Integrating process safety management into Canadian wood pellet facilities that generate combustible wood dust

Abstract Wood pellets, which are manufactured from sawmill and forest residues, are sold in bulk for biomass power generation or in bags for residential heating. Wood pellet production involves combustible dust, which presents the risk of fires and explosions. Process safety management (PSM) is a framework for preventing and mitigating process‐related incidents. While PSM has historically been integrated within the chemical process industries, there is a need to systematically manage process‐related hazards in other sectors, including wood pellet and wood product manufacturing. However, there is a need to identify an approach to PSM implementation that is reasonable and achievable based on the relative complexity of the production process, as well as onsite resources. The scope of this project was to develop an integration tool for wood pellet production to serve as the foundation for a long‐term strategy and implementation plan led by industry. This research resulted in a PSM integration tool consisting of a PSM survey for gap analysis, self‐assessment worksheets that include numerous PSM best practices, factsheets, and an implementation strategy. Using the CSA Z767 Process Safety Management standard as the basis, the research included the development of a phased approach to integrating PSM elements to help improve feasibility. The selection of PSM element phases was informed by surveys of operations and subject matter experts. This research recognizes that, while PSM is currently mostly voluntary in Canada, some organizations have adopted the CSA Z767 standard into regulations and proactively implementing a PSM framework will position companies well should regulations change.