Hazard Recognition

Hazardous chemical releases pose a significant threat to workers. The key provision of process safety management (PSM) is process hazard analysis (PHA), a careful review of what could go wrong and what safeguards must be implemented to prevent releases of hazardous chemicals. The following references help begin a PHA by recognizing process hazards.

• 29 CFR 1910.119. Process safety management of highly hazardous chemicals. OSHA Standard.
  • Appendix A. List of highly hazardous chemicals, toxics and reactives (Mandatory). Contains a listing of toxic and reactive highly hazardous chemicals which present a potential for a catastrophic event at or above the threshold quantity.
• Process Safety Management. OSHA Publication 3132, (2000).

OSHA Safety and Health Information Bulletins (SHIBs)

• Carbon Monoxide Explosion Hazards in Electric Arc Furnace Steelmaking Operations. (December 4, 2015).
• Water-Reactive Chemicals, Hazardous Materials Not Covered Under 29 CFR 1910.119. (July 3, 1996). Highlights a potentially serious hazard regarding materials not covered by the Process Safety Management Standard, 29 CFR 1910.119.
• Chemical Exposures from Industrial Valve and Piping Systems. (May 14, 1996). Heightens public awareness of the potential for death, physical injury, and/or illness resulting from the unexpected release of chemicals during refinery and other chemical process operations.
• Corrosion of Piping in Hydroprocessing Units. (July 29, 1994). Addresses potentially serious safety hazards associated with hydrocracking (hydroprocessing) units.
• Use of hydrofluoric acid in the petroleum refining alkylation process. (November 19, 1993). Alerts field personnel to the potential safety and health risks posed by hydrofluoric acid (HF) used in HF alkylation units and to present the control measures implemented by industry to reduce workers' exposure, and pertinent OSHA requirements.
• Hazards of Delayed Coker Unit (DCU) Operations. OSHA Safety and Health Information Bulletin and Environmental Protection Agency (EPA) Publication 550-F-03-001, (August 29, 2003).

Other Resources

• Center for Chemical Process Safety (CCPS) Process Safety Beacon. A resource aimed at delivering process safety messages to plant operators and other manufacturing personnel. The monthly one-page Process Safety Beacon covers the breadth of process safety issues. Each issue presents a real-life incident, and describes the lessons learned and practical means to prevent a similar incident. For an archive of past Process Safety Beacons, scroll down to "Accessing Archived Beacons".
• Chemical Reactivity Worksheet. National Oceanic and Atmospheric Administration (NOAA), Office of Response and Restoration. Provides information about the reactivity of substances or mixtures of substances.
• U.S. Chemical Safety Board (CSB). The CSB is an independent federal agency charged with investigating industrial chemical accidents. Based on these investigations, the CSB makes recommendations for controlling hazards and preventing future incidents. These lessons learned are published in investigation reports and videos provided by CSB:
  • Completed Investigations. Written reports published for each investigation performed by the CSB.
  • Video Room. Online safety videos, safety messages, and free DVDs available to order.