Which chemicals are highly hazardous?

The Standard applies to any process that contains a threshold quantity or greater amount of a large number of toxic or reactive hazardous chemicals, which are specified in Appendix A of the Standard. This list gives the chemical name, Chemical Abstract Service (CAS) number, and threshold quantity (TQ) in pounds for each substance. The Standard also applies to 10,000 pounds or greater amounts of flammable liquids and gases and to the processing activity of manufacturing explosives and pyrotechnics.

Process safety management

The Standard is performance-oriented. However, all companies are required to follow certain basic steps. For example, the Standard requires you to compile detailed information about the chemicals, technology, and equipment used in regulated processes and conduct a process hazard analysis for each regulated process. Process hazard analyses must be updated and revalidated at least every 5 years. In addition, you must develop a written plan for involving employees (both your own and contractor employees) in the management of regulated processes and provide clear written instructions for safely conducting activities involving regulated processes. You also have to inspect and test process equipment regularly, conduct full compliance audits at least every 3 years, develop a written emergency action plan, and investigate within 48 hours any incidents that result or could reasonably have resulted in catastrophic releases of highly hazardous chemicals.

Employees have to be well trained

Training for employees operating a process regulated by the Standard must include:

• Overview of the process
• Operating procedures
• Specific safety and health hazards
• Emergency operations
• Safe work practices

Refresher training is required at least every 3 years (and more often if necessary) to ensure that employees understand and follow the current operating procedures of the process. Whenever there are changes in the process, employees must be trained in those changes before the start-up of the new or modified process. Employees responsible for maintaining process equipment must be trained in the process and its hazards.