osha3132-PSM

ProcessSafetyManagementU.S.DepartmentofLaborOccupationalSafetyandHealthAdministrationOSHA31322000(Reprinted)Thisinformationalbookletisintendedtoprovideageneric,non-exhaustiveoverviewofaparticularstandards-relatedtopic.Thispublicationdoesnotitselfalterordeterminecomplianceresponsibilities,whicharesetforthinOSHAstandardsthem-selvesandtheOccupationalSafetyandHealthAct.Moreover,becauseinterpretationsandenforcementpolicymaychangeovertime,foradditionalguidanceonOSHAcompliancerequire-ments,thereadershouldconsultcurrentandadministrativeinter-pretationsanddecisionsbytheOccupationalSafetyandHealthReviewCommissionandtheCourts.Materialcontainedinthispublica-tionisinthepublicdomainandmaybereproduced,fullyorpartially,withoutpermissionoftheFederalGovernment.Sourcecreditisrequestedbutnotrequired.Thisinformationwillbemadeavailabletosensoryimpairedindividualsuponrequest.Voicephone:[phone]ProcessSafetyManagementU.S.DepartmentofLaborAlexisM.Herman,SecretaryOccupationalSafetyandHealthAdministrationCharlesN.Jeffress,AssistantSecretaryOSHA31322000(Reprinted)ContentsContentsiiiTheProblem..........................................................................1HowtheStandardWorks.......................................................5ProcessSafetyInformation...................................................7ProcessHazardAnalysis.......................................................9OperatingProcedures..........................................................12EmployeeParticipation.......................................................14Training................................................................................15InitialTraining............................................................15RefresherTraining......................................................15TrainingDocumentation.............................................15Contractors..........................................................................16Application.................................................................16EmployerResponsibilities..........................................16ContractEmployerResponsibilities...........................16Pre-StartupSafetyReview..................................................18MechanicalIntegrity............................................................19HotWorkPermit..................................................................21ManagementofChange......................................................22IncidentInvestigation..........................................................23EmergencyPlanningandResponse....................................24ComplianceAudits...............................................................25TradeSecrets.......................................................................26Part1910-OccupationalSafetyandHealthStandards........27§1910.109ExplosivesandBlastingAgents.......................27§1910.119ProcessSafetyManagementofHighlyHazardousChemicals...........................................28AppendixA-ListofHighlyHazardousChemicals,ToxicsandReactives(Mandatory)..................................42AppendixB-BlockFlowDiagramandSimplifiedProcessFlowDiagram(Nonmandatory).......................................46OSHAConsultationDirectory..............................................48StatesWithApprovedPlans................................................50RelatedPublications...........................................................54TheProblemTheProblem1Unexpectedreleasesoftoxic,reactive,orflammableliquidsandgasesinprocessesinvolvinghighlyhazardouschemicalshavebeenreportedformanyyears.Incidentscontinuetooccurinvariousindustriesthatusehighlyhazardouschemicalswhichmaybetoxic,reactive,flammable,orexplosive,ormayexhibitacombinationoftheseproperties.Regardlessoftheindustrythatusesthesehighlyhazardouschemicals,thereisapotentialforanaccidentalreleaseanytimetheyarenotproperlycontrolled.This,inturn,createsthepossibilityofdisaster.Recentmajordisastersincludethe1984Bhopal,India,incidentresultinginmorethan2,000deaths;theOctober1989PhillipsPetroleumCompany,Pasadena,TX,incidentresultingin23deathsand132injuries;theJuly1990BASF,Cincinnati,OH,incidentresultingin2deaths,andtheMay1991IMC,Sterlington,LA,incidentresultingin8deathsand128injuries.Althoughthesemajordisastersinvolvinghighlyhazardouschemicalsdrewnationalattentiontothepotentialformajorcatastro-phes,thepublicrecordisrepletewithinformationconcerningmanyotherlessnotablereleasesofhighlyhazardouschemicals.Hazard-ouschemicalreleasescontinuetoposeasignificantthreattoemploy-eesandprovideimpetus,internationallyandnationally,forauthori-tiestodeveloporconsiderdevelopinglegislationandregulationstoeliminateorminimizethepotentialforsuchevents.OnJuly17,1990,OSHApublishedintheFederalRegister(55FR29150)aproposedstandard,—”ProcessSafetyManagementofHighlyHazardousChemicals”—containingrequirementsforthemanagementofhazardsassociatedwithprocessesusinghighlyhazardouschemicalstohelpassuresafeandhealthfulworkplaces.OSHA’sproposedstandardemphasizedthema