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Timestamp: 2017-06-27 05:17:02
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Matched Legal Cases: ['§ 1910', '§ 1910', 'art 1911', 'art 1911', '§ 1910', '§ 1910', '§ 1910', '§ 1910', '§ 1910', '§ 1910', '§ 1910', 'art 1910']

Process Safety Management | Occupational Safety and Health Administration
Process Safety Management U.S. Department of Labor
§ 1910.109 Explosives and Blasting Agents
§ 1910.119 Process Safety Management of Highly Hazardous Chemicals
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, 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:
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 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.
Information on the hazards of the highly hazardous chemicals in the process shall consist of at least the following:1
Piping and instrument diagrams (P&IDs),
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.
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:
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;
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:
Emergency shutdown, including the conditions under which emergency shutdown is required, and the assignment of shut down responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner;
Normal shutdown; and
Consequences of deviation, and
Quality control for raw materials and control of hazardous chemical inventory levels; and
Safety systems (e.g., interlocks, detection or suppression systems) and their functions.
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 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.
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.
Ensure that contract employees are trained in the work practices necessary to perform their job safely;
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.
Construction and equipment are in accordance with design specifications;
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
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 â€œreplacements in kindâ€�) 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:
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.
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:
â€¢ Date of incident,
â€¢ Date investigation began,
â€¢ Description of the incident,
â€¢ Factors that contributed to the incident, and
â€¢ 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.
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).
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) 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.
A new § 1910.119 and appendices A through D* to § 1910.119 are added to read as follows:
(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:
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.
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.
Trade secret means any confidential formula, pattern, process, device, information or compilation of information that is used in an 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.
(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.
(iv) Reactivity data;
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.
(G) Material and energy balances for processes built after May 26,1992;and,
(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,
(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.
(iii) What- if/checklist;
(3) The process hazard analysis shall address;
(6) At least every five (5) years after the completion of the initial process hazard analysis, the process hazard analysis shall be updatedand 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.
(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,.
(E) Emergency Operations,
(G) Startup following a turnaround, or after an emergency shutdown,
(ii) Operating limits;
(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.
(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.
(2) Employer responsibilities. (i) The employer, when selecting a contractor, shall obtain and evaluate information regarding the contract employerâ€™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 contractorâ€™s work and the process.
(vi) The employer shall maintain a contract employee injury and illness log related to the contractorâ€™s work in process areas.
(ii) The contract employer shall assure that each contract employee is instructed in the known potential fire, explosion, or toxicrelease hazards related to his/her job and the process, and the applicable provisions of the emergency action plan.
(v) The contract employer shall advise the employer of any unique hazards presented by the contract employerâ€™s work, or of any hazards found by the contract employerâ€™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.
(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).
(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 employeeâ€™s job tasks to assure that the employee can perform the job tasks in a safe manner.
(iii) The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturersâ€™ 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.
(ii) Appropriate checks and inspections shall be performed to assure that equipment is installed properly and consistent with design specifications and the manufacturerâ€™s instructions.
(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 â€œreplacements in kindâ€�) to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process.
(iv) Necessary time period for the change; and
(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.
(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.
(ii) Date investigation began:
(iv) The factors that contributed to the incident; and
(5) Employers shall retain the two (2) most recent compliance
Appendix A to § 1910.119-List of Highly Hazardous Chemicals, Toxics and Reactives (Mandatory)
Acrolein (2-Propenal) 107-02-8
Allylamine 107-11-9
Alkylaluminums Varies
Cellulose Nitrate (concentration > 12.6% nitrogen
Diacetyl Peroxide (concentration >700%)
Dim ethy Id ich lorosi lane
2,4-Dinitroanitine
Formaldehyde (Formalinâ€™)
Hodrogen Cyanide, Anhydrous
Hydrogen Peroxide (52% by weight or greater
7783=06-4
HydroxIamine
Nickel Carbonly (Nickel Tetracarbonyl) 13463-39-3
Oleum (65% to 80% by weight; also called Fuming Sulfuric Acid
Peroxyacetic Acid (concentration >60% by Acetic Acid; also calledâ€™ Paracetic Acid)
Phosphoryl Chloride (also called Phosphorus Oxychloride
Sarin 107-44-8
Triflurochloroethylene
Appendix B to Â§ 1910.119â€”Block Flow Diagram and Simplified Process Flow Diagram (Nonmandatory)
Example of a Block Flow Diagram*
* Accessibility Assistance Contact OSHA's Office of Communications at 209-693-1999 for assistance accessing these materials.
Example of a Simplified Process Flow Diagram*
California (415) 703-5270
(850) 922-8955
011(671) 475-0136
Michigan (517) 322-6823(H) (517) 322-1809(S)
(742) 357-2396
Puerto Rico (787) 754-2171
(608) 266-8579(H) (262) 523-3040(S)
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)
Maryland Division of Labor
Department of Labor, Licensing,
of Consumer and Industry
Nevada Division of Industrial
of Labor, Licensing, and
St. Croix, VI 00820-4660
National Life Building -
Workerâ€™s Safety and
Compensation Division (WSC)
Single free copies of the following publications can be obtained from the OSHA Publications Office, Room N3101, Washington, DC 20210, (202) 693-1888.
- OSHA 3133
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.
U.S. Department of Labor Occupational Safety and Health Administration Regional Offices
Region IV (AL, FL, GA, KY,* MS, NC,*
SC,* TN*)
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.