Safety Training Presentations: Process Safety Management of Highly Hazardous Chemicals 29 CFR 1910.119 (PSM) EH&S 3-13

Safety Training Presentations
Process Safety Management of

Highly Hazardous Chemicals
CFR 1910.119 (PSM)
EH&S 3-13
EH&S Safety References
EH&S 3-13 – Process Safety Management

– Appendix A, List of Highly Hazardous Chemicals,
Toxics, and Reactives
– Appendix B, Training Record
Disasters That Led to
Process Safety Management
 Bhopal, India (1984)
– 2,000 deaths
Isocyanate release
 Pasadena, TX (1989)
– 23 deaths, 132 injuries
Petroleum explosion
 Cincinnati, OH (1990)
– 2 deaths
Explosion
 Sterlington, LA (1991)
– 8 deaths, 128 injuries
Chemical release
Clean Air Act
Amendments—1990
 Requires Secretary of Labor along with
EPA to promulgate a PSM standard
 PSM standard must include a list
of highly hazardous chemicals
 Highly hazardous chemicals list
must include: toxics, flammables,
highly reactive and explosive materials
Minimum Program Requirements
 Written safety information

 Workplace hazard assessment
 Consult with employees
 Establish a system to respond to findings
 Periodic review of assessments and response
 Written operating procedures
 Safety training and operating information
Minimum Program Requirements (cont.)
 Appropriate information
and training for contractors
 Train and educate employees
in emergency response
 Establish a quality assurance program
 Establish maintenance systems
 Pre-start-up safety reviews
 Management of change
 Incident investigation
Application of PSM
 Companies that
process highly
hazardous materials
 Flammable liquids
and gases in
quantities in excess
of 10,000 pounds
Initial Process
Hazard Analysis Deadlines
 25% complete by May 26, 1994

Process Safety Information
 Toxicity
 Permissible
Exposure Limits
 Physical Data
 Reactivity Data
 Corrosivity Data
 Thermal and Chemical
Stability Data
Process Technology
 Block flow diagram or process flow diagram

 Process chemistry
 Maximum intended inventory
 Upper and lower limits
 Consequences of deviations
Information on
Process Equipment
 Materials of construction
 Piping and instrument diagrams (PIDs)
 Electrical classification
 Relief system design
 Ventilation system design
 Design codes
 Material and energy balances
 Safety systems
Items the PHA Must Address
 Hazards of the process

 Identification of previous incidents
 Engineering and administrative controls
 Consequences of failure
 Facility siting
 Human factors
 Qualitative evaluation of Safety and Health effects
Operating Phases
 Initial start-up
 Normal operations
 Temporary operations
 Emergency shutdown
 Emergency operations
 Normal shutdown
 Start-up following turnaround
Operating Limits
 Consequences of deviation
 Steps required to correct or avoid deviation
Safety and Health Considerations
 Properties and hazards of the chemicals

 Precautions to prevent exposures
 Control measures to be taken
 Quality control for raw materials/
control of inventory
 Special or unique hazards
 Safety systems and their functions
Management of Change
 Technical basis for the proposed change
 Impact of the change on safety and health
 Modifications of the operating procedures
 Necessary time period for the change

 Authorization requirements for the change
Training Requirements
 Initial training
– Prior to work assignment
– Waved for those already in a process
 Refresher training
– Every three years
 Training documentation
Contractor Requirements
 PSM applies to contractors in or

adjacent to a process performing
– Maintenance
– Repair
– Turnaround
– Major renovation
– Specialty work
 Does not apply to incidental contractors

– Food service
– Laundry
– Delivery, etc.
Incident Investigation Reports
 Date of incident
 Date investigation began
 Description of the incident
 Factors contributing to the incident
 Recommendations resulting from
the investigation
Quiz
1. The Process Safety Management

Standard was drafted as a requirement
of the Clean Air Act. True or False
2. The PSM program must include a list
of highly hazardous chemicals. True or False
3. The initial start-up of a process is not
included as an operating phase under
the PSM Standard. True or False
4. List three items that the process hazard analysis must
address___________, __________ and __________.
5. PSM does not apply to contractors,
regardless of the work they are doing. True or False
Quiz (cont.)
6. The PSM Standard applies to companies that either

process highly _____________ materials or use
_____________ liquids and gases in excess of 10,000 pounds.
7. Process safety information includes:
______________, _____________ and _____________.
8. Fault tree analysis is one form of an
approved method of performing a process
hazard analysis. True or False
9. A technical basis is not required to change
a process covered by the PSM Standard. True or False
10. Two types of training required by the PSM
standard are ________________ and_________________.
Acknowledgement
I acknowledge that I have received proper training on process safety
management procedures. By signing below, it shows that I understand
all of the questions and answers included in this training test and
understand the verbal training presented to me today.
Print name: Signature:
Date

Safety Training Presentations: Process Safety Management of Highly Hazardous Chemicals 29 CFR 1910.119 (PSM) EH&S 3-13

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Safety Training Presentations: Process Safety Management of Highly Hazardous Chemicals 29 CFR 1910.119 (PSM) EH&S 3-13

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Safety Training Presentations

Process Safety Management of

EH&S 3-13 – Process Safety Management

 Written safety information

 25% complete by May 26, 1994

 Block flow diagram or process flow diagram

 Hazards of the process

 Properties and hazards of the chemicals

 Technical basis for the proposed change

 Impact of the change on safety and health

 Modifications of the operating procedures

 Necessary time period for the change

 PSM applies to contractors in or

 Does not apply to incidental contractors

1. The Process Safety Management

6. The PSM Standard applies to companies that either

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