Vol. 5, No. 11
OSHA 29 CFR 1910.119 - BEGINNING COMPLIANCE WITH THE
PROCESS SAFETY MANAGEMENT STANDARD
surrounding community safe. Your
What is Process Safety Compilation of a Process
corporate image as a good citizen
Management? Does This Technical Manual
should be protected. Safety manage-
Standard Affect Me? ment is essential.
Affected facilities must identify
An effective process safety
those processes that pose the greatest
OSHA has recently begun to management program requires a
risk and perform a process hazard
enforce OSHA's Process Safety systematic approach to evaluating the
analysis (PHA) on these processes.
Management Standard (29 CFR entire process. Using this approach,
At least 50 percent of processes
1910.119). The standard applies to the process design, process
should have been evaluated by May
any manufacturing facility process technology, operational and
26, 1995, with an additional 25
which stores, manufactures, handles, maintenance activities and
percent completed each following
or transports any toxic or reactive procedures, non-routine activities
year until 1997, when PHAs on all
chemical at or above the specific and procedures, emergency pre-
processes should be complete.
threshold quantities listed in the paredness plans and procedures,
Prior to completing any
standard. A listing of these training programs, and other
PHA, a written compilation of
chemicals with threshold quantities is elements which impact the process
process information must be
included with this newsletter. This are all considered in the evaluation.
performed to enable employees and
standard additionally covers As with any comprehensive
employers to identify and understand
flammable liquids or gases stored at management system, the fun-
the hazards associated with a given
one location in quantities of 10,000 damental component in the system's
process. The compiled information,
pounds or more; however, specific success is the assemblage or
referred to as the Process Technical
detailed exemptions exist which development of complete and
Manual, will be a fundamental
cannot be adequately covered in this accurate information.
resource to the team performing the
alert. The Process Safety In this first of a series of
PHA; individuals who develop
Management Standard targets highly newsletters on Process Safety
training programs, operating
hazardous chemicals and flammable Management, Environmental Invest-
procedures and perform emergency
liquids or gases that have the igations, a professional engineering
planning; contractors; insurance
potential to cause a catastrophic firm, describes the information
carriers; and enforcement officials.
incident. necessary to thoroughly document
The Process Technical Manual is to
The standard as a whole is to aid process chemicals, process
be kept for the lifetime of the process
employers in their efforts to prevent technology, and process equipment.
and updated whenever process
or mitigate episodic chemical Subsequent newsletters will discuss
alterations are made. The written
releases that could lead to a how this collection of information
summary must include a discussion
catastrophe in the workplace and should be used to perform required
of HIGHLY HAZARDOUS
possibly in the surrounding process hazard analyses, develop
CHEMICALS USED OR
community. Besides complying with safe operating procedures and
PRODUCED IN THE PROCESS,
stringent OSHA requirements and practices, conduct training programs,
TECHNOLOGY OF THE PROC-
avoiding costly regulatory penalties, deal with contractors, inspect
ESS, and EQUIPMENT UTILIZED
an effective Process Safety equipment, manage change, prepare
IN THE PROCESS.
Management program will allow you for emergencies, and audit the
to keep your workers and program's success.
Process flow diagrams including process equipment to other systems
Chemical Information. The
and population centers (control
information to be compiled about the any associated pollution control
rooms, offices and maintenance
chemicals, including process equipment. Process flow
facilities). There should also be a
intermediates, needs to be diagrams should show all main
facility layout plan which illustrates
comprehensive enough for an flow streams including valves, as
the location of safety systems,
accurate assessment of the fire and well as pressures and
including firewater headers, hy-
explosion characteristics, reactivity temperatures on all feed and
drants, extinguishers, and flammable
hazards, the safety and health product lines within major
material/toxic gas monitors and
hazards to workers and the vessels and conditions entering/
alarm systems.
community, and the corrosion and exiting headers and heat
Equipment information shall at
erosion effects on the process exchangers. Information on
least include: (1) construction mat-
equipment and monitoring tools. construction materials, pump
erials, (2) electrical classifications,
Current material safety data sheet capacities, pressure heads,
(3) backup system designs, (4) vent-
(MSDS) information can be used to compressor horsepower and
ilation system designs, (5) standard
help meet this requirement, but must vessel design pressures/temper-
design codes employed in the
be supplemented with process atures, should also be shown.
process, (6) material and energy
chemistry information, which
Process chemistry. balances for processes built after
includes the formation of secondary
May 1992, and (7) safety systems
compounds during the inadvertent
Maximum intended inventory, (i.e., interlocks, detection or
mixing of process chemicals, if
suppression systems).
applicable. Sometimes MSDSs need which also includes mateials in
to be supplemented by other storage as well as those utilized
resources such as product bulletins How to Get Started
in the manufacturing process,
and safety references. (limits beyond which would be
The following items should be considered upset conditions). The task of assembling and
addressed: (1) toxicity, (2) permis- organizing the vast amount of
Safe ranges of process operation
sible exposure limits, (3) corrosivity chemical, process, and equipment
data, (4) physical data, (5) reactivity, limits, including temperatures, information can be burdensome,
thermal stability and chemical pressures, flow rates or chemical especially for smaller companies
stability, and (6) hazardous effects of compositions. A block flow with limited environmental, safety,
inadvertent mixing of different diagram or table can be utilized and engineering staff resources.
materials. to address operation limits.
