SafeGuard PSMPSM Consulting
OSHA 1910.119Free PSM Resource
Retrofitting process safety into an operating facility can cost many times more than integrating it during design. SafeGuard Projects embeds PSM expertise from FEED through startup — so your facility launches compliant, safe, and on schedule.
Most capital projects treat PSM compliance as a pre-startup checklist item. By then, the P&IDs are frozen, the equipment is installed, and change orders are expensive. The cost of fixing a hazard multiplies at every project phase.
A P&ID hazard caught in FEED is a drawing revision. Caught after construction, it's a field modification, a schedule delay, and a budget overrun.
Procedures, training programs, mechanical integrity plans, and emergency response plans can't be written in the final weeks before startup. They need to be developed in parallel with the project.
An operating facility has years of operational learning built in. A startup has none. First-of-kind operations, untested procedures, and new crews require process safety to be right from the first day of operations.
Illustrative multipliers based on a widely cited industry rule of thumb for cost of change by project phase; actual costs vary by project. Early engagement is not an expense — it is cost avoidance at the largest possible scale.
Before SafeGuard Projects, our lead consultant held Plant Manager, Refinery Manager, PSM Manager and Commissioning Director roles on major capital projects — not as a compliance consultant, but as the person responsible for safe operations.
Responsible for all project PSM activities: PHAs, P&ID and model reviews, process safety information, and the PSM budget and schedule, with 10 direct reports. Then led commissioning for the same project.
Led the GTL Fuels/Derivatives area during FEED, with alignment work at existing facilities in South Africa, Nigeria, Qatar and Italy. The project was later postponed.
Plant Manager role during front-end engineering design for the Angola LNG export project.
Plant Manager role during front-end engineering design for Chevron’s Nigerian gas-to-liquids project.
We integrate at every phase of your project — from the earliest design sketches through first feed.
Front-End Engineering Design review from a process safety lens. We identify hazards before the design is committed, when changes cost the least and have the greatest impact. Process hazard screening, facility siting considerations, and inherent safety assessment.
Learn More →Systematic review of Piping and Instrumentation Diagrams against process safety requirements. Instrumentation completeness, relief system adequacy, isolation philosophy, human factors in control interface design, and RAGAGEP compliance of equipment specifications.
Hazard and Operability Study facilitation for new process designs. Unlike revalidation HAZOPs, new-design HAZOPs address unknowns, first-of-kind operations, and process interactions that have never been run in practice. We lead, document, and track every finding to resolution.
Learn More →Building a 14-element PSM program from a blank page is the ideal engagement — no legacy program to untangle, no resistance to change. We develop your entire program in parallel with project construction: written plans, procedures, training curricula, and management systems ready for Day 1 operations.
Learn More →Pre-Startup Safety Review (PSSR) development and execution. We work alongside your commissioning team to verify that all PSM elements are in place before any process fluid enters the equipment. Mechanical integrity verification, training confirmation, procedure validation, and safety system testing.
Learn More →On-site process safety support during initial startup operations. The most hazardous period for any facility is the first operating campaign — new procedures, untested equipment, and crews running a process for the first time. We provide experienced process safety presence when it matters most.
Learn More →Process safety is not a phase — it's a thread that runs through the entire project lifecycle. Here is where we integrate.
Hazard screening, facility siting, inherent safety assessment
We Engage HereP&ID review, HAZOP, relief system audit, PSI development
We Engage HerePSM program development, procedure writing, training design
We Engage HerePSSR execution, MI verification, system readiness confirmation
We Engage HereOn-site presence, MOC support, incident investigation readiness
We Engage HereOngoing PSM compliance — transition to SafeGuard PSM consulting
SafeGuard PSMOnce your facility is operational, our sister company SafeGuard PSM provides ongoing compliance consulting — creating a continuous relationship from construction through the life of the facility.
Most consultants show up before startup to check compliance boxes. We engage during FEED and detailed design — when a P&ID change costs a drawing revision, not a field modification.
No legacy program to work around. No embedded culture resistant to change. We build compliant, sustainable PSM programs from a blank page — the best possible starting condition.
When your facility transitions from startup to operations, SafeGuard PSM provides ongoing compliance consulting. One firm relationship from construction through the life of your facility.
Our team has studied 111 CSB incident investigations. Most catastrophic failures trace back to design decisions made years before the event. We know where to look.
Saves an estimated $10–$100 during construction and operations. The earlier the investment in process safety, the greater the return.
All 14 elements of 29 CFR 1910.119 must be in place before startup. We build them all, in parallel with your project schedule.
Completed CSB investigations analyzed element by element. We know the failure patterns. We know where programs break down. We build to avoid them.
When the PSSR is signed and first feed begins, your program is complete, your crew is trained, and your facility is compliant from the first day of operations.
Sasol US Mega Projects ($12B) and Sasol GTL ($18B), plus FEED-phase roles on Angola LNG and Nigerian GTL. Not simulated. Not case-studied. Lived.
Two consultants who came up through operations — not academia, not compliance offices. Decades of real process experience between them.
Crude distillation, reforming, hydrocracking, FCC, alkylation, hydrogen and methanol/ammonia plants, ethane crackers, LNG, and more. The hazards look different in every unit, and we have worked them firsthand.
Process safety management consulting for operating facilities. Gap assessments, audit preparation, program development, and element-specific consulting for covered processes under 29 CFR 1910.119.
Operating FacilitiesCapital project process safety integration. FEED review, P&ID hazard analysis, HAZOP, PSM program development, commissioning support, and startup assistance for new construction and greenfield facilities.
Capital Projects & New ConstructionFree, authoritative reference for 29 CFR 1910.119. The complete regulation, all 30 OSHA Letters of Interpretation, Appendix A chemical database, PHA calculator, citation library, and PSM glossary.
Free Reference ResourceThe best time to engage SafeGuard Projects is the moment a capital project is approved. The second best time is now.
Every engagement starts with a conversation about your project — scope, timeline, phase of development, and where process safety needs to integrate. There is no commitment, no obligation, and no sales pitch. Just a direct conversation with experienced process safety professionals.