[Title 29 CFR 1910.119]
[Code of Federal Regulations (annual edition) - July 1, 2002 Edition]
[Title 29 - LABOR]
[Subtitle B - Regulations Relating to Labor (Continued)]
[Chapter Xvii - OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT]
[Part 1910 - OCCUPATIONAL SAFETY AND HEALTH STANDARDS]
[Subpart H - Hazardous Materials]
[Sec. 1910.119 - Process safety management of highly hazardous chemicals.]
[From the U.S. Government Printing Office]


29LABOR52002-07-012002-07-01false1910.119Sec. 1910.119LABORRegulations Relating to Labor (Continued)OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION, DEPARTMENTOCCUPATIONAL SAFETY AND HEALTH STANDARDSHazardous Materials
Sec. 1910.119  Process safety management of highly hazardous chemicals.

    Purpose. This section contains requirements for preventing or 
minimizing the consequences of catastrophic releases of toxic, reactive, 
flammable, or explosive chemicals. These releases may result in toxic, 
fire or explosion hazards.
    (a) Application. (1) This section applies to the following:
    (i) A process which involves a chemical at or above the specified 
threshold quantities listed in appendix A to this section;
    (ii) A process which involves a flammable liquid or gas (as defined 
in 1910.1200(c) of this part) on site in one location, in a quantity of 
10,000 pounds (4535.9 kg) or more except for:
    (A) Hydrocarbon fuels used solely for workplace consumption as a 
fuel (e.g., propane used for comfort heating, gasoline for vehicle 
refueling), if such fuels are not a part of a process containing another 
highly hazardous chemical covered by this standard;
    (B) Flammable liquids stored in atmospheric tanks or transferred 
which are kept below their normal boiling point without benefit of 
chilling or refrigeration.
    (2) This section does not apply to:
    (i) Retail facilities;
    (ii) Oil or gas well drilling or servicing operations; or,
    (iii) Normally unoccupied remote facilities.
    (b) Definitions. Atmospheric tank means a storage tank which has 
been designed to operate at pressures from atmospheric through 0.5 
p.s.i.g. (pounds per square inch gauge, 3.45 Kpa).
    Boiling point means the boiling point of a liquid at a pressure of 
14.7 pounds per square inch absolute (p.s.i.a.) (760 mm.). For the 
purposes of this section, where an accurate boiling point is unavailable 
for the material in question, or for mixtures which do not have a 
constant boiling point, the 10 percent point of a distillation performed 
in accordance with the Standard Method of Test for Distillation of 
Petroleum Products, ASTM D-86-62, which is incorporated by reference as 
specified in Sec. 1910.6, may be used as the boiling point of the 
liquid.
    Catastrophic release means a major uncontrolled emission, fire, or 
explosion, involving one or more highly hazardous chemicals, that 
presents serious danger to employees in the workplace.
    Facility means the buildings, containers or equipment which contain 
a process.
    Highly hazardous chemical means a substance possessing toxic, 
reactive, flammable, or explosive properties and specified by paragraph 
(a)(1) of this section.
    Hot work means work involving electric or gas welding, cutting, 
brazing, or similar flame or spark-producing operations.
    Normally unoccupied remote facility means a facility which is 
operated, maintained or serviced by employees who visit the facility 
only periodically to check its operation and to perform necessary 
operating or maintenance tasks. No employees are permanently stationed 
at the facility.
    Facilities meeting this definition are not contiguous with, and must 
be geographically remote from all other buildings, processes or persons.
    Process means any activity involving a highly hazardous chemical 
including any use, storage, manufacturing, handling, or the on-site 
movement of such chemicals, or combination of these activities. For 
purposes of this definition, any group of vessels which are 
interconnected and separate vessels which are located such that a highly 
hazardous chemical could be involved in a potential release shall be 
considered a single process.
    Replacement in kind means a replacement which satisfies the design 
specification.
    Trade secret means any confidential formula, pattern, process, 
device, information or compilation of information that is used in an 
employer's business,

[[Page 351]]

and that gives the employer an opportunity to obtain an advantage over 
competitors who do not know or use it. Appendix D contained in 
Sec. 1910.1200 sets out the criteria to be used in evaluating trade 
secrets.
    (c) Employee participation. (1) Employers shall develop a written 
plan of action regarding the implementation of the employee 
participation required by this paragraph.
    (2) Employers shall consult with employees and their representatives 
on the conduct and development of process hazards analyses and on the 
development of the other elements of process safety management in this 
standard.
    (3) Employers shall provide to employees and their representatives 
access to process hazard analyses and to all other information required 
to be developed under this standard.
    (d) Process safety information. In accordance with the schedule set 
forth in paragraph (e)(1) of this section, the employer shall complete a 
compilation of written process safety information before conducting any 
process hazard analysis required by the standard. The compilation of 
written process safety information is to enable the employer and the 
employees involved in operating the process to identify and understand 
the hazards posed by those processes involving highly hazardous 
chemicals. This process safety information shall include information 
pertaining to the hazards of the highly hazardous chemicals used or 
produced by the process, information pertaining to the technology of the 
process, and information pertaining to the equipment in the process.
    (1) Information pertaining to the hazards of the highly hazardous 
chemicals in the process. This information shall consist of at least the 
following:
    (i) Toxicity information;
    (ii) Permissible exposure limits;
    (iii) Physical data;
    (iv) Reactivity data:
    (v) Corrosivity data;
    (vi) Thermal and chemical stability data; and
    (vii) Hazardous effects of inadvertent mixing of different materials 
that could foreseeably occur.
    Note: Material Safety Data Sheets meeting the requirements of 29 CFR 
1910.1200(g) may be used to comply with this requirement to the extent 
they contain the information required by this subparagraph.
    (2) Information pertaining to the technology of the process. (i) 
Information concerning the technology of the process shall include at 
least the following:
    (A) A block flow diagram or simplified process flow diagram (see 
appendix B to this section);
    (B) Process chemistry;
    (C) Maximum intended inventory;
    (D) Safe upper and lower limits for such items as temperatures, 
pressures, flows or compositions; and,
    (E) An evaluation of the consequences of deviations, including those 
affecting the safety and health of employees.
    (ii) Where the original technical information no longer exists, such 
information may be developed in conjunction with the process hazard 
analysis in sufficient detail to support the analysis.
    (3) Information pertaining to the equipment in the process. (i) 
Information pertaining to the equipment in the process shall include:
    (A) Materials of construction;
    (B) Piping and instrument diagrams (P&ID's);
    (C) Electrical classification;
    (D) Relief system design and design basis;
    (E) Ventilation system design;
    (F) Design codes and standards employed;
    (G) Material and energy balances for processes built after May 26, 
1992; and,
    (H) Safety systems (e.g. interlocks, detection or suppression 
systems).
    (ii) The employer shall document that equipment complies with 
recognized and generally accepted good engineering practices.
    (iii) 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.
    (e) Process hazard analysis. (1) The employer shall perform an 
initial process hazard analysis (hazard evaluation) on processes covered 
by this standard.

[[Page 352]]

The process hazard analysis shall be appropriate to the complexity of 
the process and shall identify, evaluate, and control the hazards 
involved in the process. Employers shall determine and document the 
priority order for conducting process hazard analyses based on a 
rationale which includes such considerations as extent of the process 
hazards, number of potentially affected employees, age of the process, 
and operating history of the process. The process hazard analysis shall 
be conducted as soon as possible, but not later than the following 
schedule:
    (i) No less than 25 percent of the initial process hazards analyses 
shall be completed by May 26, 1994;
    (ii) No less than 50 percent of the initial process hazards analyses 
shall be completed by May 26, 1995;
    (iii) No less than 75 percent of the initial process hazards 
analyses shall be completed by May 26, 1996;
    (iv) All initial process hazards analyses shall be completed by May 
26, 1997.
    (v) Process hazards analyses completed after May 26, 1987 which meet 
the requirements of this paragraph are acceptable as initial process 
hazards analyses. These process hazard analyses shall be updated and 
revalidated, based on their completion date, in accordance with 
paragraph (e)(6) of this section.
    (2) The employer shall use one or more of the following 
methodologies that are appropriate to determine and evaluate the hazards 
of the process being analyzed.
    (i) What-If;
    (ii) Checklist;
    (iii) What-If/Checklist;
    (iv) Hazard and Operability Study (HAZOP):
    (v) Failure Mode and Effects Analysis (FMEA);
    (vi) Fault Tree Analysis; or
    (vii) An appropriate equivalent methodology.
    (3) The process hazard analysis shall address:
    (i) The hazards of the process;
    (ii) The identification of any previous incident which had a likely 
potential for catastrophic consequences in the workplace;
    (iii) Engineering and administrative controls applicable to the 
hazards and their interrelationships such as appropriate application of 
detection methodologies to provide early warning of releases. 
(Acceptable detection methods might include process monitoring and 
control instrumentation with alarms, and detection hardware such as 
hydrocarbon sensors.);
    (iv) Consequences of failure of engineering and administrative 
controls;
    (v) Facility siting;
    (vi) Human factors; and
    (vii) A qualitative evaluation of a range of the possible safety and 
health effects of failure of controls on employees in the workplace.
    (4) The process hazard analysis shall be performed by a team with 
expertise in engineering and process operations, and the team shall 
include at least one employee who has experience and knowledge specific 
to the process being evaluated. Also, one member of the team must be 
knowledgeable in the specific process hazard analysis methodology being 
used.
    (5) The employer shall establish a system to promptly address the 
team's findings and recommendations; assure that the recommendations are 
resolved in a timely manner and that the resolution is documented; 
document what actions are to be taken; complete actions as soon as 
possible; develop a written schedule of when these actions are to be 
completed; communicate the actions to operating, maintenance and other 
employees whose work assignments are in the process and who may be 
affected by the recommendations or actions.
    (6) At least every five (5) years after the completion of the 
initial process hazard analysis, the process hazard analysis shall be 
updated and revalidated by a team meeting the requirements in paragraph 
(e)(4) of this section, to assure that the process hazard analysis is 
consistent with the current process.
    (7) Employers shall retain process hazards analyses and updates or 
revalidations for each process covered by this section, as well as the 
documented resolution of recommendations described in paragraph (e)(5) 
of this section for the life of the process.
    (f) Operating procedures (1) The employer shall develop and 
implement

