Operating Procedures

The employer must develop and implement written operating procedures that are consistent with the process safety information, and provide clear instructions for safely conducting activities involved in each covered process. Tasks and procedures related to the covered process must be appropriate, consistent, and understandable to employees. The procedures must address at least the following elements:

• Steps for each operating phase:
  • Initial startup
  • Normal operations
  • Temporary operations
  • Emergency shutdown
  • Emergency operations
  • Normal shutdown
  • Startup following a turnaround or emergency shutdown
• Operating limits:
  • Consequences of deviation
  • Steps required to correct or avoid deviation
• Safety and health considerations:
  • Properties and hazards presented by the chemicals used in the process
  • Precautions necessary to prevent exposure, including controls and personal protective equipment
  • Control measures to be taken in the event of physical contact or airborne exposure
  • Quality control for raw materials
  • Control of hazardous chemical inventory levels
  • Special or unique hazards
  • Safety systems (such as interlocks, detection, or suppression systems) and their functions

Operating procedures must be readily accessible to employees who work in or maintain a process. The employer and the employees must review the operating procedures as often as necessary to ensure that they reflect current operating practices, including changes in process chemicals, technology, equipment, and facilities. The employer must certify annually that the operating procedures are current and accurate, in an effort to avoid providing employees with inaccurate or outdated information on operating procedures.

To learn more about Process Safety Management visit our Cal/OSHA Process Safety Management Online Training web page.