Over the past several years car manufacturers have been making the change over to their new GW reduction refrigerant which just happens to be a Category 1 Flammable Gas, thus making this material a Highly Hazardous Chemical in the eyes of OSHA. And when we have over 10,000 pounds of this HHC in our “process” this process becomes a PSM Covered Process. This article is an attempt to explain how the “process” can be designed using INHERENTLY SAFE DESIGN principles which will keep the process OUT OF PSM application AND MORE IMPORTANTLY it LOWERS the RISK associated with processing this HHC.