OSHA 1910.119

PROCESS SAFETY MANAGEMENT OF

HIGHLY HAZARDOUS CHEMICALS
 

PURPOSE: 

Requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive, flammable or explosive chemicals which may result in toxic or explosive hazards. 

Section (d) : PROCESS  SAFETY INFORMATION : 

The employer shall document that equipment complies with recognized and generally accepted good engineering practices  (RAGAGEP). 

For existing equipment designed and constructed in accordance with codes, standards or practices that are no longer in general use, the employer shall determine and document that the equipment is designed, maintained, inspected, tested and operating in a safe manner. 

Section (e) : PROCESS  HAZARDOUS  ANALYSIS : 

Hazard evaluation for all process hazards using one or more of the following: 

• What-if / Checklist

• Hazard and Operability Study   (HAZOP)

• Failure Mode and Effects Analysis (FMEA)

• Fault Tree Analysis  

Section (i) : PRE - STARTUP  SAFETY REVIEW  : 

Pre-Startup Safety review (PSSR) of new facilities and modified facilities when modification is significant to confirm that prior to introduction of a highly hazardous to a process: 

Construction and equipment is in accordance with design specifications. 

Section (j) : MECHANICAL  INTEGRITY : 

Application to following process equipment:

• Pressure Vessels and Storage Tanks.

• Piping Systems (including piping components such as valves).

• Relief and vent systems and devices.

• Emergency Shutdown systems.

• Controls (including monitoring devices, sensors, alarms and interlocks).

• Pumps. 

WRITTEN PROCEDURES: 

The employer shall establish and implement written procedures to maintain the on-going integrity of  process equipment. 

INSPECTION  AND TESTING: 

• Inspection and tests shall be performed on process equipment.

• Inspection and testing procedures shall follow  RAGAGEP.

• Frequency of Inspections.

• Documentation of Inspections. 

EQUIPMENT  DEFICIENCIES: 

The employer shall correct deficiencies in equipment  that are outside acceptable limits (defined by the Process Safety Information)  before further use or in a safe and timely manner when necessary means are taken to assure safe operation. 

QUALITY  ASSURANCE:

• Equipment as fabricated is suitable for the Process Application for which they will be used.

• Appropriate checks and inspections to assure Proper installation and check consistency with  design specifications and manufacturer’s instructions.

• Maintenance materials, spare parts and equipment shall be suitable for process application for which they will be used.