Process Safety

Management

U.S. Department of Labor

Occupational Safety and Health Administration

OSHA 3132

2000 (Reprinted)
This informational booklet is

intended to provide a generic,

non-exhaustive overview of a

particular standards-related topic.

This publication does not itself

alter or determine compliance

responsibilities, which are set

forth in OSHA standards themselves and the Occupational

Safety and Health Act. Moreover,

because interpretations and

enforcement policy may change

over time, for additional guidance

on OSHA compliance requirements, the reader should consult

current and administrative interpretations and decisions by

the Occupational Safety and

Health Review Commission

and the Courts.

Material contained in this publication is in the public domain and

may be reproduced, fully or

partially, without permission

of the Federal Government.

Source credit is requested but

not required.

This information will be made

available to sensory impaired

individuals upon request.

Voice phone: (202) 693-1999
Process Safety

Management

U.S. Department of Labor

Alexis M. Herman, Secretary

Occupational Safety and Health Administration

Charles N. Jeffress, Assistant Secretary

OSHA 3132

2000 (Reprinted)
Contents

Contents iii

The Problem .......................................................................... 1

How the Standard Works ....................................................... 5

Process Safety Information ................................................... 7

Process Hazard Analysis ....................................................... 9

Operating Procedures .......................................................... 12

Employee Participation ....................................................... 14

Training ................................................................................ 15

Initial Training ............................................................ 15

Refresher Training ...................................................... 15

Training Documentation ............................................. 15

Contractors .......................................................................... 16

Application ................................................................. 16

Employer Responsibilities .......................................... 16

Contract Employer Responsibilities ........................... 16

Pre-Startup Safety Review .................................................. 18

Mechanical Integrity ............................................................ 19

Hot Work Permit .................................................................. 21

Management of Change ...................................................... 22

Incident Investigation .......................................................... 23

Emergency Planning and Response .................................... 24

Compliance Audits ............................................................... 25

Trade Secrets ....................................................................... 26

Part 1910-Occupational Safety and Health Standards........ 27

§ 1910.109 Explosives and Blasting Agents ....................... 27

§ 1910.119 Process Safety Management of

 Highly Hazardous Chemicals........................................... 28

Appendix A - List of Highly Hazardous Chemicals,

 Toxics and Reactives (Mandatory) .................................. 42

Appendix B - Block Flow Diagram and Simplified Process

 Flow Diagram (Nonmandatory) ....................................... 46

OSHA Consultation Directory .............................................. 48

States With Approved Plans ................................................ 50

Related Publications ........................................................... 54
The Problem

The Problem 1

Unexpected releases of toxic, reactive, or flammable liquids and

gases in processes involving highly hazardous chemicals have been

reported for many years. Incidents continue to occur in various

industries that use highly hazardous chemicals which may be toxic,

reactive, flammable, or explosive, or may exhibit a combination of

these properties. Regardless of the industry that uses these highly

hazardous chemicals, there is a potential for an accidental release any

time they are not properly controlled. This, in turn, creates the

possibility of disaster.

Recent major disasters include the 1984 Bhopal, India, incident

resulting in more than 2,000 deaths; the October 1989 Phillips

Petroleum Company, Pasadena, TX, incident resulting in 23 deaths

and 132 injuries; the July 1990 BASF, Cincinnati, OH, incident

resulting in 2 deaths, and the May 1991 IMC, Sterlington, LA,

incident resulting in 8 deaths and 128 injuries.

Although these major disasters involving highly hazardous

chemicals drew national attention to the potential for major catastrophes, the public record is replete with information concerning many

other less notable releases of highly hazardous chemicals. Hazardous chemical releases continue to pose a significant threat to employees and provide impetus, internationally and nationally, for authorities to develop or consider developing legislation and regulations to

eliminate or minimize the potential for such events.

On July 17, 1990, OSHA published in the Federal Register (55 FR

29150) a proposed standard,—”Process Safety Management of

Highly Hazardous Chemicals”—containing requirements for the

management of hazards associated with processes using highly

hazardous chemicals to help assure safe and healthful workplaces.

OSHA’s proposed standard emphasized the management of

hazards associated with highly hazardous chemicals and established

a comprehensive management program that integrated technologies,

procedures, and management practices.

The notice of proposed rulemaking invited comments on any

aspect of the proposed standard for process safety management of

highly hazardous chemicals and announced the scheduling of a

hearing to begin on November 27, 1990, in Washington, DC.

On November 1, 1990, OSHA published a Federal Register notice

(55 FR 46074) scheduling a second hearing to begin on February 26,
Process Safety Management

2

1991, in Houston, TX, enumerating additional issues, and extending

the written comment period until January 22, 1991.

The hearings on the proposed standard were held in Washington,

DC, from November 27, 1990, through December 4, 1990, and in

Houston, TX, from February 26, 1991, through March 7, 1991. The

Administrative Law Judge presiding at the hearings allowed participants to submit post-hearing comments until May 6, 1991, and file

post-hearing briefs until June 5, 1991. OSHA received more than

175 comments in response to the notice of proposed rulemaking. In

addition to these comments, the hearings resulted in almost 4,000

pages of testimony and almost 60 post-hearing comments and briefs.

For readers’ convenience, this publication includes, as an appendix,

the full text of the final OSHA standard issued in the Federal Register on February 24, 1992, including the list of covered chemicals and

threshold amounts.

State plan States, approved under section 18(b) of the Occupational Safety and Health Act of 1970 (see list on page 36) must adopt

standards and enforce requirements which are at least as effective as

Federal requirements. There are currently 25 State plan States; 23

covering private and public (State and local government) sectors and

two covering public sector only. Plan States must adopt comparable

standards to the Federal within six months of a Federal standard’s

promulgation.

Approximately four months after the publication of OSHA’s

proposed standard for process safety management of highly hazardous chemicals, the Clean Air Act Amendments (CAAA) were

enacted into law (November 15, 1990). Section 304 of the CAAA

requires that the Secretary of Labor, in coordination with the Administrator of the Environmental Protection Agency (EPA), promulgate,

pursuant to the Occupational Safety and Heath Act of 1970, a

chemical process safety standard to prevent accidental releases of

chemicals that could pose a threat to employees.

The CAAA requires that the standard include a list of highly

hazardous chemicals which includes toxic, flammable, highly

reactive, and explosive substances. The CAAA also specified

minimum elements that the OSHA standard must require employers

to do, as follows:
3

The Problem

(1) Develop and maintain written safety information identifying

workplace chemical and process hazards, equipment used in the

processes, and technology used in the processes;

(2) Perform a workplace hazard assessment, including, as appropriate, identification of potential sources of accidental releases,

identification of any previous release within the facility that had a

potential for catastrophic consequences in the workplace, estimation

of workplace effects of a range of releases, and estimation of the

health and safety effects of such a range on employees;

(3) Consult with employees and their representatives on the

development and conduct of hazard assessments and the development of chemical accident prevention plans and provide access to

these and other records required under the standard;

(4) Establish a system to respond to the workplace hazard assessment findings, which shall address prevention, mitigation, and

emergency responses;

(5) Review periodically the workplace hazard assessment and

response system;

(6) Develop and implement written operating procedures for the

chemical processes, including procedures for each operating phase,

operating limitations, and safety and health considerations;

(7) Provide written safety and operating information for employees and employee training in operating procedures, by emphasizing

hazards and safe practices that must be developed and made available;

(8) Ensure contractors and contract employees are provided with

appropriate information and training;

(9) Train and educate employees and contractors in emergency

response procedures in a manner as comprehensive and effective as

that required by the regulation promulgated pursuant to section

126(d) of the Superfund Amendments and Reauthorization Act;

(10) Establish a quality assurance program to ensure that initial

process-related equipment, maintenance materials, and spare parts

are fabricated and installed consistent with design specifications;
Process Safety Management

4

(11) Establish maintenance systems for critical process-related

equipment, including written procedures, employee training, appropriate inspections, and testing of such equipment to ensure ongoing

mechanical integrity;

(12) Conduct pre-startup safety reviews of all newly installed or

modified equipment;

(13) Establish and implement written procedures managing

change to process chemicals, technology, equipment and facilities;

and

(14) Investigate every incident that results in or could have resulted in a major accident in the workplace, with any findings to be

reviewed by operating personnel and modifications made, if appropriate.

Also the CAAA, identifies specific duties for EPA relative to the

prevention of accidental releases (see section 301 (r)). Generally,

EPA must develop a list of chemicals and a Risk Management Plan.
How the Standard Works 5

Process Safety Information

This booklet summarizes the OSHA final process safety management (PSM) standard. Employers and employees may prefer to read

this booklet and a companion one entitled, “Process Safety Management - Guidelines for Compliance” (OSHA 3133), before studying

the rule itself.

The standard mainly applies to manufacturing industries—particularly, those pertaining to chemicals, transportation equipment,

and fabricated metal products. Other affected sectors include natural

gas liquids; farm product warehousing; electric, gas, and sanitary

services; and wholesale trade. It also applies to pyrotechnics and

explosives manufacturers covered under other OSHA rules and has

special provisions for contractors working in covered facilities.