Environmental Investigations (EI)
Process Technology Information. Consequences of exceeding can provide the necessary resources
Process technology information will to fully document your processes and
process technology deviations
be a part of the process safety evaluate your safety needs. EI has
especially those impacting
information package and should the expertise and experience to assist
employee safety and health.
include employer-established criteria you in complying with this
for maximum inventory levels for comprehensive body of regulatory
Process Equipment Information.
process chemicals. A qualitative requirements.
An assessment of process equipment
estimate of the consequences or Our trained engineering staff can
must be conducted to determine
results of deviation that could occur assemble the necessary information
compliance with good engineering
if operating beyond the established and develop a Process Safety
practices. Piping and instrument
process limits should also be Management program that will serve
diagrams (P&ID's) are an excellent
addressed. Employers are en- not only as a regulatory compliance
tool to describe the relationship
couraged to use diagrams that will document, but will enable your
between equipment and instrumen-
help users understand the process. In company to provide a safe and
tation. Equipment diagrams should
order to address a given process efficient workplace.
clearly identify the location of the
technology the following items
should be covered:
LIST OF HIGHLY HAZARDOUS CHEMICALS, TOXICS AND REACTIVES
Diethylzinc 557-20-0 10000
CHEMICAL NAME CAS* TQ**
Diisopropyl Peroxydicarbonate 105-64-6 7500
Acetaldehyde 75-07-0 2500
Acrolein (2-Propenal) 107-02-8 150 CHEMICAL NAME CAS* TQ**
Acrylyl Chloride 814-68-6 250
Alkylaluminums Varies 5000 Dilauroyl Peroxide 105-74-8 7500
Allyl Chloride 107-05-1 1000 Dimethylamine, Anhydrous 124-40-3 2500
Allylamine 107-11-9 1000 Dimethyldichlorosilane 75-78-5 1000
Ammonia solutions (greater than Dimethylhydrazine, 1, 1- 57-14-7 1000
44% ammonia by weight) 7664-41-7 15000 2, 4-Dinitroaniline 97-02-9 5000
Ammonia, Anhydrous 7664-41-7 10000 Ethyl Methyl Ketone Peroxide
Ammonium Perchlorate 7790-98-9 7500 (also Methyl Ethyl Ketone
Ammonium Permanganate 7787-36-2 7500 peroxide; concentration greater
Arsine (also called Arsenic than 60%) 1338-23-4 5000
Hydride) 7784-42-1 100 Ethyl Nitrite 109-95-5 5000
Bis (Chloromethyl) Ether 542-88-1 100 Ethylamine 75-04-7 7500
Boron Trichloride 10294-34-5 2500 Ethylene Fluorohydrin 371-62-0 100
Boron Trifluoride 7637-07-2 250 Ethylene Oxide 75-21-8 5000
Bromine 7726-95-6 1500 Ethyleneimine 151-56-4 1000
Bromine Chloride 13863-41-7 1500 Fluorine 7782-41-4 1000
Bromine Pentafluoride 7789-30-2 2500 Formaldehyde (Formalin) 50-00-0 1000
3-Bromopropyne (also called Furan 110-00-9 500
Propargyl Bromide) 106-96-7 100 Hexafluoroacetone 684-16-2 5000
Bromine Trifluoride 7787-71-5 15000 Hydrochloric Acid, Anhydrous 7647-01-0 5000
Butyl Hydroperoxide (Tertiary) 75-91-2 5000 Hydrofluoric Acid, Anhydrous 7664-39-3 1000
Butyl Perbenzoate (Tertiary) 614-45-9 7500 Hydrogen Bromide 10035-10-6 5000
Carbonyl Chloride (see Phosgene) 75-44-5 100 Hydrogen Chloride 7647-01-0 5000
Carbonyl Fluoride 353-50-4 2500 Hydrogen Cyanide, Anhydrous 74-90-8 1000
Cellulose Nitrate (concentration Hydrogen Fluoride 7664-39-3 1000
greater than 12.6% nitrogen) 9004-70-0 2500 Hydrogen peroxide (52% by
Chlorine 7782-50-5 1500 weight or greater) 7722-84-1 7500
Chlorine Dioxide 10049-04-4 1000 Hydrogen Selenide 7783-07-5 150
Chlorine Pentrafluoride 13637-63-3 1000 Hydrogen Sulfide 7783-06-4 1500