[[Page 353]]

written operating procedures that provide clear instructions for safely 
conducting activities involved in each covered process consistent with 
the process safety information and shall address at least the following 
elements.
    (i) Steps for each operating phase:
    (A) Initial startup;
    (B) Normal operations;
    (C) Temporary operations;
    (D) Emergency shutdown including the conditions under which 
emergency shutdown is required, and the assignment of shutdown 
responsibility to qualified operators to ensure that emergency shutdown 
is executed in a safe and timely manner.
    (E) Emergency Operations;
    (F) Normal shutdown; and,
    (G) Startup following a turnaround, or after an emergency shutdown.
    (ii) Operating limits:
    (A) Consequences of deviation; and
    (B) Steps required to correct or avoid deviation.
    (iii) Safety and health considerations:
    (A) Properties of, and hazards presented by, the chemicals used in 
the process;
    (B) Precautions necessary to prevent exposure, including engineering 
controls, administrative controls, and personal protective equipment;
    (C) Control measures to be taken if physical contact or airborne 
exposure occurs;
    (D) Quality control for raw materials and control of hazardous 
chemical inventory levels; and,
    (E) Any special or unique hazards.
    (iv) Safety systems and their functions.
    (2) Operating procedures shall be readily accessible to employees 
who work in or maintain a process.
    (3) The operating procedures shall be reviewed as often as necessary 
to assure that they reflect current operating practice, including 
changes that result from changes in process chemicals, technology, and 
equipment, and changes to facilities. The employer shall certify 
annually that these operating procedures are current and accurate.
    (4) The employer shall develop and implement safe work practices to 
provide for the control of hazards during operations such as lockout/
tagout; confined space entry; opening process equipment or piping; and 
control over entrance into a facility by maintenance, contractor, 
laboratory, or other support personnel. These safe work practices shall 
apply to employees and contractor employees.
    (g) Training--(1) Initial training. (i) Each employee presently 
involved in operating a process, and each employee before being involved 
in operating a newly assigned process, shall be trained in an overview 
of the process and in the operating procedures as specified in paragraph 
(f) of this section. The training shall include emphasis on the specific 
safety and health hazards, emergency operations including shutdown, and 
safe work practices applicable to the employee's job tasks.
    (ii) In lieu of initial training for those employees already 
involved in operating a process on May 26, 1992, an employer may certify 
in writing that the employee has the required knowledge, skills, and 
abilities to safely carry out the duties and responsibilities as 
specified in the operating procedures.
    (2) Refresher training. Refresher training shall be provided at 
least every three years, and more often if necessary, to each employee 
involved in operating a process to assure that the employee understands 
and adheres to the current operating procedures of the process. The 
employer, in consultation with the employees involved in operating the 
process, shall determine the appropriate frequency of refresher 
training.
    (3) Training documentation. The employer shall ascertain that each 
employee involved in operating a process has received and understood the 
training required by this paragraph. The employer shall prepare a record 
which contains the identity of the employee, the date of training, and 
the means used to verify that the employee understood the training.
    (h) Contractors--(1) Application. This paragraph applies to 
contractors performing maintenance or repair, turnaround, major 
renovation, or specialty work on or adjacent to a covered process. It 
does not apply to contractors providing incidental services which do not 
influence process safety, such as

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janitorial work, food and drink services, laundry, delivery or other 
supply services.
    (2) Employer responsibilities. (i) The employer, when selecting a 
contractor, shall obtain and evaluate information regarding the contract 
employer's safety performance and programs.
    (ii) The employer shall inform contract employers of the known 
potential fire, explosion, or toxic release hazards related to the 
contractor's work and the process.
    (iii) The employer shall explain to contract employers the 
applicable provisions of the emergency action plan required by paragraph 
(n) of this section.
    (iv) The employer shall develop and implement safe work practices 
consistent with paragraph (f)(4) of this section, to control the 
entrance, presence and exit of contract employers and contract employees 
in covered process areas.
    (v) The employer shall periodically evaluate the performance of 
contract employers in fulfilling their obligations as specified in 
paragraph (h)(3) of this section.
    (vi) The employer shall maintain a contract employee injury and 
illness log related to the contractor's work in process areas.
    (3) Contract employer responsibilities. (i) The contract employer 
shall assure that each contract employee is trained in the work 
practices necessary to safely perform his/her job.
    (ii) The contract employer shall assure that each contract employee 
is instructed in the known potential fire, explosion, or toxic release 
hazards related to his/her job and the process, and the applicable 
provisions of the emergency action plan.
    (iii) The contract employer shall document that each contract 
employee has received and understood the training required by this 
paragraph. The contract employer shall prepare a record which contains 
the identity of the contract employee, the date of training, and the 
means used to verify that the employee understood the training.
    (iv) The contract employer shall assure that each contract employee 
follows the safety rules of the facility including the safe work 
practices required by paragraph (f)(4) of this section.
    (v) The contract employer shall advise the employer of any unique 
hazards presented by the contract employer's work, or of any hazards 
found by the contract employer's work.
    (i) Pre-startup safety review. (1) The employer shall perform a pre-
startup safety review for new facilities and for modified facilities 
when the modification is significant enough to require a change in the 
process safety information.
    (2) The pre-startup safety review shall confirm that prior to the 
introduction of highly hazardous chemicals to a process:
    (i) Construction and equipment is in accordance with design 
specifications;
    (ii) Safety, operating, maintenance, and emergency procedures are in 
place and are adequate;
    (iii) For new facilities, a process hazard analysis has been 
performed and recommendations have been resolved or implemented before 
startup; and modified facilities meet the requirements contained in 
management of change, paragraph (l).
    (iv) Training of each employee involved in operating a process has 
been completed.
    (j) Mechanical integrity--(1) Application. Paragraphs (j)(2) through 
(j)(6) of this section apply to the following process equipment:
    (i) Pressure vessels and storage tanks;
    (ii) Piping systems (including piping components such as valves);
    (iii) Relief and vent systems and devices;
    (iv) Emergency shutdown systems;
    (v) Controls (including monitoring devices and sensors, alarms, and 
interlocks) and,
    (vi) Pumps.
    (2) Written procedures. The employer shall establish and implement 
written procedures to maintain the on-going integrity of process 
equipment.
    (3) Training for process maintenance activities. The employer shall 
train each employee involved in maintaining the on-going integrity of 
process equipment in an overview of that process and its hazards and in 
the procedures

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applicable to the employee's job tasks to assure that the employee can 
perform the job tasks in a safe manner.
    (4) Inspection and testing. (i) Inspections and tests shall be 
performed on process equipment.
    (ii) Inspection and testing procedures shall follow recognized and 
generally accepted good engineering practices.
    (iii) The frequency of inspections and tests of process equipment 
shall be consistent with applicable manufacturers' recommendations and 
good engineering practices, and more frequently if determined to be 
necessary by prior operating experience.
    (iv) The employer shall document each inspection and test that has 
been performed on process equipment. The documentation shall identify 
the date of the inspection or test, the name of the person who performed 
the inspection or test, the serial number or other identifier of the 
equipment on which the inspection or test was performed, a description 
of the inspection or test performed, and the results of the inspection 
or test.
    (5) Equipment deficiencies. The employer shall correct deficiencies 
in equipment that are outside acceptable limits (defined by the process 
safety information in paragraph (d) of this section) before further use 
or in a safe and timely manner when necessary means are taken to assure 
safe operation.
    (6) Quality assurance. (i) In the construction of new plants and 
equipment, the employer shall assure that equipment as it is fabricated 
is suitable for the process application for which they will be used.
    (ii) Appropriate checks and inspections shall be performed to assure 
that equipment is installed properly and consistent with design 
specifications and the manufacturer's instructions.
    (iii) The employer shall assure that maintenance materials, spare 
parts and equipment are suitable for the process application for which 
they will be used.
    (k) Hot work permit. (1) The employer shall issue a hot work permit 
for hot work operations conducted on or near a covered process.
    (2) The permit shall document that the fire prevention and 
protection requirements in 29 CFR 1910.252(a) have been implemented 
prior to beginning the hot work operations; it shall indicate the 
date(s) authorized for hot work; and identify the object on which hot 
work is to be performed. The permit shall be kept on file until 
completion of the hot work operations.
    (l) Management of change. (1) The employer shall establish and 
implement written procedures to manage changes (except for 
``replacements in kind'') to process chemicals, technology, equipment, 
and procedures; and, changes to facilities that affect a covered 
process.
    (2) The procedures shall assure that the following considerations 
are addressed prior to any change:
    (i) The technical basis for the proposed change;
    (ii) Impact of change on safety and health;
    (iii) Modifications to operating procedures;
    (iv) Necessary time period for the change; and,
    (v) Authorization requirements for the proposed change.
    (3) Employees involved in operating a process and maintenance and 
contract employees whose job tasks will be affected by a change in the 
process shall be informed of, and trained in, the change prior to start-
up of the process or affected part of the process.
    (4) If a change covered by this paragraph results in a change in the 
process safety information required by paragraph (d) of this section, 
such information shall be updated accordingly.
    (5) If a change covered by this paragraph results in a change in the 
operating procedures or practices required by paragraph (f) of this 
section, such procedures or practices shall be updated accordingly.
    (m) Incident investigation. (1) The employer shall investigate each 
incident which resulted in, or could reasonably have resulted in a 
catastrophic release of highly hazardous chemical in the workplace.
    (2) An incident investigation shall be initiated as promptly as 
possible, but not later than 48 hours following the incident.
    (3) An incident investigation team shall be established and consist 
of at least one person knowledgeable in the process involved, including 
a contract employee if the incident involved work

