Ammonia is a highly efficient and environmentally friendly refrigerant widely used in industrial refrigeration. However, despite its natural benefits, ammonia’s toxicity requires stringent safety measures to prevent leaks and ensure the well-being of personnel and surrounding communities.
For industrial refrigeration businesses, complying with Process Safety Management (PSM) regulations isn’t just a legal requirement—it’s essential for maintaining operational efficiency, protecting employees, and ensuring business continuity. With stringent OSHA and EPA guidelines in place, an unfocused or outdated PSM program can lead to costly violations, increased risk, and potential shutdowns.
Here’s how to keep your PSM program sharp and effective
- Conduct Regular Audits and Reviews
PSM is not a “set it and forget it” program. Regular Process Hazard Analyses (PHAs) and compliance audits are critical to identifying gaps, ensuring proper documentation, and keeping procedures up to date. Conducting these audits at least every three years and acting on findings promptly can help mitigate risks and avoid costly penalties.
- Keep Your Mechanical Integrity Program Strong
A well-maintained mechanical integrity program ensures that refrigeration equipment operates safely and efficiently. Regular inspections, testing, and preventive maintenance are crucial in preventing leaks, failures, and unexpected downtime. Ensure all equipment is assessed according to manufacturer recommendations, industry standards, and regulatory requirements.
- Prioritize Employee Training and Participation
Your PSM program is only as strong as the people who implement it. Regularly training employees on operating procedures, emergency response, and hazard recognition is key to a compliant and safe work environment. Engaging employees in safety discussions, near-miss reporting, and continuous improvement efforts can help create a culture of safety and accountability.
- Ensure Accurate and Up-to-Date Documentation
PSM compliance requires meticulous documentation, including operating procedures, training records, equipment inspections, and incident investigation reports. Incomplete or outdated records can lead to compliance failures during inspections. Implementing a digital management system can help streamline recordkeeping and improve accessibility.
- Be Prepared for Regulatory Inspections
Regulatory inspections can happen at any time, and being prepared is crucial. Conduct internal audits, maintain organized records, and ensure all employees understand their roles during an inspection. Developing a robust response plan for potential compliance questions can help your facility navigate inspections smoothly.
How Bassett Mechanical Can Help
At Bassett Mechanical, we take PSM compliance seriously. Since introducing our PSM services in 2014, we have worked with customers across North America to develop and maintain comprehensive safety programs tailored to their needs. Our team of experts, including PSM Compliance Specialists and mechanical integrity professionals, provides full-service support for PSM and Risk Management Program (RMP) compliance.
Our services include:
- Developing a complete 14-element written PSM program
- Facilitating Process Hazard Analyses (PHAs)
- Conducting 3-year PSM compliance audits and 5-year mechanical integrity inspections
- Developing process safety information such as refrigerant charge calculations, piping and instrumentation diagrams, and relief system design calculations
- Creating and updating equipment and system operating procedures
- Assisting with Management of Change (MOC) and Pre-startup Safety Review (PSSR) processes
- Providing training on ammonia refrigeration system theory, safe operation and regulatory compliance
- Offering compliance management software solutions as an APSM Certified Partner
Ryan M., Bassett Mechanical’s Director of PSM Services, emphasizes the importance of staying proactive with compliance saying, “Not only do we develop PSM programs, but we also help our customers maintain them and keep them up to date to ensure they stay compliant with OSHA and EPA requirements. We’ve encountered many instances where critical safety processes were missing or not being followed. In some cases, we have identified emergency shutdown systems that didn’t function at all, posing a serious risk to worker safety, equipment damage, and a catastrophic release. Our mission is simple—helping businesses maintain safe, compliant, and efficient operations.”
Keeping Your PSM Program Strong for the Long Haul
A focused and proactive PSM program is essential for industrial refrigeration businesses to ensure compliance, safety, and efficiency. Your business can stay ahead of regulatory requirements and operational risks by regularly auditing processes, strengthening mechanical integrity, prioritizing training, maintaining accurate records, and preparing for inspections. Bassett Mechanical is here to support you every step of the way with expert guidance, compliance solutions, and hands-on training. Don’t wait for an incident to force improvements—contact us today to help keep your PSM program concentrated and effective year-round.
