OSHA 1910.119 Process Safety Management: The 14 Parts in Plain English
Some plants hold large amounts of dangerous chemicals. One leak, fire, or blast can hurt many people. OSHA’s rule for these plants is called Process Safety Management, or PSM. Its number is 29 CFR 1910.119.
Who it covers
PSM covers a process that holds a listed toxic or reactive chemical at or above a set amount. Each chemical has its own amount. For example, it is 1,500 pounds for chlorine and 10,000 pounds for anhydrous ammonia.
It also covers flammable gas or liquid of 10,000 pounds or more in one place. Retail stores and oil or gas well work are left out.
The main parts
PSM has many parts. Here they are in short form:
- Worker input: workers help plan and can see the safety studies.
- Process facts: write down the chemical hazards, the design, and the equipment.
- Hazard study: a team looks for what could go wrong. Redo it at least every 5 years.
- Written steps: for start, normal work, shut down, and emergencies. Confirm them each year.
- Training: before work starts, and a refresher at least every 3 years.
- Contractors: check their safety record and tell them the hazards.
Training for 1910.119: Learn this rule step by step in our Process Safety Management Awareness course. It is included in the Black Belt Safety Vault.
- Safety review before start-up: for new or changed equipment.
- Equipment upkeep: inspect, test, and fix the equipment.
- Hot work permits: for welding or cutting near the process.
- Change control: review any change before it is made.
- Incident checks: start within 48 hours. Keep the report for 5 years.
- Emergency plan: know what to do if there is a release.
- Audits: check the whole program at least every 3 years.
- Trade secrets: people who need the facts for safety must get them.
What to do next
PSM is big, but everyone at a covered plant needs the basics. Our Process Safety Management Awareness course gives you the full picture. Start the course or join the Vault.
This is a plain-language summary. The official rule text is what counts.
Sources
- 29 CFR 1910.119, Process safety management of highly hazardous chemicals – eCFR, National Archives, checked 2026-10-15
Frequently asked questions
What is OSHA PSM?
PSM stands for Process Safety Management. It is OSHA rule 29 CFR 1910.119 for plants that hold large amounts of dangerous chemicals.
Who must follow OSHA 1910.119?
Plants with a process that holds a listed toxic or reactive chemical at or above its set amount, or 10,000 pounds or more of flammable gas or liquid. Retail stores and oil or gas well work are left out.
How often must a PSM hazard study be redone?
At least every 5 years.
How often is PSM training and auditing required?
Training refreshers come at least every 3 years. The whole program is audited at least every 3 years.