OSHA General Industry · Part 11: Radiation, Formaldehyde and Process Safety Management
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11.3 Process Safety Management (PSM)
Many incidents each year involve the unexpected release of toxic, reactive or flammable liquids and gases in processes that use highly hazardous chemicals. OSHA's Process Safety Management standard aims to prevent or limit them. It applies to processes that involve listed chemicals at or above set quantities, or flammable liquids and gases in quantities of 10,000 pounds or more. It is found mainly in chemical manufacturing, but also in other sectors such as natural gas liquids and some storage and distribution.
| Term | Meaning |
|---|---|
| Process | Any activity with a highly hazardous chemical: use, storage, manufacture, handling or movement on site, or any combination. |
| Highly hazardous chemical | A toxic, reactive, flammable or explosive substance. |
| Catastrophic release | A major uncontrolled emission, fire or explosion that presents serious danger to workers. |
| Hot work | Welding, cutting, brazing or similar flame or spark producing work. |
| Atmospheric tank | A storage tank that works at pressures from atmospheric up to 0.5 pounds per square inch gauge. |
Elements of the standard
- Employee participation. Workers help to develop and carry out the program, and have access to process hazard analyses and other information.
- Process safety information. Written information on the hazards of the chemicals, the technology of the process and the equipment, compiled before any process hazard analysis.
- Process hazard analysis (PHA). A systematic method to identify and evaluate the hazards of a process. The first analysis must be done as soon as possible. It is updated and revalidated at least every five years. A team with engineering and process expertise carries it out, including at least one employee who knows the process and one who knows the method. The employer must have a system to act on the team's findings in good time, document the actions, set a schedule and tell maintenance and affected employees.
- Operating procedures. Written procedures for initial start up, normal operation, temporary operations, emergency shutdown, emergency operations and normal shutdown. They must be kept current and certified as accurate every year. Safe work practices apply to employees and contractors.
- Training. Each worker is trained in an overview of the process and its procedures, in the specific hazards and in emergency operations, before being assigned. Experienced workers may be certified in writing instead. Refresher training is given at least every three years, and training is documented.
- Contractors. The host employer obtains and evaluates information on a contractor's safety performance and program, and informs contractors of the hazards.
- Pre-start-up safety review for new and modified facilities.
- Mechanical integrity of critical equipment: written procedures, trained maintenance workers, inspection and testing, and correction of deficiencies.
- Hot work permits for welding, cutting and similar work in covered process areas.
- Management of change for changes to chemicals, technology, equipment and procedures.
- Incident investigation of every incident that caused, or could have caused, a catastrophic release, started within 48 hours.
- Emergency planning and response.
- Compliance audits at least every three years.
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