Process Safety Management (29 CFR 1910.119) - Training offered by Chemical Distributors, Incorporated

• The standard covers specific listed highly hazardous chemicals when present in a process in quantities at or above the threshold quantities listed in Appendix A of the standard.
• In addition, flammable liquids or gases in quantities of 10,000 pounds or more are covered unless they are used solely for heating or fuel.

Employers must develop a written plan that includes the following:

• Compile written process information, including information on:
  • the hazards of the highly hazardous chemicals used or produced by the process
  • the technology of the process
  • the equipment in the process.
• Perform a process hazard analysis. The process hazard analysis will review what could go wrong and what safeguards must be implemented to prevent releases of hazardous chemicals.
• Develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process.The procedures will address:
  • steps for each operating phase (startup, normal operation, emergency shutdown, etc.)
  • operating limits
  • safety and health considerations
  • work activities such as lockout/tagout and entrance into a facility by contractor personnel.
• Develop a written plan of action to implement the employee participation required by the standard.
• Implement an effective training program
  • initial training
  • refresher training
  • training documentation
• Establish a program for evaluating a contract employer's safety performance and programs, informing the contract employer of information about the process and emergency procedures needed for safe work, and maintaining a contract employee injury and illness log.
• 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.
• Establish and implement written procedures to maintain the ongoing mechanical integrity of process equipment.
• Require the issuance of a permit for hot work operation conducted on or near a covered process.
• 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.
• Investigate within 48 hours or sooner each incident that resulted in, or could reasonably have resulted in, a catastrophic release of a highly hazardous chemical in the workplace and establish a system to promptly address and resolve the incident report findings and recommendations.
• Develop an emergency action plan in accordance with 29 CFR 1910.38(a) and include procedures for handling small releases of hazardous chemicals; 29 CFR 1910.120 - Hazardous Waste Operations and Emergency Response, may also apply.
• Conduct compliance audits at least every 3 years to verify that the procedures and practices developed under the standard are adequate and that they are being followed.
• Provide all required information for the above steps without regard to trade secret status; confidentiality agreements may be implemented to protect an employer's trade secrets