1910.119(f): Process Safety Operating Procedures
Employers covered by process safety management must write and use clear operating procedures for each covered process. They must cover each operating phase from startup to emergency shutdown, operating limits, chemical hazards and precautions, and safety systems, be readily accessible to employees who work in or maintain the process, be reviewed as often as needed to stay current, and be certified annually as current and accurate.
Key takeaways
- 1910.119(f) is part of OSHA's general industry standards (29 CFR Part 1910, Subpart H).
- OSHA cited it 211 times in the last 3 years, in 129 inspections, with $2,043,876 in current penalties.
- 1 death is linked to inspections that cited this rule.
- Most citations: TX (27), PA (26), TN (19).
- Related part: 1910.119(f)(1) (153 citations).
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In this article
What this rule covers
29 CFR 1910.119(f) ("Operating procedures") is one requirement inside 1910.119 Process safety management of highly hazardous chemicals, an OSHA general industry standard (Part 1910, Subpart H). It includes 22 sub-paragraphs. The official text below is copied word for word from the Electronic Code of Federal Regulations (eCFR). The numbers, injury cases and training on this page show how OSHA enforces it on real job sites.
Official text
(f) Operating procedures. 211 citations
(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. Open (f)(1) 153 citations
(i) Steps for each operating phase: Open (f)(1)(i) 43 citations
(A) Initial startup; 2 citations
(B) Normal operations; 5 citations
(C) Temporary operations; 3 citations
(D) Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner. Open (f)(1)(i)(d) 14 citations
(E) Emergency Operations; 4 citations
(F) Normal shutdown; and, 4 citations
(G) Startup following a turnaround, or after an emergency shutdown. 7 citations
(ii) Operating limits: Open (f)(1)(ii) 30 citations
(A) Consequences of deviation; and 9 citations
(B) Steps required to correct or avoid deviation. 9 citations
(iii) Safety and health considerations: Open (f)(1)(iii) 29 citations
(A) Properties of, and hazards presented by, the chemicals used in the process; 5 citations
(B) Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment; Open (f)(1)(iii)(b) 14 citations
(C) Control measures to be taken if physical contact or airborne exposure occurs; 5 citations
(D) Quality control for raw materials and control of hazardous chemical inventory levels; and, 2 citations
(E) Any special or unique hazards. 1 citations
(iv) Safety systems and their functions. Open (f)(1)(iv) 3 citations
(2) Operating procedures shall be readily accessible to employees who work in or maintain a process. 4 citations
(3) The operating procedures shall be reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, and changes to facilities. The employer shall certify annually that these operating procedures are current and accurate. Open (f)(3) 22 citations
(4) The employer shall develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel. These safe work practices shall apply to employees and contractor employees. Open (f)(4) 32 citations
Source: eCFR, text current as of 2026-10-15. Read all of 1910.119.
Injuries linked to this rule
1 death is linked to inspections where OSHA cited 1910.119(f).
At 12:00 p.m. on May 1, 2024, an explosion occurred at a production line, where multiple employees were working. Four employees were hospitalized to treat burnsand toxic gas inhalation, while six others were treated on-site without hospitalization for similar injuries.
Where and how often it was cited
| Year | Citations |
|---|---|
| 2023 | 22 |
| 2024 | 70 |
| 2025 | 65 |
| 2026 | 54 |
Top states: TX (27), PA (26), TN (19), OH (18), VA (15)
Largest penalties
| Employer | Location | Penalty for this rule |
|---|---|---|
| ACCURATE ENERGETIC SYSTEMS, LLC | MC EWEN, TN | $644,000 |
| BLOUNT FINE FOOD | FALL RIVER, MA | $125,000 |
| AMERICAN NITRILE OPERATIONS, LLC. | GROVE CITY, OH | $47,292 |
| POLYCARBON INDUSTRIES, INC./SEQENS SAS | NEWBURYPORT, MA | $46,875 |
| BLUE CUBE OPERATIONS LLC | FREEPORT, TX | $33,100 |
Free toolbox talk
A 5-minute crew talk on 1910.119(f), plus alerts when this rule changes. Free.
OSHA interpretation letters
- Requirement for flame-resistant clothing in petrochemical plant covered by PSM. (2006-03-07)
- Requirements for the control of personnel entering a facility under the Process Safety Management standard. (2005-03-16)
- Compliance with PSM and ANSI/ISA-S84.01 for safety instrumented systems (2000-03-23)
Related parts of this rule
- 1910.119(f)(1) 153 citations
- 1910.119(f)(1)(i) Steps for each operating phase: 43 citations
- 1910.119(f)(4) 32 citations
- 1910.119(f)(1)(ii) Operating limits: 30 citations
- 1910.119(f)(1)(iii) Safety and health considerations: 29 citations
- 1910.119(f)(3) 22 citations
- 1910.119(f)(1)(i)(D) 14 citations
- 1910.119(f)(1)(iii)(B) 14 citations
- 1910.119(f)(1)(iv) Safety systems and their functions 3 citations
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Frequently asked questions
What must PSM operating procedures cover?
Steps for each operating phase, operating limits, safety and health considerations, and safety systems and their functions.
How often must operating procedures be certified?
The employer shall certify annually that the operating procedures are current and accurate.
Who must have access to the procedures?
Employees who work in or maintain a process.
About this page
Sources
- 29 CFR 1910.119 (eCFR), text current as of 2026-10-15
- U.S. Department of Labor enforcement data: OSHA inspections, citations and accident records, copied nightly; data as of 2026-10-21
3-year window. Federal OSHA only; state-plan rules are not counted. Plain-language text is a summary, not legal advice; the official text controls. Black Belt Safety is not part of OSHA or the Department of Labor.