1910.119(f)(1)(ii): Operating Limits in Process Safety Procedures
As part of written operating procedures for a covered process, employers must describe the operating limits, including the consequences of going outside them and the steps needed to correct or avoid going outside them.
Key takeaways
- 1910.119(f)(1)(ii) is part of OSHA's general industry standards (29 CFR Part 1910, Subpart H).
- OSHA cited it 30 times in the last 3 years, in 22 inspections, with $270,255 in current penalties.
- Most citations: PA (5), TN (3), TX (3).
- Related part: 1910.119(f) Operating procedures (211 citations).
- Free 5-minute toolbox talk for your crew below.
In this article
What this rule covers
29 CFR 1910.119(f)(1)(ii) ("Operating limits:") is one requirement inside 1910.119 Process safety management of highly hazardous chemicals, an OSHA general industry standard (Part 1910, Subpart H). It includes 2 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
(ii) Operating limits: 30 citations
(A) Consequences of deviation; and 9 citations
(B) Steps required to correct or avoid deviation. 9 citations
Source: eCFR, text current as of 2026-10-15. Read all of 1910.119.
Where and how often it was cited
| Year | Citations |
|---|---|
| 2023 | 7 |
| 2024 | 8 |
| 2025 | 6 |
| 2026 | 9 |
Top states: PA (5), TN (3), TX (3), OR (3), VA (3)
Largest penalties
| Employer | Location | Penalty for this rule |
|---|---|---|
| ACCURATE ENERGETIC SYSTEMS, LLC | MC EWEN, TN | $140,000 |
| POLYCARBON INDUSTRIES, INC./SEQENS SAS | NEWBURYPORT, MA | $31,250 |
| THE DOW CHEMICAL COMPANY | PLAQUEMINE, LA | $15,625 |
| AMERICAN NITRILE OPERATIONS, LLC. | GROVE CITY, OH | $11,823 |
| POLYCHEMIE INC. | TAYLOR, PA | $10,641 |
Free toolbox talk
A 5-minute crew talk on 1910.119(f)(1)(ii), plus alerts when this rule changes. Free.
OSHA interpretation letters
None exist. OSHA has not published a letter of interpretation for 1910.119(f)(1)(ii).
Related parts of this rule
- 1910.119(f) Operating procedures 211 citations
- 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)(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
Get your crew competent
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Frequently asked questions
What must the operating procedures say about operating limits?
They must cover the consequences of deviation and the steps required to correct or avoid deviation.
Is this part of process safety management?
Yes. It is part of the operating procedures requirement in 1910.119(f).
Why include consequences of deviation?
So operators know what can happen if the process goes outside its limits, as the rule requires.
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.