Process Safety Management of Highly Hazardous Chemicals
65 flashcards covering Process Safety Management of Highly Hazardous Chemicals for the OSHA OSHA 10/30 General Industry section.
Process Safety Management (PSM) of Highly Hazardous Chemicals focuses on preventing releases of toxic, reactive, or flammable substances that could cause major incidents like explosions or fires. This is defined by OSHA under the standard 29 CFR 1910.119, which applies to processes involving certain quantities of these chemicals in general industry settings.
On OSHA 10/30 General Industry exams, PSM questions often appear as multiple-choice scenarios testing knowledge of the 14 elements, such as process hazard analysis and emergency planning. A common trap is overlooking the need for ongoing employee participation, where workers might focus only on initial training rather than regular updates.
Remember to conduct thorough hazard reviews before starting any new process involving these chemicals.
Terms (65)
- 01
What is the definition of a highly hazardous chemical under PSM?
A highly hazardous chemical is one that is toxic, reactive, flammable, or explosive and presents a potential for a catastrophic incident, as specified in 29 CFR 1910.119 Appendix A (29 CFR 1910.119).
- 02
Under 29 CFR 1910.119, what must be included in process safety information?
Process safety information must include information pertaining to the hazards of the chemicals used, the technology of the process, and the equipment in the process (29 CFR 1910.119(d)).
- 03
How often must a process hazard analysis be performed for covered processes?
For new processes, before they are started up; for existing processes, at least every five years (29 CFR 1910.119(e)).
- 04
What is required for employee participation in PSM programs?
Employers must develop and implement written procedures for employee participation in all elements of process safety management and consult with employees on process hazard analyses (29 CFR 1910.119(c)).
- 05
Under 29 CFR 1910.119, what elements are part of operating procedures?
Operating procedures must provide clear instructions for safely conducting activities, including steps for each operating phase, operating limits, and safety systems (29 CFR 1910.119(f)).
- 06
How often must mechanical integrity inspections be conducted?
At frequencies consistent with manufacturers' recommendations and good engineering practices, such as annually or biennially for certain equipment (29 CFR 1910.119(j)).
- 07
What is the first step in managing changes to a covered process?
Employers must establish and implement written procedures to manage changes to process chemicals, technology, equipment, and facilities (29 CFR 1910.119(l)).
- 08
In a scenario where a chemical release occurs, what must the employer investigate?
The employer must investigate each incident that resulted in or could have resulted in a catastrophic release of a highly hazardous chemical (29 CFR 1910.119(m)).
- 09
Under 29 CFR 1910.119, what is required before hot work is performed?
A hot work permit must be issued, ensuring that the work area is free of fire hazards and that fire prevention measures are in place (29 CFR 1910.119(j)(4)(iii)).
- 10
What type of training is required for employees involved in operating a process?
Employees must be trained in an overview of the process and in operating procedures, initially and when a change requires it (29 CFR 1910.119(g)).
- 11
How often must compliance audits be performed for PSM programs?
At least every three years, to verify that the procedures and practices are adequate and being followed (29 CFR 1910.119(o)).
- 12
What must be included in emergency planning and response under PSM?
Employers must establish and implement an emergency action plan for the covered process areas (29 CFR 1910.119(n)).
- 13
Before starting up a new process, what safety review is required?
A pre-startup safety review must be performed to ensure that the process is designed and constructed in accordance with specifications (29 CFR 1910.119(i)).
- 14
In a scenario involving contractors in a PSM-covered process, what must the employer do?
The employer must inform contractors of known potential fire, explosion, or toxic release hazards and ensure that contractors follow safety procedures (29 CFR 1910.119(h)).
- 15
What is the purpose of process safety information in PSM?
To compile and maintain information about the hazards of the chemicals, the technology, and the equipment to ensure safe operation (29 CFR 1910.119(d)).
- 16
Under 29 CFR 1910.119, what documentation is required for incident investigations?
