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Operating Procedures
1910.119(f)
Operating Procedures & Safety
Programs Must Consider:
start-up
Initial start-up
Normal operations
Temporary operations
Emergency shutdown
Emergency operations
Normal shutdown
Start-up following turnaround
Start-up
Consequences of deviation
Steps required to correct or avoid deviation
Operating Procedures or
Standard Operating Procedures
(SOP’s)
Where Did This Methodology Come From?
Definition: A standard operating procedure is a set
of instructions having the force of a directive,
covering those features of operations that lend
themselves to a definite or standardized procedure
without loss of effectiveness. Standard Operating
Policies and Procedures can be be effective catalysts to
effective catalysts to
drive performance improvement and improving
organizational results.
organizational results. Every
Every good
good quality
quality system
system isis
based on its standard operating procedures (SOPs).
Operating Procedures
Develop and implement written operating procedures*
consistent with the process safety information and addresses
at least the following elements:
Initial start-up, normal and temporary operations
Normal and emergency shut-down procedures
Operating limits and consequences of deviation
Hazards presented by the process
The operating procedures addressing
operating parameters will contain operating
instructions about:
pressure limits
temperature ranges
rates…and
flow rates…and
what to do when an upset condition occurs
what alarms and instruments are pertinent if an
subjects.
upset condition occurs, and other subjects.
Operating Procedures - Start
Up…We Must
Describe start-up
start-up SOP's
Shut-down
Describe Shut-down
SOP’s
SOP’s
Operating Procedures - Start
Up…We Must
Include Sections such as:
Objectives
Purpose
Concerns
Procedures
Department
Operator
Equipment Involved
Location
Related Documents
For Shut-down
Shut-down
Procedures…Remember:
Procedures…Remember:
Most operations must be shut down in a
specific order!
Failure to follow these shut down
procedures could results in a catastrophic
release or system failure
Ammonia Plant Explosion Caused by
Improper Shut-down of Engine Room
Operating Procedures
Operating Limits
Operating Limits
Must be Understood
Pressures
Flows
Electrical Potential
Tolerances
Operating Procedures -
Hazards of the Process
Operating
Procedures Must
Identify the Hazards
of the Process in All
Phases:
Start Up
Normal Operating
Conditions
Temporary Operating
Condition
Shut-
Emergency Shut-
down
Now That We’ve Completed
the Operating Procedures
We Must Develop Safety Work Practices,
Programs & Procedures for Covered
Processes
Safe Work Practices
1910.119(f)(1)
Safe Work Practices
•Develop and implement safe work practices* to provide for
the control of hazards during operations such as:
–Lockout/tagout;
–Confined space entry;
–Line Opening process equipment or piping; and
–Control over entrance into a facility by maintenance,
contractor, laboratory, or other support personnel
Lockout/Tagout in
PSM
Why not Use Digital
Imaging in Your
Procedures to Identify
Critical Lockout
Critical Lockout /Tagout
/Tagout
Positions
Safe Work Practices
Line Opening
Permits
Identify Procedures
for Opening any
Process Line in a
Covered Process
Must Include
Hazards of the Line
Opening
PPE Required
Safe Work Practices
Line & Equipment Opening
A Hazard Review Must Completed for All
Line/Equipment Hazards Including:
We Have to Train
Training
1910.119(g)
PSM 29CFR1910.119(g)
Requires
(G) Training (Initial, Refresher, and Documentation)
(paragraphs (g)(1), (g)(2), and (g)(3)).
Paragraph (g)(1) requires employers to train
employees operating dangerous process. Paragraph
(g)(2) requires that the employer provide refresher
training at least every three years. Paragraph (g)(3)
requires the employer to prepare a record that
contains the name of employee, the date of training,
and the means used to verify that the employee
understood the training
PSM Training
PSM Training Programs Must be Developed
for:
Affected Employees - Those not Directly Involved
in the Process Operation
Authorized Employees -- Those
Those Directly
Directly Involved in
the Process Operation
Contractors Who May Perform Work on a Covered
Process
Vendors/Visitors who May Visit the Facility and
May Potentially be Exposed to the Covered
Process
PSM Training
Refresher training
Every three years
All Training Must be Documented
PSM Training