In each industry, PSM applies to those companies that deal with

any of more than 130 specific toxic and reactive chemicals in listed

quantities; it also includes flammable liquids and gases in quantities

of 10,000 pounds (4,535.9 Kg) or more.

Subject to the rules and procedures set forth in OSHA’s Hazard

Communication Standard (29 Code of Federal Regulations (CFR)

1910.1200(i)(1) through 1910.1200(i)(12)), employees and their

designated representatives must be given access to trade secret

information contained within the process hazard analysis and other

documents required to be developed by the PSM standard.

The key provision of PSM is process hazard analysis (PHA)—a

careful review of what could go wrong and what safeguards must be

implemented to prevent releases of hazardous chemicals. Covered

employers must identify those processes that pose the greatest risks

and begin evaluating those first. PHAs must be completed as soon as

possible. At least one-quarter of the processes must be evaluated by

May 26, 1994, with an additional 25 percent completed each following year so that by May 26, 1997, if not sooner, employers will have

evaluated all affected processes. PSM clarifies the responsibilities of

employers and contractors involved in work that affects or takes

place near covered processes to ensure that the safety of both plant

and contractor employees is considered. The standard also mandates

written operating procedures; employee training; prestartup safety

reviews; evaluation of mechanical integrity of critical equipment; and

written procedures for managing change. PSM specifies a permit

system for hot work; investigation of incidents involving releases or
Process Safety Management

6

near misses of covered chemicals; emergency, action plans; compliance audits at least every three years; and trade secret protection.

To understand PSM and its requirements, employers and employees need to understand how OSHA uses the term “process” in PSM.

Process means any activity involving a highly hazardous chemical

including using, storing, manufacturing, handling, or moving such

chemicals at the site, or any combination of these activities. For

purposes of this definition, any group of vessels that are interconnected, and separate vessels located in a way that could involve a

highly hazardous chemical in a potential release, are considered a

single process.
Process Safety Information 7

Process Safety Information

Employers must complete a compilation of written process safety

information before conducting any process hazard analysis required

by the standard. The compilation of written process safety information, completed under the same schedule required for process hazard

analyses, will help the employer and the employees involved in

operating the process to identify and understand the hazards posed

by those processes involving highly hazardous chemicals. Process

safety information must include information on the hazards of the

highly hazardous chemicals used or produced by the process, information on the technology of the process, and information on the

equipment in the process.

Information on the hazards of the highly hazardous chemicals in

the process shall consist of at least the following:1

• Toxicity,

• Permissible exposure limits,

• Physical data,

• Reactivity data,

• Corrosivity data, and

• Thermal and chemical stability data, and hazardous effects of

inadvertent mixing of different materials.

Information on the technology of the process must include at least

the following:

• A block flow diagram or simplified process flow diagram,

• Process chemistry,

• Maximum intended inventory,

• Safe upper and lower limits for such items as temperatures,

pressures, flows or compositions, and

• An evaluation of the consequences of deviations, including

those affecting the safety and health of employees.

Where the original technical information no longer exists, such

information may be developed in conjunction with the process

hazard analysis in sufficient detail to support the analysis.

1Note: Material Safety Data Sheets (MSDSs) meeting the requirements of the

Hazard Communication Standard (20 CFR 1910.1200) may be used to comply with

this requirement to the extent they contain the required information.
Process Safety Management

8

Information on the equipment in the process must include the

following:

• Materials of construction,

• Piping and instrument diagrams (P&IDs),

• Electrical classification,

• Relief system design and design basis,

• Ventilation system design,

• Design codes and standards employed,

• Material and energy balances for processes built after May 26,

1992, and

• Safety systems (e.g., interlocks, detection, or suppression

systems).

The employer shall document that equipment complies with

recognized and generally accepted good engineering practices. For

existing equipment designed and constructed in accordance with

codes, standards, or practices that are no longer in general use, the

employer shall determine and document that the equipment is

designed, maintained, inspected, tested, and operated in a safe

manner.

The compilation of the above described process safety information

provides the basis for identifying and understanding the hazards of a

process and is necessary in developing the process hazard analysis

and may be necessary for complying with other provisions of PSM

such as management of change and incident investigations.
9

Process Hazard Analysis

Process Hazard Analysis

The process hazard analysis is a thorough, orderly, systematic

approach for identifying, evaluating, and controlling the hazards of

processes involving highly hazardous chemicals. The employer must

perform an initial process hazard analysis (hazard evaluation) on all

processes covered by this standard. The process hazard analysis

methodology selected must be appropriate to the complexity of the

process and must identify, evaluate, and control the hazards involved

in the process.

First, employers must determine and document the priority order

for conducting process hazard analyses based on a rationale that

includes such considerations as the extent of the process hazards, the

number of potentially affected employees, the age of the process, and

the operating history of the process. All initial process hazard

analyses should be conducted as soon as possible, but at a minimum,

the employer must complete no fewer than 25 percent by May 26,

1994; 50 percent by May 26, 1995; 75 percent by May 26, 1996; and

all initial process hazard analyses by May 26, 1997. Where there is

only one process in a workplace, the analysis must be completed by

May 26, 1994.

Process hazard analyses completed after May 26, 1987, that meet

the requirements of the PSM standard are acceptable as initial

process hazard analyses. All process hazard analyses must be

updated and revalidated, based on their completion date, at least

every five years.

The employer must use one or more of the following methods, as

appropriate, to determine and evaluate the hazards of the process

being analyzed:

• What-if,

• Checklist,

• What-if/checklist,

• Hazard and operability study (HAZOP),

• Failure mode and effects analysis (FMEA),

• Fault tree analysis, or

• An appropriate equivalent methodology.
Process Safety Management

10

A discussion of these methods of analysis is contained in the

companion publication, OSHA 3133, Process Safety Management -

Guidelines for Compliance. Whichever method(s) are used, the

process hazard analysis must address the following:

• The hazards of the process;

• The identification of any previous incident that had a potential

for catastrophic consequences in the workplace;

• Engineering and administrative controls applicable to the

hazards and their interrelationships, such as appropriate application of detection methodologies to provide early warning of

releases. Acceptable detection methods might include process

monitoring and control instrumentation with alarms, and

detection hardware such as hydrocarbon sensors;

• Consequences of failure of engineering and administrative

controls;

• Facility siting;

• Human factors; and

• A qualitative evaluation of a range of the possible safety and

health effects on employees in the workplace if there is a failure

of controls.

OSHA believes that the process hazard analysis is best performed

by a team with expertise in engineering and process operations, and

that the team should include at least one employee who has experience with and knowledge of the process being evaluated. Also, one

member of the team must be knowledgeable in the specific analysis

methods being used.

The employer must establish a system to address promptly the

team’s findings and recommendations; ensure that the recommendations are resolved in a timely manner and that the resolutions are

documented; document what actions are to be taken; develop a

written schedule of when these actions are to be completed; complete

actions as soon as possible; and communicate the actions to operating, maintenance, and other employees whose work assignments are

in the process and who may be affected by the recommendations or

actions.
11

Process Hazard Analysis

At least every five years after the completion of the initial process

hazard analysis, the process hazard analysis must be updated and

revalidated by a team meeting the standard’s requirements to ensure

that the hazard analysis is consistent with the current process.

Employers must keep on file and make available to OSHA, on

request, process hazard analyses and updates or revalidation for each

process covered by PSM, as well as the documented resolution of

recommendations, for the life of the process.
Process Safety Management

12 Operating Procedures

The employer must develop and implement written operating

procedures, consistent with the process safety information, that

provide clear instructions for safely conducting activities involved in

each covered process. OSHA believes that tasks and procedures

related to the covered process must be appropriate, clear, consistent,

and most importantly, well communicated to employees. The

procedures must address at least the following elements:

Steps for each operating phase:

• Initial startup;

• Normal operations;

• Temporary operations;

• Emergency shutdown, including the conditions under which

emergency shutdown is required, and the assignment of shut

down responsibility to qualified operators to ensure that emer

gency shutdown is executed in a safe and timely manner;

• Emergency operations;

• Normal shutdown; and

• Startup following a turnaround, or after an emergency shutdown.

Operating limits:

• Consequences of deviation, and

• Steps required to correct or avoid deviation.

Safety and health considerations:

• Properties of, and hazards presented by, the chemicals used in

the process;

• Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective

equipment;

• Control measures to be taken if physical contact or airborne

exposure occurs;

• Quality control for raw materials and control of hazardous

chemical inventory levels; and

• Any special or unique hazards.

• Safety systems (e.g., interlocks, detection or suppression

systems) and their functions.
13

Operating Procedures

To ensure that a ready and up-to-date reference is available, and to

form a foundation for needed employee training, operating procedures must be readily accessible to employees who work in or

maintain a process. The operating procedures must be reviewed as

often as necessary to ensure that they reflect current operating

practices, including changes in process chemicals, technology, and

equipment, and facilities. To guard against outdated or inaccurate

operating procedures, the employer must certify annually that these

operating procedures are current and accurate.