A report must be prepared at the conclusion of the investigation, including findings, root causes, and recommendations (29 CFR 1910.119(m)).
- 17
How often must operating procedures be reviewed and certified?
At least annually, to ensure they are current and accurate (29 CFR 1910.119(f)(2)).
- 18
What procedure must be followed when a process hazard analysis identifies deficiencies?
Employers must promptly resolve the findings and document the resolutions (29 CFR 1910.119(e)(5)).
- 19
Under 29 CFR 1910.119, what must be done with trade secrets related to PSM?
Trade secrets must be made available to employees, their representatives, and other specified parties without regard to trade secret status (29 CFR 1910.119(p)).
- 20
What is a process hazard analysis in PSM?
A process hazard analysis is a thorough, orderly, systematic approach to identifying, evaluating, and controlling the hazards involved in the process (29 CFR 1910.119(e)).
- 21
How often must refresher training be provided for PSM-covered processes?
Refresher training must be provided at least every three years, or more frequently if necessary (29 CFR 1910.119(g)(2)).
- 22
What must employers do to ensure the mechanical integrity of process equipment?
Inspect, test, and maintain equipment to ensure proper functioning and to prevent failures (29 CFR 1910.119(j)).
- 23
In a scenario of a potential catastrophic release, what preventive measures are required?
Implement process hazard analysis recommendations and management of change procedures to mitigate risks (29 CFR 1910.119(e) and (l)).
- 24
Under 29 CFR 1910.119, what information must be in written operating procedures?
Steps for each operating phase, operating limits, safety and health considerations, and safety systems (29 CFR 1910.119(f)).
- 25
What is required when establishing safe work practices for PSM?
Safe work practices must be developed to provide for the control of hazards during operations such as lockout/tagout and confined space entry (29 CFR 1910.119(f)(4)).
- 26
How often must the results of process hazard analyses be reviewed?
The results must be reviewed and updated at least every five years (29 CFR 1910.119(e)(6)).
- 27
In a scenario where a change is made to a process, what action is needed?
A management of change review must be conducted to assess the impact on safety (29 CFR 1910.119(l)).
- 28
What employee records must be maintained under PSM?
Records of training, incident investigations, and compliance audits must be kept for specified periods (29 CFR 1910.119(g)(3) and others).
- 29
Under 29 CFR 1910.119, what constitutes a covered process?
A process involving a threshold quantity of a highly hazardous chemical as listed in Appendix A (29 CFR 1910.119(a)).
- 30
What is the role of a PSM compliance audit?
To verify that the PSM program is effective and that procedures are being followed (29 CFR 1910.119(o)).
- 31
How often must hot work permits be issued for PSM areas?
For each instance of hot work, ensuring conditions are safe (29 CFR 1910.119(j)(4)(iii)).
- 32
What must be done after an incident investigation in PSM?
Recommendations must be resolved promptly and the report retained for five years (29 CFR 1910.119(m)).
- 33
In a scenario involving multiple employers at a site, what PSM responsibilities apply?
The host employer must coordinate with contractors to ensure PSM elements are met (29 CFR 1910.119(h)).
- 34
Under 29 CFR 1910.119, what safety measures are needed for maintenance?
Lockout/tagout and other safe work practices must be used during maintenance activities (29 CFR 1910.119(j)).
- 35
What is required for the development of operating procedures in PSM?
They must be readily accessible to employees who operate the process or equipment (29 CFR 1910.119(f)).
- 36
How often must PSM programs be evaluated for effectiveness?
Through compliance audits at least every three years (29 CFR 1910.119(o)).
- 37
In a scenario of equipment failure in a PSM process, what investigation is needed?
An incident investigation if it could have led to a catastrophic release (29 CFR 1910.119(m)).
- 38
What documentation is needed for PSM training?
Certification that training has been provided, including the date and the means used (29 CFR 1910.119(g)(3)).
