Process Safety Management of Highly Hazardous Chemicals

Process Safety Management of Highly Hazardous Chemicals

/ Process Safety Management
of Highly Hazardous Chemicals | 1

Process Safety Management
of Highly Hazardous Chemicals

29 CFR 190.119

Process Safety Management

of Highly Hazardous Chemicals

The objective of Process Safety management (PSM) is to prevent unwanted releases of hazardous chemicals, especially into locations that could expose employees and others to serious hazards.

Who is Affected?

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.

What is a Process?

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.

Highly Hazardous Chemicals

A highly hazardous chemical (HHC) is any substance that is toxic, reactive, flammable or explosive. Some examples of HHCs include anhydrous ammonia, hydrogen sulfide and chlorine.

Highly hazardous chemicals are dangerous because, if they are accidentally released, they have the potential to cause a catastrophic incident that could cause injury or death at your facility and even in the surrounding community.

Who Must be Trained?

Under the PSM standard, OSHA wants to eliminate having untrained workers in the workplace and wants to ensure that everyone who needs training receives it.

  • All current employees who are involved in operating a process must receive training.
  • Second, each new employee must be trained before operating a newly-assigned process.

Employees must be trained who are involved in operating a process that involve:

  • A chemical at or above the specified threshold quantities.
  • Pressure vessels and storage tanks.
  • Piping systems, including components such as valves.
  • Relief and vent systems and their associated devices.
  • Emergency shutdown systems.
  • Controls.
  • Pumps.

The safety and health considerations of a process include anything that is likely to cause health problems or result in process-related injuries or death.

Safe Operating Procedures

Written operating procedures should be developed and implemented to provide clear instruction for safely conducting activities that are involved in the process.

Employee Training

OSHA regulations contain specific training requirements for process safety management. At 29 CFR 1910.119(g), the rule says that each employee presently involved in operating a process, and each newly assigned employee (before beginning to work on the process) must be trained in an overview of the process and in the operating procedures. The training must include emphasis on:

  • The specific safety and health hazards.
  • Emergency operations including shutdown.
  • Safe work practices applicable to the employee’s job tasks.

Refresher training must be provided at least every three 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.

Training Tips

  • Describe the hazards of the highly hazardous chemicals used in processes at your facility.
  • Inform employees who work in or maintain a process of the availability, content and location of the safe operating procedures.
  • Discuss the properties of, and hazards presented by, the chemicals used in the process.
  • Review precautions necessary to prevent exposure.
  • Review of any special or unique hazards associated with the processes in your workplace.

For more information see:

  • 29 CFR 1910.119—Process Safety Management of Highly Hazardous Chemicals

Process Safety Management

of Highly Hazardous Chemicals Handout

The main objective of Process Safety Management (PSM) is to prevent unwanted releases of hazardous chemicals, especially into locations that could expose employees and others to serious hazards.

Under the PSM standard, OSHA wants to eliminate having untrained workers in the workplace and wants to ensure that everyone who needs training receives it.

Who Must be Trained?

All employees must be trained:

  • All current employees who are involved in operating a process; and
  • Each employee before operating a newly-assigned process.

Employees must be trained if they are involved in operating a process that involve:

  • A chemical at or above the specified threshold quantities.
  • Pressure vessels and storage tanks.
  • Piping systems, including components such as valves.
  • Relief and vent systems and their associated devices.
  • Emergency shutdown systems
  • Controls.
  • Pumps.

What Employers Must Do

Your employer will provide training that emphasizes:

  • Specific safety and health hazards;
  • Procedures;
  • Emergency operations that include shutdowns;
  • Safe practices applicable to your job; and
  • Any significant changes in the process you are involved in.

Process Safety Management of Highly Hazardous Chemicals Sign–Off Sheet

The employees of ______Company Name______, have taken part in a training session Process Safety Management of Highly Hazardous Checmicals. The session covered:

  • The definition of highly hazardous chemicals.
  • Training requirements for employees who work in or maintain a process.
  • The need for safe operating porcedures.
  • The availability, content and location of the safe operating procedures.

Date of Training: / Facility:
Employee Signature / PRINT NAME

______

Supervisor’s Signature