The employer must develop and implement safe work practices to

provide for the control of hazards during work activities such as

lockout/tagout; confined space entry; opening process equipment or

piping; and control over entrance into a facility by maintenance,

contractor, laboratory, or other support personnel. These safe work

practices must apply both to employees and to contractor employees.
Process Safety Management

14 Employee Participation

Employers must develop a written plan of action to implement the

employee participation required by PSM. Under PSM, employers

must consult with employees and their representatives on the conduct

and development of process hazard analyses and on the development

of the other elements of process management, and they must provide

to employees and their representatives access to process hazard

analyses and to all other information required to be developed by the

standard.
15

Training

Training

Initial Training

OSHA believes that the implementation of an effective training

program is one of the most important steps that an employer can take

to enhance employee safety. Accordingly, PSM requires that each

employee presently involved in operating a process or a newly

assigned process must be trained in an overview of the process and in

its operating procedures. The training must include emphasis on the

specific safety and health hazards of the process, emergency operations including shutdown, and other safe work practices that apply to

the employee’s job tasks. Those employees already involved in

operating a process on the PSM effective date do not necessarily

need to be given initial training. Instead, the employer may certify in

writing that the employees have the required knowledge, skills, and

abilities to safely carry out the duties and responsibilities specified in

the operating procedures.

Refresher Training

Refresher training must be provided at least every three years, or

more often if necessary, to each employee involved in operating a

process to ensure that the employee understands and adheres to the

current operating procedures of the process. The employer, in

consultation with the employees involved in operating the process,

must determine the appropriate frequency of refresher training.

Training Documentation

The employer must determine whether each employee operating a

process has received and understood the training required by PSM.

A record must be kept containing the identity of the employee, the

date of training, and how the employer verified that the employee

understood the training.
Process Safety Management

16 Contractors

Application

Many categories of contract labor may be present at a jobsite; such

workers may actually operate the facility or do only a particular

aspect of a job because they have specialized knowledge or skill.

Others work only for short periods when there is need for increased

staff quickly, such as in turnaround operations. PSM includes special

provisions for contractors and their employees to emphasize the

importance of everyone taking care that they do nothing to endanger

those working nearby who may work for another employer.

PSM, therefore, applies to contractors performing maintenance or

repair, turnaround, major renovation, or specialty work on or adjacent to a covered process. It does not apply, however, to contractors

providing incidental services that do not influence process safety,

such as janitorial, food and drink, laundry, delivery, or other supply

services.

Employer Responsibilities

When selecting a contractor, the employer must obtain and

evaluate information regarding the contract employer’s safety

performance and programs. The employer also must inform contract

employers of the known potential fire, explosion, or toxic release

hazards related to the contractor’s work and the process; explain to

contract employers the applicable provisions of the emergency action

plan; develop and implement safe work practices to control the

presence, entrance, and exit of contract employers and contract

employees in covered process areas; evaluate periodically the performance of contract employers in fulfilling their obligations; and

maintain a contract employee injury and illness log related to the

contractor’s work in the process areas.

Contract Employer Responsibilities

The contract employer must:

• Ensure that contract employees are trained in the work practices

necessary to perform their job safely;
17

• Ensure that contract employees are instructed in the known

potential fire, explosion, or toxic release hazards related to their

job and the process, and in the applicable provisions of the

emergency action plan;

• Document that each contract employee has received and

understood the training required by the standard by preparing a

record that contains the identity of the contract employee, the

date of training, and the means used to verify that the employee

understood the training;

• Ensure that each contract employee follows the safety rules of

the facility including the required safe work practices required

in the operating procedures section of the standard; and

• Advise the employer of any unique hazards presented by the

contract employer’s work.

Training
Process Safety Management

18

Pre-Startup Safety Review

It is important that a safety review takes place before any highly

hazardous chemical is introduced into a process. PSM, therefore,

requires the employer to perform a pre-startup safety review for new

facilities and for modified facilities when the modification is significant enough to require a change in the process safety information.

Prior to the introduction of a highly hazardous chemical to a process,

the pre-startup safety review must confirm that the following:

• Construction and equipment are in accordance with design

specifications;

• Safety, operating, maintenance, and emergency procedures are

in place and are adequate;

• A process hazard analysis has been performed for new facilities

and recommendations have been resolved or implemented

before startup, and modified facilities meet the management of

change requirements; and

• Training of each employee involved in operating a process has

been completed.

Pre-Startup Safety Review
19

OSHA believes it is important to maintain the mechanical integrity of critical process equipment to ensure it is designed and installed correctly and operates properly. PSM mechanical integrity

requirements apply to the following equipment:

• Pressure vessels and storage tanks;

• Piping systems (including piping components such as valves);

• Relief and vent systems and devices;

• Emergency shutdown systems;

• Controls (including monitoring devices and sensors, alarms,

and interlocks); and

• Pumps.

The employer must establish and implement written procedures to

maintain the ongoing integrity of process equipment. Employees

involved in maintaining the ongoing integrity of process equipment

must be trained in an overview of that process and its hazards and

trained in the procedures applicable to the employees’s job tasks.

Inspection and testing must be performed on process equipment,

using procedures that follow recognized and generally accepted good

engineering practices. The frequency of inspections and tests of

process equipment must conform with manufacturers’ recommendations and good engineering practices, or more frequently if determined to be necessary by prior operating experience. Each inspection and test on process equipment must be documented, identifying

the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of

the equipment on which the inspection or test was performed, a

description of the inspection or test performed, and the results of the

inspection or test.

Equipment deficiencies outside the acceptable limits defined by

the process safety information must be corrected before further use.

In some cases, it may not be necessary that deficiencies be corrected

before further use, as long as deficiencies are corrected in a safe and

timely manner, when other necessary steps are taken to ensure safe

operation.

In constructing new plants and equipment, the employer must

ensure that equipment as it is fabricated is suitable for the process

application for which it will be used. Appropriate checks and

Mechanical Integrity

Mechanical Integrity
Process Safety Management

20

inspections must be performed to ensure that equipment is installed

properly and is consistent with design specifications and the

manufacturer’s instructions.

The employer also must ensure that maintenance materials, spare

parts, and equipment are suitable for the process application for

which they will be used.
States with Approved Plans

Hot Work Permit 21

Hot Work Permit

A permit must be issued for hot work operations conducted on or

near a covered process. The permit must document that the fire

prevention and protection requirements in OSHA regulations

(1910.252(a)) have been implemented prior to beginning the hot

work operations; it must indicate the date(s) authorized for hot work;

and identify the object on which hot work is to be performed. The

permit must be kept on file until completion of the hot work.
Process Safety Management

22 Management of Change

OSHA believes that contemplated changes to a process must be

thoroughly evaluated to fully assess their impact on employee safety

and health and to determine needed changes to operating procedures.

To this end, the standard contains a section on procedures for managing changes to processes. Written procedures to manage changes

(except for “replacements in kind”) to process chemicals, technology,

equipment, and procedures, and change to facilities that affect a

covered process, must be established and implemented. These

written procedures must ensure that the following considerations are

addressed prior to any change:

• The technical basis for the proposed change,

• Impact of the change on employee safety and health,

• Modifications to operating procedures,

• Necessary time period for the change, and

• Authorization requirements for the proposed change.

Employees who operate a process and maintenance and contract

employees whose job tasks will be affected by a change in the

process must be informed of, and trained in, the change prior to

startup of the process or startup of the affected part of the process. If

a change covered by these procedures results in a change in the

required process safety information, such information also must be

updated accordingly. If a change covered by these procedures

changes the required operating procedures or practices, they also

must be updated.
23

Incident Investigation

A crucial part of the process safety management program is a

thorough investigation of incidents to identify the chain of events and

causes so that corrective measures can be developed and implemented. Accordingly, PSM requires the investigation of each incident that resulted in, or could reasonably have resulted in, a catastrophic release of a highly hazardous chemical in the workplace.

Such an incident investigation must be initiated as promptly as

possible, but not later than 48 hours following the incident. The

investigation must be by a team consisting of at least one person

knowledgeable in the process involved, including a contract employee if the incident involved the work of a contractor, and other

persons with appropriate knowledge and experience to investigate

and analyze the incident thoroughly.

An investigation report must be prepared including at least:

• Date of incident,

• Date investigation began,

• Description of the incident,

• Factors that contributed to the incident, and

• Recommendations resulting from the investigation.

A system must be established to promptly address and resolve the

incident report findings and recommendations. Resolutions and

corrective actions must be documented and the report reviewed by all

affected personnel whose job tasks are relevant to the incident

findings (including contract employees when applicable). The

employer must keep these incident investigation reports for 5 years.

Incident Investigation
Process Safety Management

24

If, despite the best planning, an incident occurs, it is essential that

emergency pre-planning and training make employees aware of, and

able to execute, proper actions. For this reason, an emergency action

plan for the entire plant must be developed and implemented in

accordance with the provisions of other OSHA rules (29 CFR

1910.38(a)). In addition, the emergency action plan must include

procedures for handling small releases of hazardous chemicals.

Employers covered under PSM also may be subject to the OSHA

hazardous waste and emergency response regulation (29 CFR

1910.120(a), (p), and (q).