- 39
Under 29 CFR 1910.119, what elements must be in an emergency response plan?
Procedures for handling releases, including alarm systems and evacuation plans (29 CFR 1910.119(n)).
- 40
What is the minimum requirement for process safety information compilation?
It must be compiled before conducting a process hazard analysis (29 CFR 1910.119(d)).
- 41
How often must employees be informed of PSM elements?
As part of initial and refresher training (29 CFR 1910.119(g)).
- 42
In a scenario where a new chemical is introduced, what PSM step is required?
A management of change review to assess hazards (29 CFR 1910.119(l)).
- 43
What must be included in a pre-startup safety review?
Verification that construction and equipment meet design specifications and that procedures are in place (29 CFR 1910.119(i)).
- 44
Under 29 CFR 1910.119, what access to information is required for employees?
Employees must have access to process safety information and operating procedures (29 CFR 1910.119(c) and (f)).
- 45
What is the key objective of PSM for highly hazardous chemicals?
To prevent or minimize the consequences of catastrophic releases (29 CFR 1910.119).
- 46
How often must PSM-related records be retained?
For varying periods, such as five years for incident reports (29 CFR 1910.119(m)).
- 47
In a scenario of a process upset, what response is mandated?
Follow established operating procedures and emergency plans (29 CFR 1910.119(f) and (n)).
- 48
What consultation is required during process hazard analysis?
Consultation with employees and their representatives (29 CFR 1910.119(e)).
- 49
Under 29 CFR 1910.119, what oversight is needed for contractors?
Periodic evaluation of the contractor's safety performance (29 CFR 1910.119(h)).
- 50
What safety systems must be addressed in operating procedures?
Systems for maintaining the integrity of equipment, such as pressure relief (29 CFR 1910.119(f)).
- 51
How often must PSM elements be reviewed for changes?
Whenever a change is made, through management of change procedures (29 CFR 1910.119(l)).
- 52
In a scenario involving a toxic release, what investigation follows?
An incident investigation to determine causes and prevent recurrence (29 CFR 1910.119(m)).
- 53
What is required for the certification of operating procedures?
Annual certification by the employer that procedures are current (29 CFR 1910.119(f)(2)).
- 54
Under 29 CFR 1910.119, what training content is mandatory?
Overview of the process, hazards, and safe work practices (29 CFR 1910.119(g)).
- 55
What elements must be in a written PSM program?
All 14 elements specified in the standard, including hazard analysis and emergency planning (29 CFR 1910.119).
- 56
How often must safety audits include employee input?
As part of the compliance audit process (29 CFR 1910.119(o)).
- 57
In a scenario of equipment modification, what PSM requirement applies?
Management of change procedures must be followed (29 CFR 1910.119(l)).
- 58
What is the standard for evaluating process hazards?
A systematic method such as hazard and operability study (29 CFR 1910.119(e)).
- 59
Under 29 CFR 1910.119, what follow-up is needed after audits?
Prompt initiation and resolution of audit findings (29 CFR 1910.119(o)).
- 60
What access rights do employees have in PSM?
Access to information on hazards and safety procedures (29 CFR 1910.119(c)).
- 61
How often must PSM training be documented?
For each employee, with records kept for the duration of employment (29 CFR 1910.119(g)(3)).
- 62
In a scenario of a fire in a PSM area, what procedure is followed?
Activate the emergency response plan and investigate if necessary (29 CFR 1910.119(n) and (m)).
- 63
What is included in the scope of PSM for covered chemicals?
Processes with quantities at or above the thresholds in Appendix A (29 CFR 1910.119(a)).
- 64
Under 29 CFR 1910.119, what verification is needed for training?
Certification that the employee understands the training content (29 CFR 1910.119(g)(2)).
- 65
What is the requirement for retaining PSM audit reports?
For the life of the process, at a minimum (29 CFR 1910.119(o)).