Process Safety Management Assessment of Liquefied Petroleum Gas Bottling Plants in Lagos State: Gaps and Improvement Strategies

The proliferation of liquefied petroleum gas bottling plants in Lagos State, South West Nigeria, has outpaced regulatory oversight, resulting in a documented history of fire incidents, explosions, and occupational fatalities. This study assesses the level of compliance with the Process Safety Management elements prescribed by the United States Occupational Safety and Health Administration 29 CFR 1910.119 standard among ten LPG bottling plants in Lagos State, selected by stratified random sampling from operators licensed by the Nigerian Midstream and Downstream Petroleum Regulatory Authority. Data were collected through structured facility audits, document reviews, and key informant interviews with plant safety officers and regulatory inspectors. Compliance scoring was performed against 14 PSM elements including process hazard analysis, mechanical integrity, operating procedures, management of change, emergency planning, and incident investigation. Audit results revealed that no facility achieved full compliance with all 14 PSM elements. Average compliance scores ranged from 31 to 68%, with the lowest scores recorded for management of change (28% average), process hazard analysis (33%), and mechanical integrity (37%). Facilities with dedicated safety officers scored significantly higher than those without. Common deficiencies included absence of documented operating procedures, irregular pressure vessel inspections, and no formal incident learning systems. The study recommends a risk-tiered PSM compliance incentive framework for the Nigerian Midstream and Downstream Petroleum Regulatory Authority to prioritise high-risk facilities in Lagos for mandatory improvement. Keywords: process safety management, LPG bottling, compliance audit, Lagos State, NMDPRA