Chlorine Trifluoride 7790-91-2 1000 Hydroxylamine 7803-49-8 2500
1-Chloro-2, 4-Dinitrobenzene 97-00-7 5000 Iron, Pentacarbonyl 13463-40-6 250
Chlorodiethylaluminum (also called Isopropylamine 75-31-0 5000
Diethylaluminum Chloride) 96-10-6 5000 Ketene 463-51-4 100
Chloromethyl Methyl Ether 107-30-2 500 Methacrylaldehyde 78-85-3 1000
Chloropicrin 76-06-2 500 Methacryloyl Chloride 920-46-7 150
Chloropicrin and Methyl Bromide Methacryloyloxyethyl Isocyanate 30674-80-7 100
mixture None 1500 Methyl Acrylonitrile 126-98-7 250
Chloropicrin and Methyl Chloride Methyl Bromide 74-83-9 2500
mixture None 1500 Methyl Chloride 74-87-3 15000
Cumene Hydroperoxide 80-15-9 5000 Methyl Chloroformate 79-22-1 500
Cyanogen 460-19-5 2500 Methyl Ethyl Ketone Peroxide
Cyanogen Chloride 506-77-4 500 (concentration greater than 60%) 1338-23-4 5000
Cyanuric Fluoride 675-14-9 100 Methyl Fluoroacetate 453-18-9 100
Diacetyl peroxide (concentration Methyl Fluorosulfate 421-20-5 100
greater than 70%) 110-22-5 5000 Methyl Hydrazine 60-34-4 100
Diazomethane 334-88-3 500 Methyl Iodide 74-88-4 7500
Dibenzoyl Peroxide 94-36-0 7500 Methyl Isocyanate 624-83-9 250
Diborane 19287-45-7 100 Methyl Mercaptan 74-93-1 5000
Dibutyl Peroxide (Tertiary) 110-05-4 5000 Methyl Vinyl Ketone 79-84-4 100
Dichloro Acetylene 7572-29-4 250 Methylamine, Anhydrous 74-89-5 1000
Dichlorosilane 4109-96-0 2500 Methyltrichlorosilane 75-79-6 500
Nickel Carbonly
(Nickel Tetracarbonyl) 13463-39-3 150
Nitric Acid (94.5% by weight or
greater) 7697-37-2 500
LIST OF HIGHLY HAZARDOUS CHEMICALS, TOXICS AND REACTIVES
CHEMICAL NAME CAS* TQ** CHEMICAL NAME CAS* TQ**
Nitric Oxide 10102-43-9 250 Phosphorus Oxychloride (also called
Nitroaniline (para Nitroaniline) 100-01-6 5000 Phosphoryl Chloride) 10025-87-3 1000
Nitrogen Dioxide 10102-44-0 250 Phosphorus Trichloride 7719-12-2 1000
Phosphoryl Chloride (also called
Nitrogen Oxides (NO; NO2;
Phosphorus Oxychloride) 10025-87-3 1000
N2O4; N2O3) 10102-44-0 250
Propargyl Bromide 106-96-7 100
Nitrogen Tetroxide (also called
Propyl Nitrate 627-3-4 2500
Nitrogen Peroxide) 10544-72-6 250
Sarin 107-44-8 100
Nitrogen Trifluoride 7783-54-2 5000
Selenium Hexafluoride 7783-79-1 1000
Nitromethane 75-52-5 2500
Stibine (Antimony Hydride) 7803-52-3 500
Oleum (65% to 80% by weight; also
Sulfur Dioxide (liquid) 7446-09-5 1000
called Fuming Sulfuric Acid) 8014-94-7 1000
Sulfur Pentafluoride 5714-22-7 250
Osmium Tetroxide 20816-12-0 100
Sulfur Tetrafluoride 7783-60-0 250
Oxygen Difluoride (Fluorine
Sulfur Trioxide (also called
Monoxide) 7783-41-7 100
Sulfuric Anhydride) 7446-11-9 1000
Ozone 10028-15-6 100
Sulfuric Anhydride (also called
Pentaborane 19624-22-7 100
Sulfur Trioxide) 7446-11-9 1000
Peracetic Acid (concentration
Tellurium Hexafluoride 7783-80-4 250
greater 60% Acetic Acid; also
Tetrafluoroethylene 116-14-3 5000
called Peroxyacetic Acid) 79-21-0 1000
Tetrafluorohydrazine 10036-47-2 5000
Perchloric Acid (concentration
Tetramethyl Lead 75-74-1 1000
greater than 60% by weight) 7601-90-3 5000
Thionyl Chloride 7719-09-7 250
Perchloromethyl Mercaptan 594-42-3 150
Trichloro (chloromethyl) Silane 1558-25-4 100
Perchloryl Fluoride 7616-94-6 5000
Trichloro (dichlorophenyl) Silane 27137-85-5 2500
Peroxyacetic Acid (concentration
Trichlorosilane 10025-78-2 5000
greater than 60% Acetic Acid;
Trifluorochloroethylene 79-38-9 10000
also called Peracetic Acid) 79-21-0 1000
Trimethyoxysilane 2487-90-3 1500
Phosgene (also called Carbonyl
Chloride) 75-44-5 100
Phosphine (Hydrogen Phosphide) 7803-51-2 100
*Chemical Abstract Service Number
**Threshold Quantity in Pounds (Amount necessary to be covered by this standard.)
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