Process Safety Management

Scope

The regulation applies to any process that involves a chemical at or above specified threshold quantities, or any process that involves a Category 1 flammable gas as defined by Title 8 CCR 5194, or a flammable liquid with a flashpoint below 100^° F on site in one location in a quantity of 10,000 pounds or more.

Regulatory citations

• Title 8, CCR 5189 — Process Safety Management of Acutely Hazardous Materials
• Title 8, CCR 5189.1 — Process Safety Management for Petroleum Refineries
• Appendix A to 5189 — List of Acutely Hazardous Chemicals, Toxics and Reactives (Mandatory)

Key definitions

• Acutely hazardous material: A substance possessing toxic, reactive, flammable, or explosive properties and specific to a process.
• Explosive: A substance identified by the federal Department of Transportation (DOT) in 49 CFR Part 172.
• Facility: The buildings, containers, or equipment which contain a process.
• Flammable: Liquids or gases defined in Title 8 CCR 5194(c) onsite and in one location in quantities of 10,000 pounds or more.
• Hot work: Electric or gas welding, cutting, brazing, or any extreme heat, flame, or spark producing procedures or operations.
• Major accident: Any event involving fire, explosion, or release of a substance that results in fatality or a serious injury to persons in the workplace.
• Process: Any activity conducted by an employer that involves an acutely hazardous material, flammable substance, or explosive including any use, storage, manufacturing, handling, or on-site movement of any of the preceding substances or combination of these activities. Note: Any group of vessels that are interconnected and separate vessels that are located such that an acutely hazardous material could be involved in a potential release are considered a single process.
• Process Safety Management: The application of management programs (not limited to engineering guidelines) when dealing with the risks associated with handling or working near acutely hazardous materials, flammables, or explosives.
• Turnaround: A planned, periodic shutdown, total or partial, or a refinery process unit or plant, to perform maintenance, overhaul, and repair operations and to inspect, test, and replace process materials and equipment.

Summary of requirements

• Develop and maintain process safety information, including a collection of written safety information to allow the employer and the employees operating a process to identify and understand the hazards posed by the process and the hazardous chemicals. Ensure copies of the safety information are available and communicated to employees.
• Perform a process hazard analysis (PHA). The PHA must be appropriate to the complexity of the process for identifying, evaluating, and controlling hazards involved in the process. It must determine and document the priority order for conducting PHAs based on the extent of process hazards, number of potentially affected employees, and age of the process and the process operating history.
• Develop and implement written procedures that provide clear instructions for safely conducting activities involved in each process. Written procedures must address at least the following:
  • Steps for each operating phase,
  • Operating limits, and
  • Safety and health considerations.
  
  In addition, you must describe how you will:
  • Maintain the ongoing integrity of process equipment and attachments;
  • Issue hot work permits (if applicable);
  • Manage changes to process chemicals, technology, and equipment, and changes to facilities;
  • Promptly report and investigate every incident that results in, or could reasonably have resulted in, a major accident.
• Train employees. Initial training for process operators must occur before the operator works in a newly assigned process. Training must include an overview of the process and the operating procedures. Training shall emphasize specific safety and health hazards, procedures, and safe practices that apply to the employee’s job. Employers should:
  • Provide refresher and supplemental training at least every three years, and more often if necessary.
  • Establish tests to ensure employee competency and prepare a certification record for all trained and retrained employees.
• Inform contractors performing work on, or near, a process of the known potential fire, explosion, or toxic release hazards related to the contractor’s work and the process. Require that contractors have trained their employees to a level adequate to safely perform the job.
• Perform a pre-start up safety review for new facilities and for modified facilities where the process changed.
• Establish and implement an Emergency Action Plan (per Title 8 CCR 3220).
• Ensure the company’s Injury and Illness Prevention Plan (IIPP) addresses PSM.
• Develop a written plan of action to ensure employee participation in PSM.