




Process Safety Information (PSI)

  • Information pertaining to the hazards of the HHC/EHSs

Special discussion: Hazardous effects of inadvertent mixing of different materials that could foreseeably occur

  • Information pertaining to the technology of the process
    • A block flow diagram or simplified process flow diagram
    • Process chemistry
    • Maximum intended inventory
      • What is it and why does OSHA EPA require us to establish this and how we can justify our inventories
    • Safe upper and lower limits for such items as temperatures, pressures, flows or compositions
      • How these DESIGN safe upper and lower limits differ from those OPERATING safe upper and lower limits
    • An evaluation of the consequences of deviations, including those affecting the safety and health of employees
      • A design PHA of sorts
  • Information pertaining to the equipment in the process
    • Materials of Construction
    • Piping and Instrument Diagrams (P&ID's)
    • Electrical Classification
      • Depending on the makeup of the class we will discuss the exemptions in NFPA 70 for Ammonia Refrigeration and if needed discuss Classes, Divisions, and Groups
      Relief System Design and Design Basis
      • Design Basis (Rupture Disc, Valves, Dual Systems, Intervening Valves Car-Seal requirement)
      • Sizing Analysis (Fire, Blocked-In, etc.)
    • Ventilation System Design
    • Design codes and standards employed 
      • Discuss some basic requirements from ASME Section VIII, ASME B31.3, ASME A13.1, IFC, etc. to demonstrate how these become standards to follow/meet
    • Material and Energy Balances
    • Safety Systems (e.g. interlocks, detection or suppression systems)
  • Documenting that equipment complies with RAGAGEPs

Process Hazard Analysis (PHA)

  • Application
  • Scope and Complexity
    • Previous incidents which had a likely potential for catastrophic consequences in the workplace
    • Engineering and administrative controls applicable to the hazards and their interrelationships
    • Consequences of failure of engineering and administrative controls
    • Facility Siting (using RAGAGEPs and IFC for spacing/location limits)
    • Human Factors
  • Hazards involved in the process
  • Priority Order
  • Methodologies (7)
  • A qualitative evaluation of a range of the possible safety and health effects of failure of controls
  • PHA team(s) 
  • Management System to manage team's findings and recommendations
  • Resolution Documented
  • Revalidation at least every five (5) years
  • Report Retention




Operating Procedures (SOPs and SWPs)

  • Steps for each operating phase:
    • Initial startup
    • Normal operations
    • Temporary operations
    • Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner.
    • Emergency Operations
    • Normal shutdown
    • Startup following a turnaround, or after an emergency shutdown
  • Operating Limits:
    • Consequences of deviating from those limits
    • Steps required to correct or avoid the deviation
    Safety and Health Considerations:
    • Properties of, and hazards presented by, the chemicals used in the process
    • Precautions necessary to prevent exposure, including engineering controls, administrative controls, and PPE
    • Control measures to be taken if physical contact or airborne exposure occurs
    • Quality control for raw materials and control of hazardous chemical inventory levels
    • Any special or unique hazards
  • Safety Systems and their functions
  • Accessibility
  • Review and Annual Certification
  • Safe Work Practices 



  • Initial training
    • Overview of the process and SOPs 
    • Emphasis on the specific safety and health hazards, emergency operations including shutdown, and safe work practices
  • Refresher Training Frequency
  • Training Documentation
  • Means used to verify knowledge


  • Application
  • Process Owner/Operator Responsibilities
  • Contract Employer Responsibilities


Pre-startup Safety Review (PSSR)

  • Application
    • New facilities
    • Modified facilities (change in the PSI)
  • Function
    • Confirm that prior to the introduction of HHC(s)/EHS(s) to a process:
    • Construction and equipment is in accordance with design specifications;
    • Safety, operating, maintenance, and emergency procedures are in place and are adequate;
    • For new facilities, a PHA has been performed and recommendations have been resolved or implemented before startup;
    • Modified facilities meet the requirements contained in the MOC
    • Training of each employee involved in operating a process has been completed.


 DAY 4


Mechanical Integrity (MI)

  • Application
    • Pressure vessels and storage tanks
    • Piping systems (including piping components such as valves)
    • Relief and vent systems and devices
    • Emergency shutdown systems
    • Controls (including monitoring devices and sensors, alarms, and interlocks) and
    • Pumps
  • Written Procedures
  • Training for maintenance activities
  • Inspection and Testing
    • Inspections and tests shall be performed on process equipment.
    • Inspection and testing procedures shall follow RAGAGEPs (Manufacturer's Recommendations)
    • Frequency of inspections and tests
    • Documentation of each inspection and test
  • Equipment Deficiencies
  • Quality Assurance


Hot Work Permit

  • 29 CFR 1910.252(a)
  • NFPA 51B
  • Permits
    • Content
    • Issuing/Approving


Management of Change (MOC)

  • Application
  • Function
  • Written Program
    • Technical basis for the proposed change
    • Impact of change on safety and health
    • Modifications to operating procedures
    • Necessary time period for the change
    • Authorization requirements
  • Communication and Training of Changes
  • Updating PSI and SOPs/SWPs



Incident Investigation

  • Application
  • Timing
  • Team
  • Root Cause Analysis
  • Report
  • Recommendation Tracking
  • Communication
  • Retention


Emergency Planning and Response

  • Application of 1910.38 and 1910.120 (EPA's 40 CFR PART 311—WORKER PROTECTION)
  • Program(s) Content
  • Training
  • Staffing
  • Equipping
  • Inspections/Testing
  • Medical Evals

Compliance Audits

  • Application
  • Frequency
  • Team
  • Report
  • Action Plan
  • Retention


Trade Secrets

  • Application
  • Access



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2018 Training Calendar


ASSE SeminarFest


Intro to Process Safety Management

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BLR Webinar 

Confincd Space Rcscue - OSHA's Latest Requirements,

Safety & Best Practices, and Common Mistakes to Avoid

3/13/18 from 1:30 to 3 pm ET 

75 minute presentation followed by 15 minute Q&A


Process Safety Training

April 2-6, 2018

2600 N James H McGee Blvd

Dayton, OH 45417

CLICK HERE for more info


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