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of the contractor, and other persons with appropriate knowledge and 
experience to thoroughly investigate and analyze the incident.
    (4) A report shall be prepared at the conclusion of the 
investigation which includes at a minimum:
    (i) Date of incident;
    (ii) Date investigation began;
    (iii) A description of the incident;
    (iv) The factors that contributed to the incident; and,
    (v) Any recommendations resulting from the investigation.I11(5) The 
employer shall establish a system to promptly address and resolve the 
incident report findings and recommendations. Resolutions and corrective 
actions shall be documented.
    (6) The report shall be reviewed with all affected personnel whose 
job tasks are relevant to the incident findings including contract 
employees where applicable.
    (7) Incident investigation reports shall be retained for five years.
    (n) Emergency planning and response. The employer shall establish 
and implement an emergency action plan for the entire plant in 
accordance with the provisions of 29 CFR 1910.38(a). In addition, the 
emergency action plan shall include procedures for handling small 
releases. Employers covered under this standard may also be subject to 
the hazardous waste and emergency response provisions contained in 29 
CFR 1910.120 (a), (p) and (q).
    (o) Compliance Audits. (1) Employers shall certify that they have 
evaluated compliance with the provisions of this section at least every 
three years to verify that the procedures and practices developed under 
the standard are adequate and are being followed.
    (2) The compliance audit shall be conducted by at least one person 
knowledgeable in the process.
    (3) A report of the findings of the audit shall be developed.
    (4) The employer shall promptly determine and document an 
appropriate response to each of the findings of the compliance audit, 
and document that deficiencies have been corrected.
    (5) Employers shall retain the two (2) most recent compliance audit 
reports.
    (p) Trade secrets. (1) Employers shall make all information 
necessary to comply with the section available to those persons 
responsible for compiling the process safety information (required by 
paragraph (d) of this section), those assisting in the development of 
the process hazard analysis (required by paragraph (e) of this section), 
those responsible for developing the operating procedures (required by 
paragraph (f) of this section), and those involved in incident 
investigations (required by paragraph (m) of this section), emergency 
planning and response (paragraph (n) of this section) and compliance 
audits (paragraph (o) of this section) without regard to possible trade 
secret status of such information.
    (2) Nothing in this paragraph shall preclude the employer from 
requiring the persons to whom the information is made available under 
paragraph (p)(1) of this section to enter into confidentiality 
agreements not to disclose the information as set forth in 29 CFR 
1910.1200.
    (3) Subject to the rules and procedures set forth in 29 CFR 
1910.1200(i)(1) through 1910.1200(i)(12), employees and their designated 
representatives shall have access to trade secret information contained 
within the process hazard analysis and other documents required to be 
developed by this standard.

Appendix A to Sec. 1910.119--List of Highly Hazardous Chemicals, Toxics 
                        and Reactives (Mandatory)

    This appendix contains a listing of toxic and reactive highly 
hazardous chemicals which present a potential for a catastrophic event 
at or above the threshold quantity.

------------------------------------------------------------------------
                   CHEMICAL name                         CAS*      TQ**
------------------------------------------------------------------------
Acetaldehyde.......................................      75-07-0    2500
Acrolein (2-Propenal)..............................     107-02-8     150
Acrylyl Chloride...................................     814-68-6     250
Allyl Chloride.....................................     107-05-1    1000
Allylamine.........................................     107-11-9    1000
Alkylaluminums.....................................       Varies    5000
Ammonia, Anhydrous.................................    7664-41-7   10000
Ammonia solutions (44% ammonia by           7664-41-7   15000
 weight)...........................................
Ammonium Perchlorate...............................    7790-98-9    7500
Ammonium Permanganate..............................    7787-36-2    7500
Arsine (also called Arsenic Hydride)...............    7784-42-1     100
Bis(Chloromethyl) Ether............................     542-88-1     100
Boron Trichloride..................................   10294-34-5    2500
Boron Trifluoride..................................    7637-07-2     250
Bromine............................................    7726-95-6    1500
Bromine Chloride...................................   13863-41-7    1500
Bromine Pentafluoride..............................    7789-30-2    2500
Bromine Trifluoride................................    7787-71-5   15000

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3-Bromopropyne (also called Propargyl Bromide).....     106-96-7     100
Butyl Hydroperoxide (Tertiary).....................      75-91-2    5000
Butyl Perbenzoate (Tertiary).......................     614-45-9    7500
Carbonyl Chloride (see Phosgene)...................      75-44-5     100
Carbonyl Fluoride..................................     353-50-4    2500
Cellulose Nitrate (concentration 12.6%      9004-70-0    2500
 nitrogen..........................................
Chlorine...........................................    7782-50-5    1500
Chlorine Dioxide...................................   10049-04-4    1000
Chlorine Pentrafluoride............................   13637-63-3    1000
Chlorine Trifluoride...............................    7790-91-2    1000
Chlorodiethylaluminum (also called Diethylaluminum       96-10-6    5000
 Chloride).........................................
1-Chloro-2,4-Dinitrobenzene........................      97-00-7    5000
Chloromethyl Methyl Ether..........................     107-30-2     500
Chloropicrin.......................................      76-06-2     500
Chloropicrin and Methyl Bromide mixture............         None    1500
Chloropicrin and Methyl Chloride mixture...........         None    1500
Cumene Hydroperoxide...............................      80-15-9    5000
Cyanogen...........................................     460-19-5    2500
Cyanogen Chloride..................................     506-77-4     500
Cyanuric Fluoride..................................     675-14-9     100
Diacetyl Peroxide (Concentration 70%)...     110-22-5    5000
Diazomethane.......................................     334-88-3     500
Dibenzoyl Peroxide.................................      94-36-0    7500
Diborane...........................................   19287-45-7     100
Dibutyl Peroxide (Tertiary)........................     110-05-4    5000
Dichloro Acetylene.................................    7572-29-4     250
Dichlorosilane.....................................    4109-96-0    2500
Diethylzinc........................................     557-20-0   10000
Diisopropyl Peroxydicarbonate......................     105-64-6    7500
Dilaluroyl Peroxide................................     105-74-8    7500
Dimethyldichlorosilane.............................      75-78-5    1000
Dimethylhydrazine, 1,1-............................      57-14-7    1000
Dimethylamine, Anhydrous...........................     124-40-3    2500
2,4-Dinitroaniline.................................      97-02-9    5000
Ethyl Methyl Ketone Peroxide (also Methyl Ethyl        1338-23-4    5000
 Ketone Peroxide; concentration 60%)....
Ethyl Nitrite......................................     109-95-5    5000
Ethylamine.........................................      75-04-7    7500
Ethylene Fluorohydrin..............................     371-62-0     100
Ethylene Oxide.....................................      75-21-8    5000
Ethyleneimine......................................     151-56-4    1000
Fluorine...........................................    7782-41-4    1000
Formaldehyde (Formalin)............................      50-00-0    1000
Furan..............................................     110-00-9     500
Hexafluoroacetone..................................     684-16-2    5000
Hydrochloric Acid, Anhydrous.......................    7647-01-0    5000
Hydrofluoric Acid, Anhydrous.......................    7664-39-3    1000
Hydrogen Bromide...................................   10035-10-6    5000
Hydrogen Chloride..................................    7647-01-0    5000
Hydrogen Cyanide, Anhydrous........................      74-90-8    1000
Hydrogen Fluoride..................................    7664-39-3    1000
Hydrogen Peroxide (52% by weight or greater).......    7722-84-1    7500
Hydrogen Selenide..................................    7783-07-5     150
Hydrogen Sulfide...................................    7783-06-4    1500
Hydroxylamine......................................    7803-49-8    2500
Iron, Pentacarbonyl................................   13463-40-6     250
Isopropylamine.....................................      75-31-0    5000
Ketene.............................................     463-51-4     100
Methacrylaldehyde..................................      78-85-3    1000
Methacryloyl Chloride..............................     920-46-7     150
Methacryloyloxyethyl Isocyanate....................   30674-80-7     100
Methyl Acrylonitrile...............................     126-98-7     250
Methylamine, Anhydrous.............................      74-89-5    1000
Methyl Bromide.....................................      74-83-9    2500
Methyl Chloride....................................      74-87-3   15000
Methyl Chloroformate...............................      79-22-1     500
Methyl Ethyl Ketone Peroxide (concentration 60%)...........................................
Methyl Fluoroacetate...............................     453-18-9     100
Methyl Fluorosulfate...............................     421-20-5     100
Methyl Hydrazine...................................      60-34-4     100
Methyl Iodide......................................      74-88-4    7500
Methyl Isocyanate..................................     624-83-9     250
Methyl Mercaptan...................................      74-93-1    5000
Methyl Vinyl Ketone................................      79-84-4     100
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
Nitric Oxide.......................................   10102-43-9     250
Nitroaniline (para Nitroaniline....................     100-01-6    5000
Nitromethane.......................................      75-52-5    2500
Nitrogen Dioxide...................................   10102-44-0     250
Nitrogen Oxides (NO; NO2; N204; N203)..............   10102-44-0     250
Nitrogen Tetroxide (also called Nitrogen Peroxide).   10544-72-6     250
Nitrogen Trifluoride...............................    7783-54-2    5000
Nitrogen Trioxide..................................   10544-73-7     250
Oleum (65% to 80% by weight; also called Fuming        8014-94-7    1000
 Sulfuric Acid)....................................
Osmium Tetroxide...................................   20816-12-0     100
Oxygen Difluoride (Fluorine Monoxide)..............    7783-41-7     100
Ozone..............................................   10028-15-6     100
Pentaborane........................................   19624-22-7     100
Peracetic Acid (concentration 60% Acetic      79-21-0    1000
 Acid; also called Peroxyacetic Acid)..............
Perchloric Acid (concentration 60% by       7601-90-3    5000
 weight)...........................................
Perchloromethyl Mercaptan..........................     594-42-3     150
Perchloryl Fluoride................................    7616-94-6    5000
Peroxyacetic Acid (concentration 60%          79-21-0    1000
 Acetic Acid; also called Peracetic Acid)..........
Phosgene (also called Carbonyl Chloride)...........      75-44-5     100
Phosphine (Hydrogen Phosphide).....................    7803-51-2     100
Phosphorus Oxychloride (also called Phosphoryl        10025-87-3    1000
 Chloride).........................................
Phosphorus Trichloride.............................    7719-12-2    1000
Phosphoryl Chloride (also called Phosphorus           10025-87-3    1000
 Oxychloride)......................................
Propargyl Bromide..................................     106-96-7     100
Propyl Nitrate.....................................      627-3-4    2500
Sarin..............................................     107-44-8     100
Selenium Hexafluoride..............................    7783-79-1    1000
Stibine (Antimony Hydride).........................    7803-52-3     500
Sulfur Dioxide (liquid)............................    7446-09-5    1000
Sulfur Pentafluoride...............................    5714-22-7     250
Sulfur Tetrafluoride...............................    7783-60-0     250
Sulfur Trioxide (also called Sulfuric Anhydride)...    7446-11-9    1000
Sulfuric Anhydride (also called Sulfur Trioxide)...    7446-11-9    1000
Tellurium Hexafluoride.............................    7783-80-4     250
Tetrafluoroethylene................................     116-14-3    5000
Tetrafluorohydrazine...............................   10036-47-2    5000
Tetramethyl Lead...................................      75-74-1    1000
Thionyl Chloride...................................    7719-09-7     250
Trichloro (chloromethyl) Silane....................    1558-25-4     100
Trichloro (dichlorophenyl) Silane..................   27137-85-5    2500
Trichlorosilane....................................   10025-78-2    5000
Trifluorochloroethylene............................      79-38-9   10000
Trimethyoxysilane..................................    2487-90-3    1500
------------------------------------------------------------------------
*Chemical Abstract Service Number.
**Threshold Quantity in Pounds (Amount necessary to be covered by this
  standard).


