1910.119(f)(1): Written Operating Procedures for Covered Processes
Employers must develop and implement written operating procedures with clear instructions for each covered process, consistent with the process safety information. They must cover each operating phase, including startup, normal, temporary and emergency operations and shutdowns, operating limits with consequences of deviation and how to correct them, safety and health considerations such as chemical hazards and exposure precautions, and safety systems and their functions.
Key takeaways
- 1910.119(f)(1) is part of OSHA's general industry standards (29 CFR Part 1910, Subpart H).
- OSHA cited it 153 times in the last 3 years, in 97 inspections, with $1,548,602 in current penalties.
- 1 death is linked to inspections that cited this rule.
- Most citations: PA (20), OH (17), TX (15).
- 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) is one requirement inside 1910.119 Process safety management of highly hazardous chemicals, an OSHA general industry standard (Part 1910, Subpart H). It includes 18 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
(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. 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
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)(1).
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 | 19 |
| 2024 | 46 |
| 2025 | 49 |
| 2026 | 39 |
Top states: PA (20), OH (17), TX (15), TN (15), VA (12)
Largest penalties
| Employer | Location | Penalty for this rule |
|---|---|---|
| ACCURATE ENERGETIC SYSTEMS, LLC | MC EWEN, TN | $560,000 |
| 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 |
| AMTEC CORPORATION | CLEAR LAKE, SD | $32,262 |
Free toolbox talk
A 5-minute crew talk on 1910.119(f)(1), plus alerts when this rule changes. Free.
OSHA interpretation letters
- Requirement for flame-resistant clothing in petrochemical plant covered by PSM. (2006-03-07)
- Compliance with PSM and ANSI/ISA-S84.01 for safety instrumented systems (2000-03-23)
Related parts of this rule
- 1910.119(f) Operating procedures 211 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
Get your crew competent
Trainers on Black Belt Safety: Marc Harvey, Dana Reyes
Trainers and suppliers: feature your business on this rule for $25/month.
Frequently asked questions
Which operating phases must procedures cover?
Initial startup, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown, and startup after a turnaround or emergency shutdown.
What must procedures say about operating limits?
The consequences of deviation and the steps required to correct or avoid deviation.
Must emergency shutdown responsibility be assigned?
Yes, to qualified operators so emergency shutdown is executed safely and in a timely manner.
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.