Emergency Planning and Response
Compliance Audits

Compliance Audits

25

To be certain process safety management is effective, employers

must certify that they have evaluated compliance with the provisions

of PSM at least every three years This will verify that the procedures

and practices developed under the standard are adequate and are

being followed. The compliance audit must be conducted by at least

one person knowledgeable in the process and a report of the findings

of the audit must be developed and documented noting deficiencies

that have been corrected. The two most recent compliance audit

reports must be kept on file.
Process Safety Management

26 Trade Secrets

Employers must make available all information necessary to

comply with PSM to those persons responsible for compiling the

process safety information, those developing the process hazard

analysis, those responsible for developing the operating procedures,

and those performing incident investigations, emergency planning

and response, and compliance audits, without regard to the possible

trade secret status of such information. Nothing in PSM, however,

precludes the employer from requiring those persons to enter into

confidentiality agreements not to disclose the information.
Part 1910-Occupational Safety and Health Standards 27

Part 1910-Occupational Safety and Health Standards

The following sections comprise the process safety management

standard, in its entirety, as published in the Federal Register (FR

57(36):6403-6408, February 24, 1992).

1. The authority citation for Subpart H of Part 1910 is revised to

read as follows:

Authority Secs. 4, 6, 8, Occupational Safety and Health Act of

1970 (29 U.S.C. 653, 655, 657): Secretary of Labor’s Order No. 12-

71 (36 FR 8754), 8-76 (41 FR 25059), 9-83 (48 FR 35736) or 1-90

(55 FR 9033), as applicable.

Sections 1910.103, 1910.106, 1910.107, 1910.108, 1910.109,

1910.110, 1910.111 and 1910.119 are also issued under 29 CFR part

1911.

Section 1910.119 is also issued under Sec. 304, Clean Air Act

Amendments of 1990 (Public Law 101 -549, Nov. 15, 1990, reprinted at 29 U.S.C. 655 Note (Supp. 1991)).

Section 1910.120 is also issued under Sec. 126, Superfund

Amendments and Reauthorization Act of 1986 as amended (29

U.S.C. 655 note), 5 U.S.C. 553 and 29 CFR Part 1911.

2. Section 1910.109 is amended by revising paragraph (k) to read

as follows:

§ 1910.109 Explosives and Blasting Agents

(k) Scope. (1) This section applies to the manufacture, keeping,

having, storage, sale, transportation, and use of explosives, blasting

agents, and pyrotechnics. The section does not apply to the sale and

use (public display) of pyrotechnics, commonly known as fireworks,

nor the use of explosives in the form prescribed by the official U.S.

Pharmacopeia.

(2) The manufacturer of explosives as defined in paragraph (a)(3)

of this section shall also meet the requirements contained in

§ 1910.119.

(3) The manufacture of pyrotechnics as defined in paragraph (a)(1

0) of this section shall also meet the requirements contained in

§ 1910.119.
Process Safety Management

28

A new § 1910.119 and appendices A through D* to § 1910.119

are added to read as follows:

1910.119 Process Safety Management of Highly Hazardous

Chemicals

Purpose. This section contains requirements for preventing or

minimizing the consequences of catastrophic releases of toxic,

reactive, flammable, or explosive chemicals. These releases may

result in toxic, fire or explosion hazards.

(a) Application. (1) This section applies to the following:

(i) A process which involves a chemical at or above the specified

threshold quantities listed in Appendix A to this section;

(ii) A process which involves flammable liquid or gas (as defined

in 1910.1200(c) of this part) on site in one location, in a quantity of

10,000 pounds (4535.9kg) or more except for:

(A) Hydrocarbon fuels used solely for workplace consumption as

a fuel (e.g., propane used for comfort heating, gasoline for vehicle

refueling), if such fuels are not a part of a process containing another

highly hazardous chemical covered by this standard;

(B) Flammable liquids stored in atmospheric tanks or transferred

which are kept below their normal boiling point without benefit of

chilling or refrigeration.

(2) This section does not apply to:

(i) Retail facilities;

(ii) Oil or gas well drilling or servicing operations; or,

(iii) Normally unoccupied remote facilities.

(b) Definitions. Atmospheric tank means a storage tank which has

been designed to operate at pressures from atmospheric through 0.5

p.s.i.g. (pounds per square inch gauge, 3.45 Kpa).

*Appendices C and D are not reprinted here. See OSHA 3133 Process Safety

Management Guidelines for Compliance for text of Appendix C. See Federal

Register (FR 56(36) 6416-6417, February 24, 1992), for Appendix D - Sources of

Further Information.
Part 1910-Occupational Safety and Health Standards

Boiling point means the boiling point of a liquid at a pressure of

14.7 pounds per square inch absolute (p.s.i.a.) (760mm). For the

purposes of this section, where an accurate boiling point is unavailable for the material in question, or for mixtures which do not have a

constant boiling point, the 10 percent point of a distillation performed in accordance with the Standard Method of Test for Distillation of Petroleum Products, ASTM D-86-62, may be used as the

boiling point of the liquid.

Catastrophic release means a major uncontrolled emission, fire, or

explosion, involving one or more highly hazardous chemicals that

presents serious danger to employees in the workplace.

Facility means the buildings, containers or equipment which

contain a process.

Highly hazardous chemical means a substance possessing toxic,

reactive, flammable, or explosive properties and specified by paragraph (a)(1) of this section.

Hot work means work involving electric or gas welding, cutting,

brazing, or similar flame or spark-producing operations.

Normally unoccupied remote facility means a facility which is

operated, maintained or serviced by employees who visit the facility

only periodically to check its operation and to perform necessary

operating or maintenance tasks. No employees are permanently

stationed at the facility.

Facilities meeting this definition are not contiguous with, and

must be geographically remote from, all other buildings, processes or

persons.

Process means any activity involving a highly hazardous chemical

including any use, storage, manufacturing, handling, or the on-site

movement of such chemicals, or combination of these activities. For

purposes of this definition, any group of vessels which are interconnected and separate vessels that are located such a that a highly

hazardous chemical could be involved in a potential release shall be

considered a single process.

Replacement in kind means a replacement which satisfies the

design specification.

Trade secret means any confidential formula, pattern, process,

device, information or compilation of information that is used in an

29
Process Safety Management

30

employer’s business, and that gives the employer an opportunity to

obtain advantage over competitors who do not know or use it.

Appendix D contained in § 1910.1200 sets out the criteria to be used

in evaluating trade secrets.

(c) Employee participation. (1) Employers shall develop a written

plan of action regarding the implementation of the employee participation required by this paragraph.

(2) Employers shall consult with employees and their representatives on the conduct and development of process hazard analyses and

on the development of the other elements of process safety management in this standard.

(3) Employers shall provide to employees and their representatives

access to process hazard analyses and to all other information

required to be developed under this standard.

(d) Process safety information. In accordance with the schedule

set forth in paragraph (e)(1) of this section, the employer shall

complete a compilation of written process safety information before

conducting any process hazard analysis required by the standard.

The compilation of written process safety information is to enable

the employer and the employees involved in operating the process to

identify and understand the hazards posed by those processes involving highly hazardous chemicals. This process safety information

shall include information pertaining to the hazards of the highly

hazardous chemicals used or produced by the process, information

pertaining to the technology of the process, and information pertaining to the equipment in the process.

(1) Information pertaining to the hazards of the highly hazardous

chemicals in the process. This information shall consist of at least

the following:

(i) Toxicity information;

(ii) Permissible exposure limits;

(iii) Physical data;

(iv) Reactivity data;

(v) Corrosivity data;

(vi) Thermal and chemical stability data; and
Part 1910-Occupational Safety and Health Standards

31

(vii) Hazardous effects of inadvertent mixing of different materials

that could foreseeably occur.

Note: Material Safety Data Sheets meeting the requirements of 29

CFR 1910.1200(g) may be used to comply with this requirement to

the extent that they contain the information required by this subparagraph.

(2) Information pertaining to the technology of the process. (i)

Information concerning the technology of the process shall include at

least the following:

(A) A block flow diagram or simplified process flow diagram (see

Appendix B to this section);

(B) Process chemistry;

(C) Maximum intended inventory;

(D) Safe upper and lower limits for such items as temperatures,

pressures, flows or compositions; and,

(E) An evaluation of the consequences of deviations, including

those affecting the safety and health of employees.

(ii) Where the original technical information no longer exists, such

information may be developed in conjunction with the process

hazard analysis in sufficient detail to support the analysis.

(3) Information pertaining to the equipment in the process.

(i) Information pertaining to the equipment in the process shall

include:

(A) Materials of construction;

(B) Piping and instrument diagrams (P&ID’s);

(C) Electrical classification;

(D) Relief system design and design basis;

(E) Ventilation system design;

(F) Design codes and standards employed;

(G) Material and energy balances for processes built after May

26,1992;and,

(H) Safety systems (e.g. interlocks, detection or suppression

systems).
Process Safety Management

32

(ii) The employer shall document that equipment complies with

recognized and generally accepted good engineering practices.