[[Page 358]]

 Appendix B to Sec. 1910.119--Block Flow Diagram and Simplified Process 
                       Flow Diagram (Nonmandatory)
[GRAPHIC] [TIFF OMITTED] TC27OC91.026


[[Page 359]]


[GRAPHIC] [TIFF OMITTED] TC27OC91.027

 Appendix C to Sec. 1910.119--Compliance Guidelines and Recommendations 
              for Process Safety Management (Nonmandatory)

    This appendix serves as a nonmandatory guideline to assist employers 
and employees in complying with the requirements of this section, as 
well as provides other helpful recommendations and information. Examples 
presented in this appendix are not the only means of achieving the 
performance goals in the standard. This appendix neither adds nor 
detracts from the requirements of the standard.
    1. Introduction to Process Safety Management. The major objective of 
process safety management of highly hazardous chemicals is to prevent 
unwanted releases of hazardous chemicals especially into locations which 
could expose employees and others to serious hazards. An effective 
process safety management program requires a systematic approach to 
evaluating the whole process. Using this approach the process design, 
process technology, operational and maintenance activities and 
procedures, nonroutine activities and procedures, emergency preparedness 
plans and procedures, training programs, and other elements which impact 
the process are all considered in the evaluation. The various lines of 
defense that have been incorporated into the design and operation of the 
process to prevent or mitigate the release of hazardous chemicals need 
to be evaluated and strengthened to assure their effectiveness at each 
level. Process safety management is the proactive identification, 
evaluation and mitigation or prevention of chemical releases that could 
occur as a result of failures in process, procedures or equipment.
    The process safety management standard targets highly hazardous 
chemicals that

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have the potential to cause a catastrophic incident. This standard as a 
whole is to aid employers in their efforts to prevent or mitigate 
episodic chemical releases that could lead to a catastrophe in the 
workplace and possibly to the surrounding community. To control these 
types of hazards, employers need to develop the necessary expertise, 
experiences, judgement and proactive initiative within their workforce 
to properly implement and maintain an effective process safety 
management program as envisioned in the OSHA standard. This OSHA 
standard is required by the Clean Air Act Amendments as is the 
Environmental Protection Agency's Risk Management Plan. Employers, who 
merge the two sets of requirements into their process safety management 
program, will better assure full compliance with each as well as 
enhancing their relationship with the local community.
    While OSHA believes process safety management will have a positive 
effect on the safety of employees in workplaces and also offers other 
potential benefits to employers (increased productivity), smaller 
businesses which may have limited resources available to them at this 
time, might consider alternative avenues of decreasing the risks 
associated with highly hazardous chemicals at their workplaces. One 
method which might be considered is the reduction in the inventory of 
the highly hazardous chemical. This reduction in inventory will result 
in a reduction of the risk or potential for a catastrophic incident. 
Also, employers including small employers may be able to establish more 
efficient inventory control by reducing the quantities of highly 
hazardous chemicals on site below the established threshold quantities. 
This reduction can be accomplished by ordering smaller shipments and 
maintaining the minimum inventory necessary for efficient and safe 
operation. When reduced inventory is not feasible, then the employer 
might consider dispersing inventory to several locations on site. 
Dispersing storage into locations where a release in one location will 
not cause a release in another location is a practical method to also 
reduce the risk or portential for catastrophic incidents.
    2. Employee Involvement in Process Safety Management. Section 304 of 
the Clean Air Act Amendments states that employers are to consult with 
their employees and their representatives regarding the employers 
efforts in the development and implementation of the process safety 
management program elements and hazard assessments. Section 304 also 
requires employers to train and educate their employees and to inform 
affected employees of the findings from incident investigations required 
by the process safety management program. Many employers, under their 
safety and health programs, have already established means and methods 
to keep employees and their representatives informed about relevant 
safety and health issues and employers may be able to adapt these 
practices and procedures to meet their obligations under this standard. 
Employers who have not implemented an occupational safety and health 
program may wish to form a safety and health committee of employees and 
management representatives to help the employer meet the obligations 
specified by this standard. These committees can become a significant 
ally in helping the employer to implement and maintain an effective 
process safety managment program for all employees.
    3. Process Safety Information. Complete and accurate written 
information concerning process chemicals, process technology, and 
process equipment is essential to an effective process safety management 
program and to a process hazards analysis. The compiled information will 
be a necessary resource to a variety of users including the team that 
will perform the process hazards analysis as required under paragraph 
(e); those developing the training programs and the operating 
procedures; contractors whose employees will be working with the 
process; those conducting the pre-startup reviews; local emergency 
preparedness planners; and insurance and enforcement officials.
    The information to be compiled about the chemicals, including 
process intermediates, needs to be comprehensive enough for an accurate 
assessment of the fire and explosion characteristics, reactivity 
hazards, the safety and health hazards to workers, and the corrosion and 
erosion effects on the process equipment and monitoring tools. Current 
material safety data sheet (MSDS) information can be used to help meet 
this requirement which must be supplemented with process chemistry 
information including runaway reaction and over pressure hazards if 
applicable.
    Process technology information will be a part of the process safety 
information package and it is expected that it will include diagrams of 
the type shown in appendix B of this section as well as employer 
established criteria for maximum inventory levels for process chemicals; 
limits beyond which would be considered upset conditions; and a 
qualitative estimate of the consequences or results of deviation that 
could occur if operating beyond the established process limits. 
Employers are encouraged to use diagrams which will help users 
understand the process.
    A block flow diagram is used to show the major process equipment and 
interconnecting process flow lines and show flow rates, stream 
composition, temperatures, and pressures when necessary for clarity. The 
block flow diagram is a simplified diagram.
    Process flow diagrams are more complex and will show all main flow 
streams including valves to enhance the understanding of

