Operating Procedures

The employer must develop and implement written operating procedures, consistent with the process safety information, that provide clear instructions for safely conducting activities involved in each covered process. OSHA believes that tasks and procedures related to the covered process must be appropriate, clear, consistent, and most importantly, well communicated to employees. The procedures must address at least the following elements.

Steps for each operating phase:

  • • Initial start-up
  • • Normal operations
  • • Temporary operations
  • • 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
  • • Emergency operations
  • • Normal shutdown
  • • Start-up following a turnaround, or after an emergency shutdown Operating limits:
  • • Consequences of deviation
  • • Steps required to correct or avoid deviation

Safety and health considerations:

  • • Properties of, and hazards presented by, the chemicals used in the process
  • • Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment
  • • Control measures to be taken if physical contact or airborne exposure occurs
  • • Quality control for raw materials and control of hazardous chemical inventory levels
  • • Any special or unique hazards
  • • Safety systems (e.g., interlocks, detection or suppression systems) and their functions.
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