(iii) For existing equipment designed and constructed in accordance with codes, standards, or practices that are no longer in general

use, the employer shall determine and document that the equipment

is designed, maintained, inspected, tested, and operating in a safe

manner,

(e) Process hazard analysis. (1) The employer shall perform an

initial process hazard analysis (hazard evaluation) on processes

covered by this standard. The process hazard analysis shall be

appropriate to the complexity of the process and shall identify,

evaluate, and control the hazards involved in the process. Employers

shall determine and document the priority order for conducting

process hazard analyses based on a rationale which includes such

considerations as extent of the process hazards, number of potentially

affected employees, age of the process, and operating history of the

process. The process hazard analysis shall be conducted as soon as

possible, but not later than the following schedule:

(i) No less than 25 percent of the initial process hazards analyses

shall be completed by May 26, 1994;

(ii) No less than 50 percent of the initial process hazards analyses

shall be completed by May 26, 1995;

(iii) No less than 75 percent of the initial process hazards analyses

shall be completed by May 26, 1996;

(iv) All initial process hazards analyses shall be completed by

May 26,1997.

(v) Process hazards analyses completed after May 26, 1987, which

meet the requirements of this paragraph are acceptable as initial

process hazards analyses. The process hazard analyses shall be

updated and revalidated, based on their completion date, in accordance with paragraph (e)(6) of this section.

(2) The employer shall use one or more of the following methodologies that are appropriate to determine and evaluate the hazards of

the process being analyzed.

(i) What-if;

(ii) Checklist;

(iii) What- if/checklist;
33

(iv) Hazard and Operability Study (HAZOP);

(v) Failure Mode and Effects Analysis (FMEA);

(vi) Fault Tree Analysis; or

(vii) An appropriate equivalent methodology.

(3) The process hazard analysis shall address;

(i) The hazards of the process;

(ii) The identification of any previous incident which had a likely

potential for catastrophic consequences in the workplace;

(iii) Engineering and administrative controls applicable to the

hazards and their interrelationships such as appropriate application of

detection methodologies to provide early warning of releases.

(Acceptable detection methods might include process monitoring and

control instrumentation with alarms, and detection hardware such as

hydrocarbon sensors.);

(iv) Consequences of failure of engineering and administrative

controls;

(v) Facility siting;

(vi) Human factors; and

(vii) A qualitative evaluation of a range of the possible safety and

health effects of failure of controls on employees in the workplace.

(4) The process hazard analysis shall be performed by a team with

expertise in engineering and process operations, and the team shall

include at least one employee who has experience and knowledge

specific to the process being evaluated. Also, one member of the

team must be knowledgeable in the specific process hazard analysis

methodology being used.

(5) The employer shall establish a system to promptly address the

team’s findings and recommendations; assure that the recommendations are resolved in a timely manner and that the resolution is

documented; document what actions are to be taken; complete

actions as soon as possible; develop a written schedule of when these

actions are to be completed; communicate the actions to operating,

maintenance and other employees whose work assignments are in the

process and who may be affected by the recommendations or actions.

(6) At least every five (5) years after the completion of the initial

process hazard analysis, the process hazard analysis shall be updated

Part 1910-Occupational Safety and Health Standards
Process Safety Management

34

and revalidated by a team meeting the requirements in paragraph

(e)(4) of this section, to assure that the process hazard analysis is

consistent with the current process.

(7) Employers shall retain process hazards analyses and updates or

revalidations for each process covered by this section, as well as the

documented resolution of recommendations described in paragraph

(e)(5) of this section for the life of the process.

(f) Operating procedures. (1) The employer shall develop and

implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered

process consistent with the process safety information and shall

address at least the following elements,.

(i) Steps for each operating phase:

(A) Initial startup;

(B) Normal operations;

(C) Temporary operations;

(D) Emergency shutdown including the conditions under which

emergency shutdown is required, and the assignment of shutdown

responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner.

(E) Emergency Operations,

(F) Normal shutdown; and,

(G) Startup following a turnaround, or after an emergency shutdown,

(ii) Operating limits;

(A) Consequences of deviation; and

(B) Steps required to correct or avoid deviation.

(iii) Safety and health considerations:

(A) Properties of, and hazards presented by, the chemicals used in

the process;

(B) Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective

equipment;

(C) Control measures to be taken if physical contact or airborne

exposure occurs;
35

Part 1910-Occupational Safety and Health Standards

(D) Quality control for raw materials and control of hazardous

chemical inventory levels; and,

(E) Any special or unique hazards.

(iv) Safety systems and their functions.

(2) Operating procedures shall be readily accessible to employees

who work in or maintain a process.

(3) The operating procedures shall be reviewed as often as necessary to assure that they reflect current operating practices, including

changes that result from changes in process chemicals, technology,

and equipment, and changes to facilities. The employer shall certify

annually that these operating procedures are current and accurate.

(4) The employer shall develop and implement safe work practices

to provide for the control of hazards during operations such as

lockout/tagout; confined space entry; opening process equipment or

piping; and control over entrance into a facility by maintenance,

contractor, laboratory, or other support personnel. These safe work

practices shall apply to employees and contractor employees.

(g) Training. (1) Initial training. (i) Each employee presently

involved in operating a process, and each employee before being

involved in operating a newly assigned process, shall be trained in an

overview of the process and in the operating procedures as specified

in paragraph (f) of this section. The training shall include emphasis

on the specific safety and health hazards, emergency operations

including shutdown, and safe work practices applicable to the

employee’s job tasks.

(ii) In lieu of initial training for those employees already involved

in operating a process on May 26, 1992, an employer may certify in

writing that the employee has the required knowledge, skills, and

abilities to safely carry out the duties and responsibilities as specified

in the operating procedures.

(2) Refresher training. Refresher training shall be provided at

least every 3 years, and more often if necessary, to each employee

involved in operating a process to assure that the employee understands and adheres to the current operating procedures of the process.

The employer, in consultation with the employees involved in

operating the process, shall determine the appropriate frequency of

refresher training.
Process Safety Management

36

(3) Training documentation. The employer shall ascertain that

each employee involved in operating a process has received and

understood the training required by this paragraph. The employer

shall prepare a record which contains the identity of the employee,

the date of training, and the means used to verify that the employee

understood the training.

(h) Contractors. (1) Application. This paragraph applies to

contractors performing maintenance or repair, turnaround, major

renovation, or specialty work on or adjacent to a covered process. It

does not apply to contractors providing incidental services which do

not influence process safety, such as janitorial work, food and drink

services, laundry, delivery or other supply services.

(2) Employer responsibilities. (i) The employer, when selecting a

contractor, shall obtain and evaluate information regarding the

contract employer’s safety and performance and programs.

(ii) The employer shall inform contract employers of the known

potential fire, explosion, or toxic release hazards related to the

contractor’s work and the process.

(iii) The employer shall explain to contract employers the applicable provisions of the emergency action plan required by paragraph

(n) of this section.

(iv) The employer shall develop and implement safe work practices consistent with paragraph (f)(4) of this section, to control the

entrance, presence and exit of contract employers and contract

employees in covered process areas.

(v) The employer shall periodically evaluate the performance of

contract employers in fulfilling their obligations as specified in

paragraph (h)(3) of this section.

(vi) The employer shall maintain a contract employee injury and

illness log related to the contractor’s work in process areas.

(3) Contract employer responsibilities.

(i) The contract employer shall assure that each contract employee

is trained in the work practices necessary to safely perform his/her

job.

(ii) The contract employer shall assure that each contract employee is instructed in the known potential fire, explosion, or toxic
Part 1910-Occupational Safety and Health Standards

37

release hazards related to his/her job and the process, and the applicable provisions of the emergency action plan.

(iii) The contract employer shall document that each contract

employee has received and understood the training required by this

paragraph. The contract employer shall prepare a record which

contains the identity of the contract employee, the date of training,

and the means used to verify that the employee understood the

training.

(iv) The contract employer shall assure that each contract employee follows the safety rules of the facility including the safe work

practices required by paragraph (f)(4) of this section.

(v) The contract employer shall advise the employer of any unique

hazards presented by the contract employer’s work, or of any hazards

found by the contract employer’s work.

(i) Pre-startup review. (1) The employer shall perform a prestartup

safety review for new facilities and for modified facilities when the

modification is significant enough to require a change in the process

safety information.

(2) The pre-startup safety review shall confirm that prior to the

introduction of highly hazardous chemicals to a process:

(i) Construction and equipment is in accordance with design

specifications;

(ii) Safety, operating, maintenance, and emergency procedures are

in place and are adequate;

(iii) For new facilities, a process hazard analysis has been performed and recommendations have been resolved or implemented

before startup; and modified facilities meet the requirements contained in management of change, paragraph (1).

(iv) Training of each employee involved in operating a process has

been completed.

(j) Mechanical Integrity. (1) Application. Paragraphs (j)(2)

through (j)(6) of this section apply to the following process equipment:

(i) Pressure vessels and storage tanks;

(ii) Piping systems (including piping components such as valves);
Process Safety Management

38

(iii) Relief and vent systems and devices;

(iv) Emergency shutdown systems;

(v) Controls (including monitoring devices and sensors, alarms,

and interlocks) and,

(vi) Pumps.

(2) Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process

equipment.

(3) Training for process maintenance activities. The employer

shall train each employee involved in maintaining the on-going

integrity of process equipment in an overview of that process and its

hazards and in the procedures applicable to the employee’s job tasks

to assure that the employee can perform the job tasks in a safe

manner.