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the process, as well as pressures and temperatures on all feed and 
product lines within all major vessels, in and out of headers and heat 
exchangers, and points of pressure and temperature control. Also, 
materials of construction information, pump capacities and pressure 
heads, compressor horsepower and vessel design pressures and 
temperatures are shown when necessary for clarity. In addition, major 
components of control loops are usually shown along with key utilities 
on process flow diagrams.
    Piping and instrument diagrams (P&IDs) may be the more appropriate 
type of diagrams to show some of the above details and to display the 
information for the piping designer and engineering staff. The P&IDs are 
to be used to describe the relationships between equipment and 
instrumentation as well as other relevant information that will enhance 
clarity. Computer software programs which do P&IDs or other diagrams 
useful to the information package, may be used to help meet this 
requirement.
    The information pertaining to process equipment design must be 
documented. In other words, what were the codes and standards relied on 
to establish good engineering practice. These codes and standards are 
published by such organizations as the American Society of Mechanical 
Engineers, American Petroleum Institute, American National Standards 
Institute, National Fire Protection Association, American Society for 
Testing and Materials, National Board of Boiler and Pressure Vessel 
Inspectors, National Association of Corrosion Engineers, American 
Society of Exchange Manufacturers Association, and model building code 
groups.
    In addition, various engineering societies issue technical reports 
which impact process design. For example, the American Institute of 
Chemical Engineers has published technical reports on topics such as two 
phase flow for venting devices. This type of technically recognized 
report would constitute good engineering practice.
    For existing equipment designed and constructed many years ago in 
accordance with the codes and standards available at that time and no 
longer in general use today, the employer must document which codes and 
standards were used and that the design and construction along with the 
testing, inspection and operation are still suitable for the intended 
use. Where the process technology requires a design which departs from 
the applicable codes and standards, the employer must document that the 
design and construction is suitable for the intended purpose.
    4. Process Hazard Analysis. A process hazard analysis (PHA), 
sometimes called a process hazard evaluation, is one of the most 
important elements of the process safety management program. A PHA is an 
organized and systematic effort to identify and analyze the significance 
of potential hazards associated with the processing or handling of 
highly hazardous chemicals. A PHA provides information which will assist 
employers and employees in making decisions for improving safety and 
reducing the consequences of unwanted or unplanned releases of hazardous 
chemicals. A PHA is directed toward analyzing potential causes and 
consequences of fires, explosions, releases of toxic or flammable 
chemicals and major spills of hazardous chemicals. The PHA focuses on 
equipment, instrumentation, utilities, human actions (routine and 
nonroutine), and external factors that might impact the process. These 
considerations assist in determining the hazards and potential failure 
points or failure modes in a process.
    The selection of a PHA methodology or technique will be influenced 
by many factors including the amount of existing knowledge about the 
process. Is it a process that has been operated for a long period of 
time with little or no innovation and extensive experience has been 
generated with its use? Or, is it a new process or one which has been 
changed frequently by the inclusion of innovative features? Also, the 
size and complexity of the process will influence the decision as to the 
appropriate PHA methodology to use. All PHA methodologies are subject to 
certain limitations. For example, the checklist methodology works well 
when the process is very stable and no changes are made, but it is not 
as effective when the process has undergone extensive change. The 
checklist may miss the most recent changes and consequently the changes 
would not be evaluated. Another limitation to be considered concerns the 
assumptions made by the team or analyst. The PHA is dependent on good 
judgement and the assumptions made during the study need to be 
documented and understood by the team and reviewer and kept for a future 
PHA.
    The team conducting the PHA need to understand the methodology that 
is going to be used. A PHA team can vary in size from two people to a 
number of people with varied operational and technical backgrounds. Some 
team members may only be a part of the team for a limited time. The team 
leader needs to be fully knowledgeable in the proper implementation of 
the PHA methodology that is to be used and should be impartial in the 
evaluation. The other full or part time team members need to provide the 
team with expertise in areas such as process technology, process design, 
operating procedures and practices, including how the work is actually 
performed, alarms, emergency procedures, instrumentation, maintenance 
procedures, both routine and nonroutine tasks, including how the tasks 
are authorized, procurement of parts and supplies, safety and health, 
and any other relevant subject as the

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need dictates. At least one team member must be familiar with the 
process.
    The ideal team will have an intimate knowledge of the standards, 
codes, specifications and regulations applicable to the process being 
studied. The selected team members need to be compatible and the team 
leader needs to be able to manage the team, and the PHA study. The team 
needs to be able to work together while benefiting from the expertise of 
others on the team or outside the team, to resolve issues, and to forge 
a consensus on the findings of the study and recommendations.
    The application of a PHA to a process may involve the use of 
different methodologies for various parts of the process. For example, a 
process involving a series of unit operation of varying sizes, 
complexities, and ages may use different methodologies and team members 
for each operation. Then the conclusions can be integrated into one 
final study and evaluation. A more specific example is the use of a 
checklist PHA for a standard boiler or heat exchanger and the use of a 
Hazard and Operability PHA for the overall process. Also, for batch type 
processes like custom batch operations, a generic PHA of a 
representative batch may be used where there are only small changes of 
monomer or other ingredient ratios and the chemistry is documented for 
the full range and ratio of batch ingredients. Another process that 
might consider using a generic type of PHA is a gas plant. Often these 
plants are simply moved from site to site and therefore, a generic PHA 
may be used for these movable plants. Also, when an employer has several 
similar size gas plants and no sour gas is being processed at the site, 
then a generic PHA is feasible as long as the variations of the 
individual sites are accounted for in the PHA. Finally, when an employer 
has a large continuous process which has several control rooms for 
different portions of the process such as for a distillation tower and a 
blending operation, the employer may wish to do each segment separately 
and then integrate the final results.
    Additionally, small businesses which are covered by this rule, will 
often have processes that have less storage volume, less capacity, and 
less complicated than processes at a large facility. Therefore, OSHA 
would anticipate that the less complex methodologies would be used to 
meet the process hazard analysis criteria in the standard. These process 
hazard analyses can be done in less time and with a few people being 
involved. A less complex process generally means that less data, P&IDs, 
and process information is needed to perform a process hazard analysis.
    Many small businesses have processes that are not unique, such as 
cold storage lockers or water treatment facilities. Where employer 
associations have a number of members with such facilities, a generic 
PHA, evolved from a checklist or what-if questions, could be developed 
and used by each employer effectively to reflect his/her particular 
process; this would simplify compliance for them.
    When the employer has a number of processes which require a PHA, the 
employer must set up a priority system of which PHAs to conduct first. A 
preliminary or gross hazard analysis may be useful in prioritizing the 
processes that the employer has determined are subject to coverage by 
the process safety management standard. Consideration should first be 
given to those processes with the potential of adversely affecting the 
largest number of employees. This prioritizing should consider the 
potential severity of a chemical release, the number of potentially 
affected employees, the operating history of the process such as the 
frequency of chemical releases, the age of the process and any other 
relevant factors. These factors would suggest a ranking order and would 
suggest either using a weighing factor system or a systematic ranking 
method. The use of a preliminary hazard analysis would assist an 
employer in determining which process should be of the highest priority 
and thereby the employer would obtain the greatest improvement in safety 
at the facility.
    Detailed guidance on the content and application of process hazard 
analysis methodologies is available from the American Institute of 
Chemical Engineers' Center for Chemical Process Safety (see appendix D).
    5. Operating Procedures and Practices. Operating procedures describe 
tasks to be performed, data to be recorded, operating conditions to be 
maintained, samples to be collected, and safety and health precautions 
to be taken. The procedures need to be technically accurate, 
understandable to employees, and revised periodically to ensure that 
they reflect current operations. The process safety information package 
is to be used as a resource to better assure that the operating 
procedures and practices are consistent with the known hazards of the 
chemicals in the process and that the operating parameters are accurate. 
Operating procedures should be reviewed by engineering staff and 
operating personnel to ensure that they are accurate and provide 
practical instructions on how to actually carry out job duties safely.
    Operating procedures will include specific instructions or details 
on what steps are to be taken or followed in carrying out the stated 
procedures. These operating instructions for each procedure should 
include the applicable safety precautions and should contain appropriate 
information on safety implications. For example, the operating 
procedures addressing operating parameters will contain operating 
instructions about pressure limits, temperature ranges, flow rates, what 
to do when an upset condition

[[Page 363]]

occurs, what alarms and instruments are pertinent if an upset condition 
occurs, and other subjects. Another example of using operating 
instructions to properly implement operating procedures is in starting 
up or shutting down the process. In these cases, different parameters 
will be required from those of normal operation. These operating 
instructions need to clearly indicate the distinctions between startup 
and normal operations such as the appropriate allowances for heating up 
a unit to reach the normal operating parameters. Also the operating 
instructions need to describe the proper method for increasing the 
temperature of the unit until the normal operating temperature 
parameters are achieved.
    Computerized process control systems add complexity to operating 
instructions. These operating instructions need to describe the logic of 
the software as well as the relationship between the equipment and the 
control system; otherwise, it may not be apparent to the operator.
    Operating procedures and instructions are important for training 
operating personnel. The operating procedures are often viewed as the 
standard operating practices (SOPs) for operations. Control room 
personnel and operating staff, in general, need to have a full 
understanding of operating procedures. If workers are not fluent in 
English then procedures and instructions need to be prepared in a second 
language understood by the workers. In addition, operating procedures 
need to be changed when there is a change in the process as a result of 
the management of change procedures. The consequences of operating 
procedure changes need to be fully evaluated and the information 
conveyed to the personnel. For example, mechanical changes to the 
process made by the maintenance department (like changing a valve from 
steel to brass or other subtle changes) need to be evaluated to 
determine if operating procedures and practices also need to be changed. 
All management of change actions must be coordinated and integrated with 
current operating procedures and operating personnel must be oriented to 
the changes in procedures before the change is made. When the process is 
shut down in order to make a change, then the operating procedures must 
be updated before startup of the process.
    Training in how to handle upset conditions must be accomplished as 
well as what operating personnel are to do in emergencies such as when a 
pump seal fails or a pipeline ruptures. Communication between operating 
personnel and workers performing work within the process area, such as 
nonroutine tasks, also must be maintained. The hazards of the tasks are 
to be conveyed to operating personnel in accordance with established 
procedures and to those performing the actual tasks. When the work is 
completed, operating personnel should be informed to provide closure on 
the job.
    6. Employee Training. All employees, including maintenance and 
contractor employees, involved with highly hazardous chemicals need to 
fully understand the safety and health hazards of the chemicals and 
processes they work with for the protection of themselves, their fellow 
employees and the citizens of nearby communities. Training conducted in 
compliance with Sec. 1910.1200, the Hazard Communication standard, will 
help employees to be more knowledgeable about the chemicals they work 
with as well as familiarize them with reading and understanding MSDS. 
However, additional training in subjects such as operating procedures 
and safety work practices, emergency evacuation and response, safety 
procedures, routine and nonroutine work authorization activities, and 
other areas pertinent to process safety and health will need to be 
covered by an employer's training program.
    In establishing their training programs, employers must clearly 
define the employees to be trained and what subjects are to be covered 
in their training. Employers in setting up their training program will 
need to clearly establish the goals and objectives they wish to achieve 
with the training that they provide to their employees. The learning 
goals or objectives should be written in clear measurable terms before 
the training begins. These goals and objectives need to be tailored to 
each of the specific training modules or segments. Employers should 
describe the important actions and conditions under which the employee 
will demonstrate competence or knowledge as well as what is acceptable 
performance.
    Hands-on-training where employees are able to use their senses 
beyond listening, will enhance learning. For example, operating 
personnel, who will work in a control room or at control panels, would 
benefit by being trained at a simulated control panel or panels. Upset 
conditions of various types could be displayed on the simulator, and 
then the employee could go through the proper operating procedures to 
bring the simulator panel back to the normal operating parameters. A 
training environment could be created to help the trainee feel the full 
reality of the situation but, of course, under controlled conditions. 
This realistic type of training can be very effective in teaching 
employees correct procedures while allowing them to also see the 
consequences of what might happen if they do not follow established 
operating procedures. Other training techniques using videos or on-the-
job training can also be very effective for teaching other job tasks, 
duties, or other important information. An effective training program 
will allow the employee to fully participate in the training process and 
to practice their skill or knowledge.

