Process Safety Management (PSM)

Related Technical Links:

• Ammonia Refrigeration

Recognition

• Reactive Material Hazards-What You Need to Know. Center for Chemical Process Safety, AICHE (2001, October 1), 291 KB PDF, 11 pages. An introduction to reactive material handling issues for people whose main business is NOT reactive materials and systems.
• Process Safety Management of Highly Hazardous Chemicals. OSHA Fact Sheet 93-45 (1993, January 1).
• OSHA Regulations 1910.119 App A. List of Highly Hazardous Chemicals, Toxics and Reactives (Mandatory).

• Hazard Information Bulletins
• Water-Reactive Chemicals, Hazardous Materials Not Covered Under 29 CFR 1910.119, (1996, July 3).
• Chemical Exposures from Industrial Valve and Piping Systems, (1996, May 14).
• Defective Imported Lap Joint Stub Ends, (1994, August 24).
• Use of hydrofluoric acid in the petroleum refining alkylation process, (1993, November 19).
• Corrosion of Piping in Hydroprocessing Units, (1994, July 29).
• Accidental Release of Anhydrous Ammonia at Storage/Dispensing Facilities and Elevators, (1994, February 28).

Evaluation

• The Chemical Reactivity Worksheet. Office of Response and Restoration, National Ocean Service, NOAA, and the Chemical Emergency Prevention and Preparedness Office of the EPA. (1998), 3.1 MB program. A free program that can be used to find out about the reactivity of substances or mixtures of substances.
• Petroleum Refining Processes. OSHA Technical Manual (TED 1-0.15A), Section IV - Chapter 2 (1999, January 20), 84 pages.
• OSHA Regulations 1910.119 App C. Compliance Guidelines and Recommendations for Process Safety Management (Nonmandatory).
• Protecting Building Occupants from Explosions and Fires in Processing Facilities. EQE Review (Fall 1995), 5 pages.

Control

• Pressure Vessel Guidelines. OSHA Technical Manual (TED 1-0.15A), Section IV - Chapter 3 (1999, January 20), 16 pages.
  • Recordkeeping Data for Steel Vessels and Low Pressure Storage Tanks. Appendix IV:3-1.

Compliance

• OSHA Standards

General Industry
• 1910.119, Process safety management of highly hazardous chemicals.
• App A, List of Highly Hazardous Chemicals, Toxics and Reactives (Mandatory).
• App B, Block Flow Diagram and Simplified Process Flow Diagram (Nonmandatory).
• App C, Compliance Guidelines and Recommendations for Process Safety Management (Nonmandatory).
• App D, Sources of Further Information (Nonmandatory).
Construction
• 1926.64, Process safety management of highly hazardous chemicals.
• App A, List of Highly Hazardous Chemicals, Toxics and Reactives (Mandatory).
• App B, Block Flow Diagram and Simplified Process Flow Diagram (Nonmandatory).
• App C, Compliance Guidelines and Recommendations for Process Safety Management (Nonmandatory).
• App D, Sources of Further Information (Nonmandatory).
  
  
• Preambles to OSHA Standards
• Process Safety Management
  
  
• OSHA Directives
• CPL 2-2.45A CH-1. Process Safety Management of Highly Hazardous Chemicals – Compliance Guidelines and Enforcement Procedures (1994, September 13), 89 pages. (Some original CPL and audit guidelines are not included in this document).
• CPL 2.94. OSHA Response to Significant Events of Potentially Catastrophic Consequences (1991, July 22), 47 Pages.
  
  
• Review Commission and Administrative Law Judge Decisions
  The Occupational Safety and Health Review Commission (OSHRC) is an independent Federal agency created to decide contests of citations or penalties resulting from OSHA inspections of American work places. To locate decisions related to this topic, search for keywords at the OSHRC site.
  
  
• OSHA Unified Agenda
  • Process Safety Management of Highly Hazardous Chemicals [Completed Actions]. OSHA Unified Agenda (2001, December 5). OSHA is considering two regulatory actions concerning the Process Safety Management of Highly Hazardous Chemicals (PSM) standard.

Training

• Synthetic Organic Chemical Manufacturers Association (SOCMA) Chemical Process Operator Training Manuals (1999, March). Synthetic Organic Chemical Manufacturers Association, 1850 M St., NW #700, Washington, DC 20036. (202) 721-4100.
• OSHA Training Institute Schedule of Courses. Office of Training and Education (2002), 82 KB PDF, 43 pages. Scroll down to read about the following course:
  • Course #330 – Safety and Health in the Chemical Processing Industries (OSHA personnel only)
  • Course #330A – Safety and Health in the Chemical Processing Industries (private sector enrollment available)
  • Course #340 – Hazard Analysis in the Chemical Processing Industries (OSHA personnel only)
• The OSHA Office of Training and Education's OSHA Construction Industry Safety and Health Outreach Program (1996, May) contains a section on process safety management:
• Process Safety Management and Highly Hazardous Chemicals.