(4) Inspection and testing. (i) Inspections and tests shall be

performed on process equipment.

(ii) Inspection and testing procedures shall follow recognized and

generally accepted good engineering practices.

(iii) The frequency of inspections and tests of process equipment

shall be consistent with applicable manufacturers’ recommendations

and good engineering practices, and more frequently if determined to

be necessary by prior operating experience.

(iv) The employer shall document each inspection and test that has

been performed on process equipment. The documentation shall

identify the date of the inspection or test, the name of the person who

performed the inspection or test, the serial number or other identifier

of the equipment on which the inspection or test was performed, a

description of the inspection or test performed, and the results of the

inspection test.

(5) Equipment deficiencies. The employer shall correct deficiencies in equipment that are outside acceptable limits (defined by the

process safety information on paragraph (d) of this section) before

further use or in a safe and timely manner when necessary means are

taken to assure safe operation.

(6) Quality assurance. (i) In the construction of new plants and

equipment, the employer shall assure that equipment as it is fabri-
Part 1910-Occupational Safety and Health Standards

39

cated is suitable for the process application for which they will be

used.

(ii) Appropriate checks and inspections shall be performed to

assure that equipment is installed properly and consistent with design

specifications and the manufacturer’s instructions.

(iii) The employer shall assure that maintenance materials, spare

parts and equipment are suitable for the process application for

which they will be used.

(k) Hot work permit. (1) The employer shall issue a hot work

permit for hot work operations conducted on or near a covered

process.

(2) The permit shall document that the fire prevention and protection requirements of 29 CFR 1910.252(a) have been implemented

prior to beginning the hot work operations; it shall indicate the

date(s) authorized for hot work; and identify the object on which hot

work is to be performed. The permit shall be kept on file until

completion of the hot work operations.

(1) Management of change. (1) The employer shall establish and

implement written procedures to manage changes except for “replacements in kind”) to process chemicals, technology, equipment,

and procedures; and, changes to facilities that affect a covered

process.

(2) The procedures shall assure that the following considerations

are addressed prior to any change:

(i) The technical basis for the proposed change;

(ii) Impact of change on safety and health;

(iii) Modifications to operating procedures;

(iv) Necessary time period for the change; and

(v) Authorization requirements for the proposed change.

(3) Employees involved in operating a process and maintenance

and contract employees whose job tasks will be affected by a change

in the process shall be informed of, and trained in, the change prior

to start-up of the process or affected part of the process.

(4) If a change covered by this paragraph results in a change in the

operating procedures or practices required by paragraph (d) of this

section, such information shall be updated accordingly.
Process Safety Management

(5) If a change covered by this paragraph results in a change in the

operating procedures or practices required by paragraph (f) of this

section, such procedures or practices shall be updated accordingly.

(m) Incident investigation. (1) The employer shall investigate

each incident which resulted din, or could reasonably have resulted

in a catastrophic release of highly hazardous chemical in the workplace.

(2) An incident investigation shall be initiated as promptly as

possible, but not later than 48 hours following the incident.

(3) An incident investigation team shall be established and consist

of at least one person knowledgeable in the process involved, including a contract employee if the incident involved work of the contractor, and other persons with appropriate knowledge and experience to

thoroughly investigate and analyze the incident.

(4) A report shall be prepared at the conclusion of the investigation which includes at a minimum:

(i) Date of incident;

(ii) Date investigation began:

(iii) A description of the incident;

(iv) The factors that contributed to the incident; and

(v) Any recommendations resulting from the investigation.

(5) The employer shall establish a system to promptly address and

resolve the incident report findings and recommendations. Resolutions and corrective actions shall be documented.

(6) The report shall be reviewed with all affected personnel whose

job tasks are relevant to the incident findings including contract

employees where applicable.

(7) Incident investigation reports shall be retained for five years.

(n) Emergency planning and response. The employer shall

establish and implement an emergency action plan for the entire

plant in accordance with the provisions of 29 CFR 1910.38(a). In

addition, the emergency action plan shall include procedures for

handling small releases. Employers covered under this standard may

also be subject to the hazardous waste and emergency response

provisions contained in 29 CFR 1910.120(a), (p) and (q).

40
Part 1910-Occupational Safety and Health Standards

(o) Compliance audits. (1) Employers shall certify that they have

evaluated compliance with the provisions of this section at least

every three years to verify that the procedures and practices developed under the standard are adequate and are being followed.

(2) The compliance audit shall be conducted by at least one person

knowledgeable in the process.

(3) A report of the findings of the audit shall be developed.

(4) The employer shall promptly determine and document an

appropriate response to each of the findings of the compliance audit,

and document that deficiencies have been corrected.

(5) Employers shall retain the two (2) most recent compliance

audit reports.

(p) Trade secrets. (1) Employers shall make all information

necessary to comply with the section available to those persons

responsible for compiling the process safety information (required by

paragraph (d) of this section), those assisting in the development of

the process hazard analysis (required by paragraph (e) of this section), those responsible for developing the operating procedures

(required by paragraph (f) of this section), and those involved in

incident investigations (required by paragraph (m) of this section),

emergency planning and response (paragraph (n) of this section) and

compliance audits (paragraph (o) of this section) without regard to

possible trade secret status of such information.

(2) Nothing in this paragraph shall preclude the employer from

requiring the persons to whom the information is made available

under paragraph (p)(1) of this section to enter into confidentiality

agreements not to disclose the information as set forth in 29 CFR

1910.1200.

(3) Subject to the rules and procedures set forth in 29 CFR

1910.1200(i)(1) through 1910.1200(i)(12), employees and their

designated representatives shall have access to trade secret information contained within the process hazard analysis and other documents required to be developed by this standard.

41
Process Safety Management

42 Appendix A to § 1910.119

Appendix A to § 1910.119—List of Highly Hazardous Chemicals,

Toxics and Reactives (Mandatory)

This Appendix contains a listing of toxic and reactive highly

hazardous chemicals which present a potential for a catastrophic

event at or above the threshold quantity.