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    Employers need to periodically evaluate their training programs to 
see if the necessary skills, knowledge, and routines are being properly 
understood and implemented by their trained employees. The means or 
methods for evaluating the training should be developed along with the 
training program goals and objectives. Training program evaluation will 
help employers to determine the amount of training their employees 
understood, and whether the desired results were obtained. If, after the 
evaluation, it appears that the trained employees are not at the level 
of knowledge and skill that was expected, the employer will need to 
revise the training program, provide retraining, or provide more 
frequent refresher training sessions until the deficiency is resolved. 
Those who conducted the training and those who received the training 
should also be consulted as to how best to improve the training process. 
If there is a language barrier, the language known to the trainees 
should be used to reinforce the training messages and information.
    Careful consideration must be given to assure that employees 
including maintenance and contract employees receive current and updated 
training . For example, if changes are made to a process, impacted 
employees must be trained in the changes and understand the effects of 
the changes on their job tasks (e.g., any new operating procedures 
pertinent to their tasks). Additionally, as already discussed the 
evaluation of the employee's absorption of training will certainly 
influence the need for training.
    7. Contractors. Employers who use contractors to perform work in and 
around processes that involve highly hazardous chemicals, will need to 
establish a screening process so that they hire and use contractors who 
accomplish the desired job tasks without compromising the safety and 
health of employees at a facility. For contractors, whose safety 
performance on the job is not known to the hiring employer, the employer 
will need to obtain information on injury and illness rates and 
experience and should obtain contractor references. Additionally, the 
employer must assure that the contractor has the appropriate job skills, 
knowledge and certifications (such as for pressure vessel welders). 
Contractor work methods and experiences should be evaluated. For 
example, does the contractor conducting demolition work swing loads over 
operating processes or does the contractor avoid such hazards?
    Maintaining a site injury and illness log for contractors is another 
method employers must use to track and maintain current knowledge of 
work activities involving contract employees working on or adjacent to 
covered processes. Injury and illness logs of both the employer's 
employees and contract employees allow an employer to have full 
knowledge of process injury and illness experience. This log will also 
contain information which will be of use to those auditing process 
safety management compliance and those involved in incident 
investigations.
    Contract employees must perform their work safely. Considering that 
contractors often perform very specialized and potentially hazardous 
tasks such as confined space entry activities and nonroutine repair 
activities it is quite important that their activities be controlled 
while they are working on or near a covered process. A permit system or 
work authorization system for these activities would also be helpful to 
all affected employers. The use of a work authorization system keeps an 
employer informed of contract employee activities, and as a benefit the 
employer will have better coordination and more management control over 
the work being performed in the process area. A well run and well 
maintained process where employee safety is fully recognized will 
benefit all of those who work in the facility whether they be contract 
employees or employees of the owner.
    8. Pre-Startup Safety. For new processes, the employer will find a 
PHA helpful in improving the design and construction of the process from 
a reliability and quality point of view. The safe operation of the new 
process will be enhanced by making use of the PHA recommendations before 
final installations are completed. P&IDs are to be completed along with 
having the operating procedures in place and the operating staff trained 
to run the process before startup. The initial startup procedures and 
normal operating procedures need to be fully evaluated as part of the 
pre-startup review to assure a safe transfer into the normal operating 
mode for meeting the process parameters.
    For existing processes that have been shutdown for turnaround, or 
modification, etc., the employer must assure that any changes other than 
``replacement in kind'' made to the process during shutdown go through 
the management of change procedures. P&IDs will need to be updated as 
necessary, as well as operating procedures and instructions. If the 
changes made to the process during shutdown are significant and impact 
the training program, then operating personnel as well as employees 
engaged in routine and nonroutine work in the process area may need some 
refresher or additional training in light of the changes. Any incident 
investigation recommendations, compliance audits or PHA recommendations 
need to be reviewed as well to see what impacts they may have on the 
process before beginning the startup.
    9. Mechanical Integrity. Employers will need to review their 
maintenance programs and schedules to see if there are areas where 
``breakdown'' maintenance is used rather than an on-going mechanical 
integrity program. Equipment used to process, store, or

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handle highly hazardous chemicals needs to be designed, constructed, 
installed and maintained to minimize the risk of releases of such 
chemicals. This requires that a mechanical integrity program be in place 
to assure the continued integrity of process equipment. Elements of a 
mechanical integrity program include the identification and 
categorization of equipment and instrumentation, inspections and tests, 
testing and inspection frequencies, development of maintenance 
procedures, training of maintenance personnel, the establishment of 
criteria for acceptable test results, documentation of test and 
inspection results, and documentation of manufacturer recommendations as 
to meantime to failure for equipment and instrumentation.
    The first line of defense an employer has available is to operate 
and maintain the process as designed, and to keep the chemicals 
contained. This line of defense is backed up by the next line of defense 
which is the controlled release of chemicals through venting to 
scrubbers or flares, or to surge or overflow tanks which are designed to 
receive such chemicals, etc. These lines of defense are the primary 
lines of defense or means to prevent unwanted releases. The secondary 
lines of defense would include fixed fire protection systems like 
sprinklers, water spray, or deluge systems, monitor guns, etc., dikes, 
designed drainage systems, and other systems which would control or 
mitigate hazardous chemicals once an unwanted release occurs. These 
primary and secondary lines of defense are what the mechanical integrity 
program needs to protect and strengthen these primary and secondary 
lines of defenses where appropriate.
    The first step of an effective mechanical integrity program is to 
compile and categorize a list of process equipment and instrumentation 
for inclusion in the program. This list would include pressure vessels, 
storage tanks, process piping, relief and vent systems, fire protection 
system components, emergency shutdown systems and alarms and interlocks 
and pumps. For the categorization of instrumentation and the listed 
equipment the employer would prioritize which pieces of equipment 
require closer scrutiny than others. Meantime to failure of various 
instrumentation and equipment parts would be known from the 
manufacturers data or the employer's experience with the parts, which 
would then influence the inspection and testing frequency and associated 
procedures. Also, applicable codes and standards such as the National 
Board Inspection Code, or those from the American Society for Testing 
and Material, American Petroleum Institute, National Fire Protection 
Association, American National Standards Institute, American Society of 
Mechanical Engineers, and other groups, provide information to help 
establish an effective testing and inspection frequency, as well as 
appropriate methodologies.
    The applicable codes and standards provide criteria for external 
inspections for such items as foundation and supports, anchor bolts, 
concrete or steel supports, guy wires, nozzles and sprinklers, pipe 
hangers, grounding connections, protective coatings and insulation, and 
external metal surfaces of piping and vessels, etc. These codes and 
standards also provide information on methodologies for internal 
inspection, and a frequency formula based on the corrosion rate of the 
materials of construction. Also, erosion both internal and external 
needs to be considered along with corrosion effects for piping and 
valves. Where the corrosion rate is not known, a maximum inspection 
frequency is recommended, and methods of developing the corrosion rate 
are available in the codes. Internal inspections need to cover items 
such as vessel shell, bottom and head; metallic linings; nonmetallic 
linings; thickness measurements for vessels and piping; inspection for 
erosion, corrosion, cracking and bulges; internal equipment like trays, 
baffles, sensors and screens for erosion, corrosion or cracking and 
other deficiencies. Some of these inspections may be performed by state 
of local government inspectors under state and local statutes. However, 
each employer needs to develop procedures to ensure that tests and 
inspections are conducted properly and that consistency is maintained 
even where different employees may be involved. Appropriate training is 
to be provided to maintenance personnel to ensure that they understand 
the preventive maintenance program procedures, safe practices, and the 
proper use amd application of special equipment or unique tools that may 
be required. This training is part of the overall training program 
called for in the standard.
    A quality assurance system is needed to help ensure that the proper 
materials of construction are used, that fabrication and inspection 
procedures are proper, and that installation procedures recognize field 
installation concerns. The quality assurance program is an essential 
part of the mechanical integrity program and will help to maintain the 
primary and secondary lines of defense that have been designed into the 
process to prevent unwanted chemical releases or those which control or 
mitigate a release. ``As built'' drawings, together with certifications 
of coded vessels and other equipment, and materials of construction need 
to be verified and retained in the quality assurance documentation. 
Equipment installation jobs need to be properly inspected in the field 
for use of proper materials and procedures and to assure that qualified 
craftsmen are used to do the job. The use of appropriate gaskets, 
packing, bolts, valves, lubricants and welding rods need to be verified 
in the field. Also

