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OSHA Process Safety Management Requirements

According to the Occupational Safety and Health Administration (OSHA), "unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals have been reported for many years." All industries that use hazardous chemicals have the potential for accidental release if they do not follow proper safety and control measures. OSHA uses federal regulation 29 CFR 1910.119 to provide the requirements for process safety management.

  1. Process Safety Information

    • Employers must post a written safety plan that includes chemical and process hazard identification, process equipment and the technology used in the workplace. Material Safety Data Sheets (MSDS) are a primary tool to explain chemical hazards. Restricting access to process equipment areas minimizes injuries or illnesses.

    Process Hazard Analysis

    • OSHA requires employers to conduct a “what-if” workplace hazard assessment to identify potential sources of accidental releases, identify past releases and estimate the health and safety effects on employees. Engineering and administrative controls, including detection devices, alarms and how they interact, are analyzed. A process hazard analysis is required at least every five years.

    Operating Procedures

    • Written operating procedures are required. Detailed instructions for equipment operation include initial startup, normal operation, emergency shutdown, normal shutdown and restart procedures. Operating procedures are also required to encompass safety and health issues including properties of the chemicals used, control measures used to prevent exposure, procedures if an exposure occurs and safety systems. Operating procedures should be reviewed annually.

    Employee Participation

    • Employers must allow worker participation in the process safety management system. Employees should assist with conducting process hazard analysis and developing accident prevention plans. Employees must have full access to safety records.

    Training

    • Initial comprehensive employee training includes knowledge of process operating procedures, the ability to recognize symptoms of chemical exposure, emergency evacuation plans and emergency response cleanup procedures. Refresher training is required every three years, when employees show a lack of knowledge or when the process operating procedures change. Employers must maintain training records reflecting the employee’s name, date of training and verification of employee understanding.

    Incident Investigation

    • Employers must investigate an incident within 48 hours. The investigation must include a description of the incident, the cause of the incident and recommendations to prevent reoccurrences. Employers must maintain a written record of the investigation for five years.

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