Process Safety Management
Managing Process Risk. Strengthening Mechanical Integrity. Improving Operational Reliability.
Appalachian EHS & Process Safety Consulting, LLC provides comprehensive process safety consulting services to chemical manufacturing, petrochemical, energy, Oil & Gas, and other industrial operations nationwide.
Our services support the development, implementation, evaluation, and continuous improvement of process safety management systems, with particular expertise in OSHA Process Safety Management (29 CFR 1910.119), EPA Risk Management Program (40 CFR Part 68), mechanical integrity, and risk-based process safety practices.
We work alongside operations, engineering, maintenance, and facility leadership to develop practical, technically defensible solutions that address process hazards, equipment integrity, operational risk, and regulatory requirements.
PSM & RMP Compliance
OSHA PSM and EPA RMP applicability assessments
Comprehensive PSM compliance audits
PSM program development and implementation
Process safety information (PSI) development and validation
Operating procedure development and evaluation
Management of Change (MOC) program development
Pre-Startup Safety Reviews (PSSR)
Contractor qualification (safety review), management and employee participation programs
Process safety performance metrics and KPI development
Process Hazard Analysis & Risk Assessment
Process Hazard Analysis (PHA) facilitation
HAZOP, What-If, Checklist, and hybrid methodologies
PHA revalidation and recommendation management
Layers of Protection Analysis (LOPA)
Independent Protection Layer (IPL) evaluation
Safety Instrumented Systems (SIS) assessments
Safety Integrity Level (SIL) determination support
Facility siting and human factors assessments
Risk ranking and safeguard evaluation
Our Process Safety Capabilities
Mechanical Integrity & Asset Reliability
Mechanical Integrity (MI) program development
MI Quality Assurance (MIQA)
Asset Criticality Ranking (ACR)
Risk-Based Inspection (RBI) program support
Inspection and preventive maintenance program evaluations
Pressure equipment and piping integrity program support
Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) assessments
Equipment deficiency identification and management
Supplier and contractor quality assurance
Incident Investigation & Operational Learning
Process safety incident investigations
Root Cause Analysis (RCA)
Equipment failure investigations
Corrective action development and verification
Organizational and human factors evaluations
Recurring incident and process deviation analysis
Human and Organizational Performance (HOP) principles
Beyond Regulatory Compliance
Effective process safety management requires more than maintaining documentation or completing periodic regulatory audits.
Our approach emphasizes the relationship between people, equipment, operating conditions, management systems, and organizational decision-making.
We help clients establish sustainable programs that identify weaknesses before they contribute to significant operational events, improve management of process risk, and strengthen the reliability of critical safeguards.
Flexible Process Safety Support
Whether you need an independent PHA facilitator, a mechanical integrity program assessment, a comprehensive PSM audit, or ongoing process safety leadership support, Appalachian EHS can tailor its services to your facility's operational and regulatory needs.
Need specialized process safety support?
Contact Appalachian EHS to discuss your facility, process hazards, and project requirements.
PSM Program Improvement
PSM element ownership and accountability
Compliance gap assessments
Process safety management system development
Leading and lagging performance indicators
Action item tracking and management review
Program sustainment and continuous improvement
Supplemental process safety leadership and technical support