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procedures for installation of safety devices need to be verified, such 
as the torque on the bolts on ruptured disc installations, uniform 
torque on flange bolts, proper installation of pump seals, etc. If the 
quality of parts is a problem, it may be appropriate to conduct audits 
of the equipment supplier's facilities to better assure proper purchases 
of required equipment which is suitable for its intended service. Any 
changes in equipment that may become necessary will need to go through 
the management of change procedures.
    10. Nonroutine Work Authorizations. Nonroutine work which is 
conducted in process areas needs to be controlled by the employer in a 
consistent manner. The hazards identified involving the work that is to 
be accomplished must be communicated to those doing the work, but also 
to those operating personnel whose work could affect the safety of the 
process. A work authorization notice or permit must have a procedure 
that describes the steps the maintenance supervisor, contractor 
representative or other person needs to follow to obtain the necessary 
clearance to get the job started. The work authorization procedures need 
to reference and coordinate, as applicable, lockout/tagout procedures, 
line breaking procedures, confined space entry procedures and hot work 
authorizations. This procedure also needs to provide clear steps to 
follow once the job is completed in order to provide closure for those 
that need to know the job is now completed and equipment can be returned 
to normal.
    11. Managing Change. To properly manage changes to process 
chemicals, technology, equipment and facilities, one must define what is 
meant by change. In this process safety management standard, change 
includes all modifications to equipment, procedures, raw materials and 
processing conditions other than ``replacement in kind''. These changes 
need to be properly managed by identifying and reviewing them prior to 
implementation of the change. For example, the operating procedures 
contain the operating parameters (pressure limits, temperature ranges, 
flow rates, etc.) and the importance of operating within these limits. 
While the operator must have the flexibility to maintain safe operation 
within the established parameters, any operation outside of these 
parameters requires review and approval by a written management of 
change procedure.
    Management of change covers such as changes in process technology 
and changes to equipment and instrumentation. Changes in process 
technology can result from changes in production rates, raw materials, 
experimentation, equipment unavailability, new equipment, new product 
development, change in catalyst and changes in operating conditions to 
improve yield or quality. Equipment changes include among others change 
in materials of construction, equipment specifications, piping pre-
arrangements, experimental equipment, computer program revisions and 
changes in alarms and interlocks. Employers need to establish means and 
methods to detect both technical changes and mechanical changes.
    Temporary changes have caused a number of catastrophes over the 
years, and employers need to establish ways to detect temporary changes 
as well as those that are permanent. It is important that a time limit 
for temporary changes be established and monitored since, without 
control, these changes may tend to become permanent. Temporary changes 
are subject to the management of change provisions. In addition, the 
management of change procedures are used to insure that the equipment 
and procedures are returned to their original or designed conditions at 
the end of the temporary change. Proper documentation and review of 
these changes is invaluable in assuring that the safety and health 
considerations are being incorporated into the operating procedures and 
the process.
    Employers may wish to develop a form or clearance sheet to 
facilitate the processing of changes through the management of change 
procedures. A typical change form may include a description and the 
purpose of the change, the technical basis for the change, safety and 
health considerations, documentation of changes for the operating 
procedures, maintenance procedures, inspection and testing, P&IDs, 
electrical classification, training and communications, pre-startup 
inspection, duration if a temporary change, approvals and authorization. 
Where the impact of the change is minor and well understood, a check 
list reviewed by an authorized person with proper communication to 
others who are affected may be sufficient. However, for a more complex 
or significant design change, a hazard evaluation procedure with 
approvals by operations, maintenance, and safety departments may be 
appropriate. Changes in documents such as P&IDs, raw materials, 
operating procedures, mechanical integrity programs, electrical 
classifications, etc., need to be noted so that these revisions can be 
made permanent when the drawings and procedure manuals are updated. 
Copies of process changes need to be kept in an accessible location to 
ensure that design changes are available to operating personnel as well 
as to PHA team members when a PHA is being done or one is being updated.
    12. Investigation of Incidents. Incident investigation is the 
process of identifying the underlying causes of incidents and 
implementing steps to prevent similar events from occurring. The intent 
of an incident investigation is for employers to learn from past 
experiences and thus avoid repeating past

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mistakes. The incidents for whicn OSHA expects employers to become aware 
and to investigate are the types of events which result in or could 
reasonably have resulted in a catastrophic release. Some of the events 
are sometimes referred to as ``near misses,'' meaning that a serious 
consequence did not occur, but could have.
    Employers need to develop in-house capability to investigate 
incidents that occur in their facilities. A team needs to be assembled 
by the employer and trained in the techniques of investigation including 
how to conduct interviews of witnesses, needed documentation and report 
writing. A multi-disciplinary team is better able to gather the facts of 
the event and to analyze them and develop plausible scenarios as to what 
happened, and why. Team members should be selected on the basis of their 
training, knowledge and ability to contribute to a team effort to fully 
investigate the incident. Employees in the process area where the 
incident occurred should be consulted, interviewed or made a member of 
the team. Their knowledge of the events form a significant set of facts 
about the incident which occurred. The report, its findings and 
recommendations are to be shared with those who can benefit from the 
information. The cooperation of employees is essential to an effective 
incident investigation. The focus of the investigation should be to 
obtain facts, and not to place blame. The team and the investigation 
process should clearly deal with all involved individuals in a fair, 
open and consistent manner.
    13. Emergency Preparedness. Each employer must address what actions 
employees are to take when there is an unwanted release of highly 
hazardous chemicals. Emergency preparedness or the employer's tertiary 
(third) lines of defense are those that will be relied on along with the 
secondary lines of defense when the primary lines of defense which are 
used to prevent an unwanted release fail to stop the release. Employers 
will need to decide if they want employees to handle and stop small or 
minor incidental releases. Whether they wish to mobilize the available 
resources at the plant and have them brought to bear on a more 
significant release. Or whether employers want their employees to 
evacuate the danger area and promptly escape to a preplanned safe zone 
area, and allow the local community emergency response organizations to 
handle the release. Or whether the employer wants to use some 
combination of these actions. Employers will need to select how many 
different emergency preparedness or tertiary lines of defense they plan 
to have and then develop the necessary plans and procedures, and 
appropriately train employees in their emergency duties and 
responsibilities and then implement these lines of defense.
    Employers at a minimum must have an emergency action plan which will 
facilitate the prompt evacuation of employees due to an unwanted release 
of a highly hazardous chemical. This means that the employer will have a 
plan that will be activated by an alarm system to alert employees when 
to evacuate and, that employees who are physically impaired, will have 
the necessary support and assistance to get them to the safe zone as 
well. The intent of these requirements is to alert and move employees to 
a safe zone quickly. Delaying alarms or confusing alarms are to be 
avoided. The use of process control centers or similar process buildings 
in the process area as safe areas is discouraged. Recent catastrophes 
have shown that a large life loss has occurred in these structures 
because of where they have been sited and because they are not 
necessarily designed to withstand over-pressures from shockwaves 
resulting from explosions in the process area.
    Unwanted incidental releases of highly hazardous chemicals in the 
process area must be addressed by the employer as to what actions 
employees are to take. If the employer wants employees to evacuate the 
area, then the emergency action plan will be activated. For outdoor 
processes where wind direction is important for selecting the safe route 
to a refuge area, the employer should place a wind direction indicator 
such as a wind sock or pennant at the highest point that can be seen 
throughout the process area. Employees can move in the direction of 
cross wind to upwind to gain safe access to the refuge area by knowing 
the wind direction.
    If the employer wants specific employees in the release area to 
control or stop the minor emergency or incidental release, these actions 
must be planned for in advance and procedures developed and implemented. 
Preplanning for handling incidental releases for minor emergencies in 
the process area needs to be done, appropriate equipment for the hazards 
must be provided, and training conducted for those employees who will 
perform the emergency work before they respond to handle an actual 
release. The employer's training program, including the Hazard 
Communication standard training is to address the training needs for 
employees who are expected to handle incidental or minor releases.
    Preplanning for releases that are more serious than incidental 
releases is another important line of defense to be used by the 
employer. When a serious release of a highly hazardous chemical occurs, 
the employer through preplanning will have determined in advance what 
actions employees are to take. The evacuation of the immediate release 
area and other areas as necessary would be accomplished under the 
emergency action