CHEMICAL name CAS* TQ**

Acetaldehyde ............................................. 75-07-0 2500

Acrolein (2-Propenal) ................................ 107-02-8 150

Acrytyl Chloride ........................................ 814-68-6 250

Allyl Chloride ............................................ 107-05-1 1000

Allylamine ................................................. 107-11-9 1000

Alkylaluminums ........................................ Varies 5000

Ammonia, Anhydrous................................ 7664-41-7 10000

Ammonia solutions

 (>44% ammonia by weight) .................. 7664-41-7 15000

Ammonium Perchlorate............................. 7790-98-9 7500

Ammonium Permanganate ........................ 7787-36-2 7500

Arsine (also called Arsenic Hydride) ........ 7784-42-1 100

Bis(Chloromethyl) Ether ........................... 542-88-1 100

Boron Trichloride ...................................... 10294-34-5 2500

Boron Trifluoride ....................................... 7637-07-2 250

Bromine ..................................................... 7726-95-6 1500

Bromine Chloride ...................................... 13863-41-7 1500

Bromine Pentafluoride............................... 7789-30-2 2500

Bromine Trifluoride ................................... 7787-71-5 15000

3-Bromopropyne (also called

 Propargyl Bromide) ............................... 106-96-7 100

Butyl Hydroperoxide (Tertiary) ................. 75-91-2 5000

Butyl Perbenzoate (Tertiary) ..................... 614-45-9 7500

Carbonyl Chloride (see Phosgene) ............ 75-44-5 100

Carbonyl Fluoride ...................................... 353-50-4 2500

Cellulose Nitrate (concentration

 > 12.6% nitrogen ................................... 9004-70-0 2500

Chlorine ..................................................... 7782-50-5 1500

Chlorine Dioxide ....................................... 10049-04-4 1000

Chlorine Pentrafluoride ............................. 13637-63-3 1000

Chlorine Trifluoride ................................... 7790-91-2 1000

Chlorodiethylaluminum (also called

 Diethylaluminum Chloride) ................... 96-10-6 5000

1-Chloro-2, 4-Dinitrobenzene ................... 97-00-7 5000

Chloromethyl Methyl Ether ....................... 107-30-2 500

Chloropicrin ............................................... 76-06-2 500

CHEMICAL name .................................... CAS* TQ**
43

Appendix A to § 1910.119

CHEMICAL name CAS* TQ**

Chloropicrin and Methyl

 Bromide mixture .................................... None 1500

Chloropicrin and Methyl

 Chloride mixture .................................... None 1500

Cumene Hydroperoxide............................. 80-15-9 5000

Cyanogen ................................................... 460-19-5 2500

Cyanogen Chloride .................................... 506-77-4 500

Cyanuric Fluoride ...................................... 675-14-9 100

Diacetyl Peroxide

 (concentration >700%) .......................... 110-22-5 5000

Diazomethane ............................................ 334-88-3 500

Dibenzoyl Peroxide ................................... 94-36-0 7500

Diborane .................................................... 19287-45-7 100

Dibutyl Peroxide (Tertiary) ....................... 110-05-4 5000

Dichloro Acetylene .................................... 7572-29-4 250

Dichlorosilane ........................................... 4109-96-0 2500

Diethylzinc ................................................ 557-20-0 10000

Diisopropyl Peroxydicarbonate ................. 105-64-6 7500

Dilaluroyl Peroxide ................................... 105-74-8 7500

Dim ethy Id ich lorosi lane ........................ 75-78-5 1000

Dimethylhydrazine, 1,1 ............................. 57-14-7 1000

Dimethylamine, Anhydrous ....................... 124-40-3 2500

2,4-Dinitroanitine ...................................... 97-02-9 5000

Ethyl Methyl Ketone Peroxide

 (also Methyl Ethyl Ketone

 Peroxide; concentration >60%) ............. 1338-23-4 5000

Ethyl Nitrite ............................................... 109-95-5 5000

Ethylamine ................................................. 75-04-7 7500

Ethylene Fluorohydrin ............................... 371-62-0 100

Ethylene Oxide .......................................... 75-21-8 5000

Ethyleneimine ............................................ 151-56-4 1000

Fluorine ..................................................... 7782-41-4 100

Formaldehyde (Formalin’) ........................ 50-00-0 1000

Furan .......................................................... 110-00-9 500

Hexafluoroacetone ..................................... 684-16-2 5000

Hydrochloric Acid, Anhydrous .................. 7647-01-0 5000

Hydrofluoric Acid, Anhydrous .................. 7664-39-3 1000

Hydrogen Bromide .................................... 10035-10-6 5000

Hydrogen Chloride .................................... 7647-01-0 5000

Hodrogen Cyanide, Anhydrous ................. 74-90-8 1000

Hydrogen Fluoride .................................... 7664-39-3 1000

Hydrogen Peroxide (52% by

 weight or greater .................................... 7722-84-1 7500

Hydrogen Selenide .................................... 7783-07-5 150

Hydrogen Sulfide ....................................... 7783=06-4 1500
Process Safety Management

44

CHEMICAL name CAS* TQ**

HydroxIamine ............................................ 7803-49-8 2500

Iron, Pentacarbonyl .................................... 13463-40-6 250

Isopropylamine .......................................... 75-31-0 5000

Ketene ........................................................ 463-51-4 100

Methacrylaldehyde .................................... 78-85-3 1000

Methacryloyl Chloride ............................... 920-46-7 150

Methacryloyloxyethyl Isocyanate.............. 30674-80-7 100

Methyl Acrylonitrile .................................. 126-98-7 250

Methylamine, Anhydrous .......................... 74-89-5 1000

Methyl Bromide......................................... 74-83-9 2500

Methyl Chloride......................................... 74-87-3 15000

Methyl Chloroformate ............................... 79-22-1 500

Methyl Ethyl Ketone Peroxide

 (concentration >60%) ............................ 1338-23-4 5000

Methyl Fluoroacetate ................................. 453-18-9 100

Methyl Fluorosulfate ................................. 421-20-5 100

Methyl Hydrazine ...................................... 60-34-4 100

Methyl Iodide ............................................ 74-88-4 7500

Methyl Isocyanate ..................................... 624-83-9 250

Methyl Mercaptan ..................................... 74-93-1 5000

Methyl Vinyl Ketone ................................. 79-84-4 100

Methyltrichlorosilane ................................ 75-79-6 500

Nickel Carbonly (Nickel

 Tetracarbonyl) ........................................ 13463-39-3 150

Nitric Acid (94.5% by

 weight or greater) .................................. 7697-37-2 500

Nitric Oxide ............................................... 10102-43-9 250

Nitroaniline (para Nitroaniline) ................. 100-01-6 5000

Nitromethane ............................................. 75-52-5 2500

Nitrogen Dioxide ....................................... 10102-44-0 250

Nitrogen Oxides (NO; NO2

;

 N204; N203) .......................................... 10102-44-0 250

Nitrogen Tetroxide (also called

 Nitrogen Peroxide) ................................ 10544-72-6 250

Nitrogen Trifluoride .................................. 7783-54-2 5000

Nitrogen Trioxide ...................................... 10544-73-7 250

Oleum (65% to 80% by weight;

 also called Fuming Sulfuric Acid .......... 8014-94-7 1000

Osmium Tetroxide ..................................... 20816-12-0 100

Oxygen Difluoride (Fluorine

 Monoxide) ............................................. 7783-41-7 100

Ozone ......................................................... 10028-15-6 100

Pentaborane ............................................... 19624-22-7 100
45

CHEMICAL name CAS* TQ**

Peracetic Acid (concentration

 >60% Acetic Acid; also called

 Peroxyacetic Acid)................................. 79-21-0 1000

Perchloric Acid (concentration

 >60% by weight) ................................... 7601-90-3 5000

Perchloromethyl Mercaptan ...................... 594-42-3 150

Perchloryl Fluoride .................................... 7616-94-6 5000

Peroxyacetic Acid (concentration

 >60% by Acetic Acid; also called’

 Paracetic Acid) ....................................... 79-21-0 1000

Phosgene (also called

 Carbonyl Chloride) ................................ 75-44-5 100

Phosphine (Hydrogen Phosphide) ............. 7803-51-2 100

Phosphorus Oxychloride (also

 called Phosphoryl Chloride) .................. 10025-87-3 1000

Phosphorus Trichloride .............................. 7719-12-2 1000

Phosphoryl Chloride (also called

 Phosphorus Oxychloride ....................... 10025-87-3 1000

Propargyl Bromide .................................... 106-96-7 100

Propyl Nitrate ............................................ 627-3-4 100

Sarin ........................................................... 107-44-8 100

Selenium Hexafluoride .............................. 7783-79-1 1000

Stibine (Antimony Hydride) ...................... 7803-52-3 500

Sulfur Dioxide (liquid) .............................. 7446-09-5 1000

Sulfur Pentafluoride................................... 5714-22-7 250

Sulfur Tetrafluoride ................................... 7783-60-0 250

Sulfur Trioxide (also called

 Sulfuric Anhydride) ............................... 7446-11-9 1000

Sulfuric Anhydride (also called

 Sulfur Trioxide) ..................................... 7446-11-9 1000

Tellurium Hexafluoride ............................. 7783-80-4 250

Tetrafluoroethylene .................................... 116-14-3 5000

Tetrafluorohydrazine ................................. 10036-47-2 5000

Tetramethyl Lead ....................................... 75-74-1 1000

Thionyl Chloride ....................................... 7719-09-7 250

Trichloro (chloromethyl) Silane ................ 1558-25-4 100

Trichloro (dichlorophenyl) Silane ............. 27137-85-5 2500

Trichlorosilane ........................................... 10025-78-2 5000

Triflurochloroethylene ............................... 79-38-9 10000

Trimethyoxysilane ..................................... 2487-90-3 1500

 *Chemical Abstract Service Number.

**Threshold Quantity in Pounds (Amount necessary to be covered by this standard).

Appendix A to § 1910.119
Process Safety Management

46 Appendix B to § 1910.119

Appendix B to § 1910.119—Block Flow Diagram and Simplified

Process Flow Diagram (Nonmandatory)

Example of a Block Flow Diagram
47

Appendix B to § 1910.119

Example of a Simplified Process Flow Diagram
Process Safety Management

48 OSHA Consultation Directory

State Telephone

Alabama ...................................................................... (205) 348-3033

Alaska ......................................................................... (907) 269-4957

Arizona ....................................................................... (602) 542-1695

Arkansas ..................................................................... (501) 682-4522

California .................................................................... (415) 703-5270

Colorado ..................................................................... (970) 491-6151

Connecticut ................................................................. (860) 566-4550

Delaware ..................................................................... (302) 761-8219

District of Columbia ................................................... (202) 576-6339

Florida......................................................................... (850) 922-8955

Georgia ....................................................................... (404) 894-2643

Guam ............................................................. ..... 011(671) 475-0136

Hawaii ......................................................................... (808) 586-9100

Idaho ........................................................................... (208) 426-3283

Illinois ......................................................................... (312) 814-2337

Indiana ........................................................................ (317) 232-2688

Iowa ............................................................................ (515) 965-7162

Kansas......................................................................... (785) 296-7476

Kentucky ..................................................................... (502) 564-6895

Louisiana .................................................................... (504) 342-9601

Maine .......................................................................... (207) 624-6460

Maryland..................................................................... (410) 880-4970

Massachusetts ............................................................. (617) 727-3982

Michigan ..................................................................... (517) 322-6823(H)

............................................................................... (517) 322-1809(S)

Minnesota ................................................................... (612) 297-2393

Mississippi .................................................................. (601) 987-3981

Missouri ...................................................................... (573) 751-3403

Consultation programs provide free services to employers who

request help in identifying and correcting specific hazards, want to

improve their safety and health programs, and/or need further

assistance in training and education. Funded by OSHA and delivered

by well-trained professional staff of state governments, consultation

services are comprehensive, and include an appraisal of all workplace hazards, practices, and job safety and health programs; conferences and agreements with management; assistance in implementing

recommendations; and a follow-up appraisal to ensure that any

required corrections are made. For more information on consultation

programs, contact the appropriate office in your state listed below.
49

Montana ...................................................................... (406) 444-6418