Other

• API Documents
• (ANSI/API RP 574-1992). Inspection of Pressure Relieving Devices, First Edition (1992, September).
• (ANSI/API RP 520-1-1992). Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries Part I, "Sizing and Selection," Sixth Edition (1993, March).
• (ANSI/API Std 2015-1994). Safe Entry and Cleaning of Petroleum Storage Tanks, Planning and Managing Tank Entry from Decommissioning Through Recommissioning, Fifth Edition (1994, May).
• (ANSI/API Std 500-1992). Classification of Locations for Electrical Installations at Petroleum Facilities, First Edition (1991, June 1).
• (ANSI/API Std 510-1992). Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration, Seventh Edition (1992, March). Includes Supplement 1 (1993, September), and Supplement 2 (1994, December).
• Std 598. Valve Inspection and Testing, Seventh Edition (1996, November).
• Publ 2009. Safe Welding and Cutting Practices in Refineries, Gasoline Plants, and Petrochemical Plants, Sixth Edition (1995, September).
• RP 752. Management of Hazards Associated With Location of Process Plant Buildings, CMA Manager's Guide, First Edition (1995, May).
• RP 2003. Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents, Fifth Edition (1991, December).
• (ANSI/API RP 574-1992). Inspection of Piping, Tubing, Valves, and Fittings, First Edition (1990, June).
• API - Reference Manual Repairs and Alterations to Boilers and Pressure Vessels
• RP 55. Conducting Oil and Gas Producing and Gas Processing Plant Operations Involving Hydrogen Sulfide, Second Edition (1995, February 15).
• Std 653. Tank Inspection, Repair, Alteration, and Reconstruction, Second Edition (1995, December). Includes Addendum 1 (1996, December).
• (ANSI/API Std 2510-1996). Design and Construction of Liquefied Petroleum Gas Installations (LPG), Seventh Edition (1995, May).
• RP 2220. Improving Owner and Contractor Safety Performance, First Edition (1991, September).
• RP 750. Management of Process Hazards, First Edition (1990, January).  Reaffirmed (1995, May).
• (ANSI/API RP 521-1992). Guide for Pressure-Relieving and Depressuring Systems, Third Edition (1990, November).
• (ANSI/API Publ 945-1992). Avoiding Environmental Cracking in Amine Units, First Edition (1990, August).
• (ANSI/API Publ 920- 1992). Prevention of Brittle Fracture of Pressure Vessels, First Edition (1990, March).
  
  
• American Chemistry Council Documents (formerly the Chemical Manufacturers Association) 
• Process Safety Management (Control or Acute Hazards). 
• Evaluating Process Safety in the Chemical Industry.
• Safe Warehousing of Chemical.
• A Managers Guide to Reducing Human Errors Improving Human Performance in the Chemical Industry.
  
  
• Institute of Makers of Explosives Safety Library Publications, 1120 19th Street, N.W., Suite 310, Washington, D.C. 20036
• No. 1 Construction Guide for Storage Magazines
• No. 2 The American Table of Distances
• No. 3 Suggested Code of Regulations for the Manufacture, Transportation, Storage, Sale, Possession, and Use of Explosive Materials
• No. 4 "Do's and Don'ts" Instructions and Warnings
• No. 12 Glossary of Industry Terms
• No. 17 Safety in the Transportation, Storage, Handling and Use of Explosives
• No. 20 Safety Guide for the Prevention of Radio Frequency Radiation Hazards in the Use of Electrical Blasting Caps
• No. 22 IME Standard for the Safe Transportation of Class C Detonators (Blasting Caps) in a Vehicle with Certain Other Explosives
  
  
• Department of Defense (DOD) Standards:
• DOD 5154.4S DOD - Ammunition & Explosives Safety Standards
• DOD 4145.26M DOD - Contractor's Safety Manual for Ammunition, Explosives and Related Dangerous Material
  
  
• National Fire Protection Association (NFPA) Codes
• NFPA 495 - Explosive Materials Code. Covers the manufacture, transportation, storage, sale, and use of explosive materials.
• NFPA 77 - Recommended Practice on Static Electricity
• NFPA 780 - Standard for the Installation of Lightning Protection Systems
  
  
• Other Sites
  • American Institute of Chemical Engineers
  • Center for Chemical Process Safety
  • American Petroleum Institute (API)
  • American Chemistry Council (formerly the Chemical Manufacturers Association).
  • National Fire Protection Association (NFPA)

Revision Date: 29 March 2002