[[Page 368]]

plan. If the employer wishes to use plant personnel such as a fire 
brigade, spill control team, a hazardous materials team, or use 
employees to render aid to those in the immediate release area and 
control or mitigate the incident, these actions are covered by 
Sec. 1910.120, the Hazardous Waste Operations and Emergency Response 
(HAZWOPER) standard. If outside assistance is necessary, such as through 
mutual aid agreements between employers or local government emergency 
response organizations, these emergency responders are also covered by 
HAZWOPER. The safety and health protections required for emergency 
responders are the responsibility of their employers and of the on-scene 
incident commander.
    Responders may be working under very hazardous conditions and 
therefore the objective is to have them competently led by an on-scene 
incident commander and the commander's staff, properly equipped to do 
their assigned work safely, and fully trained to carry out their duties 
safely before they respond to an emergency. Drills, training exercises, 
or simulations with the local community emergency response planners and 
responder organizations is one means to obtain better preparedness. This 
close cooperation and coordination between plant and local community 
emergency preparedness managers will also aid the employer in complying 
with the Environmental Protection Agency's Risk Management Plan 
criteria.
    One effective way for medium to large facilities to enhance 
coordination and communication during emergencies for on plant 
operations and with local community organizations is for employers to 
establish and equip an emergency control center. The emergency control 
center would be sited in a safe zone area so that it could be occupied 
throughout the duration of an emergency. The center would serve as the 
major ccommunication link between the on-scene incident commander and 
plant or corporate management as well as with the local community 
officials. The communication equipment in the emergency control center 
should include a network to receive and transmit information by 
telephone, radio or other means. It is important to have a backup 
communication network in case of power failure or one communication 
means fails. The center should also be equipped with the plant layout 
and community maps, utility drawings including fire water, emergency 
lighting, appropriate reference materials such as a government agency 
notification list, company personnel phone list, SARA Title III reports 
and material safety data sheets, emergency plans and procedures manual, 
a listing with the location of emergency response equipment, mutual aid 
information, and access to meteorological or weather condition data and 
any dispersion modeling data.
    14. Compliance Audits. Employers need to select a trained individual 
or assemble a trained team of people to audit the process safety 
management system and program. A small process or plant may need only 
one knowledgeable person to conduct an audit. The audit is to include an 
evaluation of the design and effectiveness of the process safety 
management system and a field inspection of the safety and health 
conditions and practices to verify that the employer's systems are 
effectively implemented. The audit should be conducted or lead by a 
person knowledgeable in audit techniques and who is impartial towards 
the facility or area being audited. The essential elements of an audit 
program include planning, staffing, conduting the audit, evaluation and 
corrective action, follow-up and documentation.
    Planning in advance is essential to the success of the auditing 
process. Each employer needs to establish the format, staffing, 
scheduling and verification methods prior to conducting the audit. The 
format should be designed to provide the lead auditor with a procedure 
or checklist which details the requirements of each section of the 
standard. The names of the audit team members should be listed as part 
of the format as well. The checklist, if properly designed, could serve 
as the verification sheet which provides the auditor with the necessary 
information to expedite the review and assure that no requirements of 
the standard are omitted. This verification sheet format could also 
identify those elements that will require evaluation or a response to 
correct deficiencies. This sheet could also be used for developing the 
follow-up and documentation requirements.
    The selection of effective audit team members is critical to the 
success of the program. Team members should be chosen for their 
experience, knowledge, and training and should be familiar with the 
processes and with auditing techniques, practices and procedures. The 
size of the team will vary depending on the size and complexity of the 
process under consideration. For a large, complex, highly instrumented 
plant, it may be desirable to have team members with expertise in 
process engineering and design, process chemistry, instrumentation and 
computer controls, electrical hazards and classifications, safety and 
health disciplines, maintenance, emergency preparedness, warehousing or 
shipping, and process safety auditing. The team may use part-time 
members to provide for the depth of expertise required as well as for 
what is actually done or followed, compared to what is written.
    An effective audit includes a review of the relevant documentation 
and process safety information, inspection of the physical facilities, 
and interviews with all levels of plant personnel. Utilizing the audit 
procedure and checklist developed in the

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preplanning stage, the audit team can systematically analyze compliance 
with the provisions of the standard and any other corporate policies 
that are relevant. For example, the audit team will review all aspects 
of the training program as part of the overall audit. The team will 
review the written training program for adequacy of content, frequency 
of training, effectiveness of training in terms of its goals and 
objectives as well as to how it fits into meeting the standard's 
requirements, documentation, etc. Through interviews, the team can 
determine the employee's knowledge and awareness of the safety 
procedures, duties, rules, emergency response assignments, etc. During 
the inspection, the team can observe actual practices such as safety and 
health policies, procedures, and work authorization practices. This 
approach enables the team to identify deficiencies and determine where 
corrective actions or improvements are necessary.
    An audit is a technique used to gather sufficient facts and 
information, including statistical information, to verify compliance 
with standards. Auditors should select as part of their preplanning a 
sample size sufficient to give a degree of confidence that the audit 
reflects the level of compliance with the standard. The audit team, 
through this systematic analysis, should document areas which require 
corrective action as well as those areas where the process safety 
management system is effective and working in an effective manner. This 
provides a record of the audit procedures and findings, and serves as a 
baseline of operation data for future audits. It will assist future 
auditors in determining changes or trends from previous audits.
    Corrective action is one of the most important parts of the audit. 
It includes not only addressing the identified deficiencies, but also 
planning, followup, and documentation. The corrective action process 
normally begins with a management review of the audit findings. The 
purpose of this review is to determine what actions are appropriate, and 
to establish priorities, timetables, resource allocations and 
requirements and responsibilities. In some cases, corrective action may 
involve a simple change in procedure or minor maintenance effort to 
remedy the concern. Management of change procedures need to be used, as 
appropriate, even for what may seem to be a minor change. Many of the 
deficiencies can be acted on promptly, while some may require 
engineering studies or indepth review of actual procedures and 
practices. There may be instances where no action is necessary and this 
is a valid response to an audit finding. All actions taken, including an 
explanation where no action is taken on a finding, needs to be 
documented as to what was done and why.
    It is important to assure that each deficiency identified is 
addressed, the corrective action to be taken noted, and the audit person 
or team responsible be properly documented by the employer. To control 
the corrective action process, the employer should consider the use of a 
tracking system. This tracking system might include periodic status 
reports shared with affected levels of management, specific reports such 
as completion of an engineering study, and a final implementation report 
to provide closure for audit findings that have been through management 
of change, if appropriate, and then shared with affected employees and 
management. This type of tracking system provides the employer with the 
status of the corrective action. It also provides the documentation 
required to verify that appropriate corrective actions were taken on 
deficiencies identified in the audit.

      Appendix D to Sec. 1910.119--Sources of Further Information 
                             (Nonmandatory)

    1. Center for Chemical Process Safety, American Institute of 
Chemical Engineers, 345 East 47th Street, New York, NY 10017, (212) 705-
7319.
    2. ``Guidelines for Hazard Evaluation Procedures,'' American 
Institute of Chemical Engineers; 345 East 47th Street, New York, NY 
10017.
    3. ``Guidelines for Technical Management of Chemical Process 
Safety,'' Center for Chemical Process Safety of the American Institute 
of Chemical Engineers; 345 East 47th Street, New York, NY 10017.
    4. ``Evaluating Process Safety in the Chemical Industry,'' Chemical 
Manufacturers Association; 2501 M Street NW, Washington, DC 20037.
    5. ``Safe Warehousing of Chemicals,'' Chemical Manufacturers 
Association; 2501 M Street NW, Washington, DC 20037.
    6. ``Management of Process Hazards,'' American Petroleum Institute 
(API Recommended Practice 750); 1220 L Street, N.W., Washington, D.C. 
20005.
    7. ``Improving Owner and Contractor Safety Performance,'' American 
Petroleum Institute (API Recommended Practice 2220); API, 1220 L Street 
N.W., Washington, D.C. 20005.
    8. Chemical Manufacturers Association (CMA's Manager Guide), First 
Edition, September 1991; CMA, 2501 M Street, N.W., Washington, D.C. 
20037.
    9. ``Improving Construction Safety Performance,'' Report A-3, The 
Business Roundtable; The Business Roundtable, 200 Park Avenue, New York, 
NY 10166. (Report includes criteria to evaluate contractor safety 
performance and criteria to enhance contractor safety performance).
    10. ``Recommended Guidelines for Contractor Safety and Health,'' 
Texas Chemical Council; Texas Chemical Council, 1402 Nueces Street, 
Austin, TX 78701-1534.

[[Page 370]]

    11. ``Loss Prevention in the Process Industries,'' Volumes I and II; 
Frank P. Lees, Butterworth; London 1983.
    12. ``Safety and Health Program Management Guidelines,'' 1989; U.S. 
Department of Labor, Occupational Safety and Health Administration.
    13. ``Safety and Health Guide for the Chemical Industry,'' 1986, 
(OSHA 3091); U.S. Department of Labor, Occupational Safety and Health 
Administration; 200 Constitution Avenue, N.W., Washington, D.C. 20210.
    14. ``Review of Emergency Systems,'' June 1988; U.S. Environmental 
Protection Agency (EPA), Office of Solid Waste and Emergency Response, 
Washington, DC 20460.
    15. ``Technical Guidance for Hazards Analysis, Emergency Planning 
for Extremely Hazardous Substances,'' December 1987; U.S. Environmental 
Protection Agency (EPA), Federal Emergency Management Administration 
(FEMA) and U.S. Department of Transportation (DOT), Washington, DC 
20460.
    16. ``Accident Investigation * * * A New Approach,'' 1983, National 
Safety Council; 444 North Michigan Avenue, Chicago, IL 60611-3991.
    17. ``Fire & Explosion Index Hazard Classification Guide,'' 6th 
Edition, May 1987, Dow Chemical Company; Midland, Michigan 48674.
    18. ``Chemical Exposure Index,'' May 1988, Dow Chemical Company; 
Midland, Michigan 48674.

[57 FR 6403, Feb. 24, 1992; 57 FR 7847, Mar. 4, 1992, as amended at 61 
FR 9238, Mar. 7, 1996]