Implementation guide for process safety management

Abstract A general guide how to implement process safety management (PSM) is missing in the literature. This article provides general procedure to implement PSM which any industry in underdeveloped, developing and developed countries can adopt to start PSM implementation. PSM implementation can be initiated through the proposed framework consisting of four steps: (1) PSM introduction, (2) Assigning departmental wise PSM duties, (3) Trainings and (4) Audits and improvements. Trainings include process hazard analysis (PHA) using Integrated What‐If/HAZOP analysis, quantitative risk assessments using ALOHA or equivalent software, PSM forms developments and other trainings. In a case study, ammonia release is estimated and quantified using ALOHA. Nine various forms for PSM are required to be developed for industry implementing PSM. Various trainings should be arranged including specific learning outcomes and few examples are discussed in this article. An audit scheme is proposed for any new industry implementing PSM. PSM elements implementation sequence is discussed. New established industries can adopt this procedure to implement PSM following suggested forms and sequences, which can help engineers in understanding PSM implementation. This PSM implementation proposed framework is being implemented in the fertilizer industry and caustic industry.