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29 CFR 1910.119: Process safety management

Subpart H—Hazardous Materials · official heading: Process safety management of highly hazardous chemicals

Sites that hold large amounts of highly hazardous chemicals need a full process safety program: hazard analysis, written operating procedures, training, equipment integrity checks, change management and audits.

5,449citations since 2015
1,164employers cited
78%serious, willful or repeat
$3,100median penalty per item

OSHA has cited 29 CFR 1910.119 5,449 times since 2015, against 1,164 employers. Penalties on these items add up to $28,633,372 at their current amounts.

Citations per year

The parts of the rule cited most

1910.119(j)(2) · 374 citations

(2) Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment.

1910.119(d)(3)(ii) · 321 citations

(ii) The employer shall document that equipment complies with recognized and generally accepted good engineering practices.

1910.119(l)(1) · 218 citations

(l) Management of change. (1) The employer shall establish and implement written procedures to manage changes (except for “replacements in kind”) to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process.

1910.119(d)(3)(ib) · 212 citations

(B) Piping and instrument diagrams (P&ID's);

1910.119(f)(1) · 197 citations

(f) Operating procedures. (1) The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address at least the following elements.

1910.119(j)(4)(i) · 190 citations

(4) Inspection and testing. (i) Inspections and tests shall be performed on process equipment.

1910.119(e)(1) · 177 citations

(e) Process hazard analysis. (1) The employer shall perform an initial process hazard analysis (hazard evaluation) on processes covered by this standard. The process hazard analysis shall be appropriate to the complexity of the process and shall identify, evaluate, and control the hazards involved in the process. Employers shall determine and document the priority order for conducting process hazard analyses based on a rationale which includes such considerations as extent of the process hazards, number of potentially affected employees, age of the process, and operating history of the process. The process hazard analysis shall be conducted as soon as possible, but not later than the following schedule:

1910.119(n) · 171 citations

(n) Emergency planning and response. The employer shall establish and implement an emergency action plan for the entire plant in accordance with the provisions of 29 CFR 1910.38. In addition, the emergency action plan shall include procedures for handling small releases. Employers covered under this standard may also be subject to the hazardous waste and emergency response provisions contained in 29 CFR 1910.120 (a), (p) and (q).

Industries cited most

  • Manufacturing 3,764
  • Wholesale Trade 425
  • Utilities 361
  • Transportation and Warehousing 352
  • Mining, Quarrying, and Oil and Gas Extraction 174
  • Public Administration 127

States cited most

Recently cited employers