Process Safety Management Program
Process hazard analysis, mechanical integrity, management of change, emergency planning, and covered chemical threshold documentation.
What this document is
This document is a complete written Process Safety Management Program tailored for contractors who handle listed chemicals. It assembles the required policies, procedures, and records into one organized reference that satisfies both federal and California rules.
The regulation that requires it
29 CFR 1910.119 contains the federal Process Safety Management of Highly Hazardous Chemicals standard. In California the parallel requirements appear in Title 8 CCR Section 5189 and the California Accidental Release Prevention (CalARP) program under Title 19 CCR Division 2 Chapter 4.5. The rule requires employers to perform process hazard analysis, maintain mechanical integrity of equipment, manage changes, develop emergency plans, and keep documentation showing that covered chemicals are below threshold quantities or that full PSM elements are in place.
Who needs it
General contractors, mechanical contractors, and specialty trades that operate or maintain processes containing 10,000 pounds or more of flammable liquids or gases or the threshold quantities of specific toxic chemicals need this program. It is required in all states under federal OSHA and carries additional CalARP obligations for employers in California. Even contractors who do not own the process may be cited as controlling employers at multi-employer worksites.
What happens without it
OSHA and Cal/OSHA cite the absence of a PSM program as a serious violation with penalties currently ranging from $15,625 to $156,259 per violation depending on severity and history. Willful or repeated violations can reach the statutory maximum. Inspectors routinely issue multi-employer citations to contractors on covered sites, and the lack of documentation increases the chance of shutdown orders during accidents or routine inspections.
What's included in the generated document
- Process Hazard Analysis policy and worksheet templates
- Mechanical Integrity inspection and testing procedures
- Management of Change form and approval process
- Emergency planning and response procedures
- Covered chemical threshold inventory documentation
How to implement it at your company
- Download the PDF and review every section against your current jobs and chemical inventories.
- Assign a qualified person to complete the process hazard analysis for each covered process.
- Schedule and document mechanical integrity inspections using the forms provided.
- Train supervisors and affected employees on the management of change and emergency procedures.
- Keep the completed document on site and update it whenever a process, chemical, or contractor changes.