Nebraska ..................................................................... (402) 471-4717

Nevada ........................................................................ (702) 486-9140

New Hampshire .......................................................... (603) 271-2024

New Jersey .................................................................. (609) 292-3923

New Mexico ............................................................... (505) 827-4230

New York .................................................................... (518) 457-2238

North Carolina ............................................................ (919) 807-2905

North Dakota .............................................................. (701) 328-5188

Ohio ............................................................................ (614) 644-2246

Oklahoma ................................................................... (405) 528-1500

Oregon ........................................................................ (503) 378-3272

Pennsylvania ............................................................... (742) 357-2396

Puerto Rico ................................................................. (787) 754-2171

Rhode Island ............................................................... (401) 222-2438

South Carolina ............................................................ (803) 734-9614

South Dakota .............................................................. (605) 688-4101

Tennessee .................................................................... (615) 741-7036

Texas ........................................................................... (512) 804-4640

Utah ............................................................................ (801) 530-6901

Vermont ...................................................................... (802) 828-2765

Virginia ....................................................................... (804) 786-6359

Virgin Islands .............................................................. (340) 772-1315

Washington ................................................................. (360) 902-5638

West Virginia .............................................................. (304) 558-7890

Wisconsin ................................................................... (608) 266-8579(H)

............................................................................... (262) 523-3040(S)

Wyoming .................................................................... (307) 777-7786

(H) - Health

(S) - Safety

OSHA Consultation Directory
Process Safety Management

50 States with Approved Plans

States administering their own occupational safety and health

programs through plans approved under section 18(b) of the Occupational Safety and Health Act of 1970 must adopt standards and

enforce requirements that are at least as effective as federal

requirements.

There are currently 25 state plan states; 23 cover the private and

public (state and local government) sections and 2 cover the public

sector only (Connecticut and New York)

Commissioner

Alaska Department of Labor

1111 West 8th Street

Room 304

Juneau, AK 99801-1149

(907) 465-2700

Director

Industrial Commission of Arizona

800 W. Washington

Phoenix, AZ 85007-2922

(602) 542-5795

Director

California Department

 of Industrial Relations

455 Golden Gate Avenue -

 10th Floor

San Francisco, CA 94102

(415) 703-5050

Commissioner

Connecticut Department of Labor

200 Folly Brook Boulevard

Wethersfield, CT 06109

(203) 566-5123

Director

Hawaii Department of Labor

 and Industrial Relations

830 Punchbowl Street

Honolulu, HI 96813

(808) 586-8844

Commissioner

Indiana Department of Labor

 State Office Building

402 West Washington Street

Room W195

Indianapolis, IN 46204-2751

(317) 232-2378

Commissioner

Iowa Division of Labor Services

1000 E. Grand Avenue

Des Moines, IA 50319-0209

(515) 281-3447

Secretary

Kentucky Labor Cabinet

1047 U.S. Highway, 127 South,

 Suite 4

Frankfort, KY 40601

(502) 564-3070
51

States with Approved Plans

Commissioner

Maryland Division of Labor

 and Industry

Department of Labor, Licensing,

 and Regulation

1100 N. Eutaw Street,

Room 613

Baltimore, MD 21201-2206

(410) 767-2215

Director

Michigan Department

 of Consumer and Industry

 Services

P.O. Box 30643

Lansing, MI 48909-8143

(517) 322-1814

Commissioner

Minnesota Department of Labor

 and Industry

443 Lafayette Road

St. Paul, MN 55155-4307

(651) 296-2342

Administrator

Nevada Division of Industrial

 Relations

400 West King Street

Carson City, NV 89710

(775) 687-3032

Secretary

New Mexico Environment

 Department

1190 St. Francis Drive

P.O. Box 26110

Santa Fe, NM 87502

(505) 827-2850

Commissioner

New York Department of Labor

W. Averell Harriman State Office

 Building - 12, Room 500

Albany, NY 12240

(518) 457-2741

Commissioner

North Carolina Department

 of Labor

4 West Edenton Street

Raleigh, NC 27601-1092

(919) 807-7166

Administrator

Department of Consumer

 and Business Services

Occupational Safety and Health

 Division (OR-OSHA)

350 Winter Street, NE,

 Room 430

Salem, OR 97310-0220

(503) 378-3272
Process Safety Management

52

Secretary

Puerto Rico Department

 of Labor and Human Resources

Prudencio Rivera Martinez

 Building

505 Munoz Rivera Avenue

Hato Rey, PR 00918

(787) 754-2119

Director

South Carolina Department

 of Labor, Licensing, and

 Regulation

Koger Office Park,

 Kingstree Building

110 Centerview Drive

P.O. Box 11329

Columbia, SC 29210

(803) 896-4300

Commissioner

Tennessee Department of Labor

Attention: Robert Taylor

710 James Robertson Parkway

Nashville, TN 37243-0659

(615) 741-2582

Commissioner

Labor Commission of Utah

160 East 300 South, 3rd Floor

P.O. Box 146650

Salt Lake City, UT 84114-6650

(801) 530-6898

Commissioner

Vermont Department

 of Labor and Industry

National Life Building -

 Drawer 20

National Life Drive

Montpelier, VT 05620-3401

(802) 828-5098

Commissioner

Virginia Department of Labor

 and Industry

Powers-Taylor Building

13 South 13th Street

Richmond, VA 23219

(804) 786-2377

Commissioner

Virgin Islands Department

 of Labor

2203 Church Street

Christiansted

St. Croix, VI 00820-4660

(340) 773-1994

Director

Washington Department

 of Labor and Industries

P.O. Box 44001

Olympia, WA 98504-4001

(360) 902-4200

States with Approved Plans
53

Administrator

Worker’s Safety and

 Compensation Division (WSC)

Wyoming Department

 of Employment

Herschler Building,

 2nd Floor East

122 West 25th Street

Cheyenne, WY 82002

(307) 777-7786

States with Approved Plans
54

Single free copies of the following publications can be obtained

from the OSHA Publications Office, Room N3101, Washington, DC

20210, (202) 693-1888.

All About OSHA - OSHA 2056

Chemical Hazard Communication - OSHA 3084

Consultation Services for the Employer - OSHA 3047

Employee Workplace Rights - OSHA 3021

How to Prepare for Workplace Emergencies - OSHA 3088

OSHA Inspections - OSHA 2098

OSHA: Employee Workplace Rights - OSHA 3021

Personal Protective Equipment - OSHA 3077

Process Safety Management Guidelines for Compliance

 - OSHA 3133

Respiratory Protection - OSHA 3079

Process Safety Management of Highly Hazardous Chemicals

Standard, Title 29, Code of Federal Regulations (CFR) Part

1910.119 (FR 57(36):6356 - 6417, February 24, 1992). This contains

the actual text of the PSM rule.

The following items are available from the Superintendent of

Documents, U.S. Government Printing Office, Washington, DC

20402, (202) 783-3238.

OSHA 3104 Hazard Communication - (A reference guide to stepby-step requirements of the OSHA standard.) GPO Order No. 029-

016-00200-6, $17.00.

Related Publications
Region I

(CT,* MA, ME, NH, RI, VT*)

JFK Federal Building

Room E-340

Boston, MA 02203

Telephone: (617) 565-9860

Region II

(NJ, NY,* PR,* VI*)

201 Varick Street

Room 670

New York, NY 10014

Telephone: (212) 337-2378

Region III

(DC, DE, MD,* PA, VA,* WV)

The Curtis Center - Suite 740 West

170 S. Independence Mall West

Philadelphia, PA 19106-3309

Telephone: (215) 861-4900

Region IV

(AL, FL, GA, KY,* MS, NC,*

SC,* TN*)

Atlanta Federal Center

61 Forsyth Street, SW, Room 6T50

Atlanta, GA 30303

Telephone: (404) 562-2300

Region V

(IL, IN,* MI,* MN,* OH, WI)

230 South Dearborn Street

Room 3244

Chicago, IL 60604

Telephone: (312) 353-2220

*These states and territories operate their own OSHA-approved job safety

and health programs (Connecticut and New York plans cover public employees

only). States with approved programs must have a standard that is identical to,

or at least as effective as, the federal standard.

Region VI

(AR, LA, MN,* OK, TX)

525 Griffin Street

Room 602

Dallas, TX 75202

Telephone: (214) 767-4731

Region VII

(IA,* KS, MO, NE)

City Center Square

1100 Main Street, Suite 800

Kansas City, MO 64105

Telephone: (816) 426-5861

Region VIII

(CO, MT, ND, SD, UT,* WY*)

1999 Broadway

Suite 1690

Denver, CO 80202-5716

Telephone: (303) 844-1600

Region IX

(American Samoa, AZ,* CA,*

Guam, HI,* NV,* Trust

Territories of the Pacific)

71 Stevenson Street

4th Floor

San Francisco, CA 94105

Telephone: (415) 975-4310

Region X

(AK,* ID, OR,* WA*)

1111 Third Avenue

Suite 715

Seattle, WA 98101-3212

Telephone: (206) 553-5930

U.S. Department of Labor

Occupational Safety and Health Administration

Regional Offices