SAFETY 101: HIGHLY HAZARDOUS CHEMICALS What does the OSHA standard, Process Safety Management of Highly Hazardous Chemicals, cover? This standard contains requirements for the safe management of hazards associated with processes using, storing, manufacturing, handling, or moving highly hazardous chemicals onsite. It emphasizes the management of hazards through an established comprehensive program that integrates technologies, procedures, and management practices. Why is this standard necessary? Unexpected releases of highly hazardous chemicals including toxic, reactive, or flammable liquids and gases from processes have been reported for many years. Incidents continue to occur in various industries that use highly hazardous chemicals that may be toxic, reactive, flammable, or explosive, or may exhibit a combination of these properties. Regardless of the industry using these highly hazardous chemicals, there is a potential for an accidental release any time they are not properly controlled. This, in turn, creates the possibility of a disaster. What industries does the rule cover? OSHA's standard applies mainly to manufacturing industries - particularly those pertaining to chemicals, transportation equipment, and fabricated metal products. Other affected sectors include those involved with natural gas liquids; farm product warehousing; food processing, electric, gas, and sanitary services; and wholesale trade. The standard also applies to pyrotechnics and explosives manufacturers. It has special provisions for contractors working in covered facilities. What does the standard require? The key provision of the standard is a process hazard analysis (PHA) that is based on a compilation of process safety information. A PHA is a careful review of what could go wrong and what safeguards must be implemented to prevent releases of hazardous chemicals. The standard also mandates written operating procedures, employee training and participation, pre-startup safety reviews, evaluation of the mechanical integrity of critical equipment, contractor requirements, and written procedures for managing change. It requires a permit system for hot work, investigation of incidents involving releases of covered chemicals or "near-misses," emergency action plans, compliance audits at least every 3 years, and trade secret protection. Where can I learn more about the standard and its requirements? For specific requirements see Title 29 of the Code of Federal Regulations, Part 1910.119. OSHA also has two publications that provide information about the process safety management standard and its application. Process Safety Management (OSHA 3132) and Process Safety Management - Guidelines for Compliance (OSHA 3133). NOTE: Minnesota OSHA has not adopted the enforcement policy on coverage of stored flammables under the Process Safety Management standard established by federal OSHA following the Meer decision (issued May 12, 1997). Minnesota OSHA has been and will continue to enforce the standard on a case-by-case basis. For help tailored to your specific needs, contact the South Dakota Safety Council at 605-361-7785 or 1-800-952-5539.

Acknowledgments:
U.S. Dept. of Labor, OSHA