[NAME OF ORGANIZATION]

STANDARD OPERATING PROCEDURES

[Insert the name/location/type of process]
Date last updated:

The standard operating procedures (SOPs) apply to routine operations and maintenance tasks
performed by workers in or near covered processes. Review the requirements for hot work
permits and consult with the process safety management (PSM) Administrator or designee before
performing nonroutine tasks.

[Modify the following procedures as applicable to your facility.]

Initial Start-Up
( ) Check storage containers for leaks, corrosion, or other damage.
( ) Conduct pressure tests and leak checks on containers, connectors, valves, and processing
equipment.
( ) Inspect all equipment before it is used to handle or process hazardous chemicals.

Normal Operations
Check the following factors that affect the process to ensure they are within designated limits:
( ) The capacity of containers, tanks, process equipment, valves, connectors, and transfer
equipment (for example, hoses)
( ) The pressure within containers, tanks, process equipment, and all other components of the
process
( ) The temperature of the process, equipment, and other components
( ) Weather conditions, such as storms, that may affect the process

Use the following information to review safe operations for each process:
( ) A block-flow diagram or simplified process-flow diagram
( ) Information on process chemistry
( ) Maximum intended inventory of the regulated chemical
( ) Safe upper and lower limits for such items as temperature, pressure, flows, or composition
( ) Steps to take should the limits be surpassed

Loading and Unloading

When loading and unloading highly hazardous chemicals:
( ) Notify management if a suspicious shipment is offered.
( ) Verify that tank trucks are grounded.
( ) Inspect the tank for objects that are not bonded.
( ) Inspect valves, connections, emergency shutoff valves, and pipes.
( ) Verify that container is safe for filling.
( ) Verify that all truck electrical systems are off.
( ) Use wheel chocks to prevent the vehicle from moving.
( ) Check the compatibility of mixed loads.
( ) Check the weight distribution of loads.
( ) Verify that the cargo is properly secured.
( ) Check the type, number, and stacking arrangement of load.
( ) For trucks, conduct a walk-around inspection before the vehicle is driven away.

Chemical Storage
When storing chemicals:
( ) Never store incompatible chemicals together.
( ) Always consult the safety data sheet (SDS) to identify incompatible chemicals.
( ) Always segregate chemicals by hazard class.
( ) Store flammable solvents in a flammable storage cabinet; nonflammable solvents may be
stored in the same cabinet.
( ) Store acids in a separate storage cabinet.
( ) Keep oxidizers away from organic materials.
( ) Keep acids away from bases.
( ) Keep cyanides and sulfides away from acids.

Maintenance
Repair Operations
When conducting repairs on any equipment:
( ) Always wear personal protective equipment.
( ) Replace or repair defective or damaged power and hand tools.
( ) Repair or replace damaged processing equipment, such as meters or cathodic protection
systems, that show signs of leaks, corrosion, or low pressure.

Mechanical Integrity
( ) Regularly inspect containers and tanks and repair those that show signs of leaks or corrosion.
( ) Check the condition of the foundation under containers.
( ) Replace footings that are loose or crumbling.
( ) Repair corrosion at the container and masonry contact area.
( ) Replace faulty flow and backflow check valves.
( ) Check for abrasions or cuts on hoses and check for leaks.
( ) Ensure that connectors, plugs, caps, and gaskets are in good condition.
[Discuss facility-specific maintenance steps for containers, tanks, and foundations. Include the
items that operators and handlers should look for on a daily basis to be sure that the equipment
is running safely.]
[Discuss facility-specific maintenance steps for connectors and fittings. Include the items that
operators and handlers should look for on a daily basis to be sure that the equipment is running
safely.]

Gauges and Pressure Valves

( ) Make sure the pressurized equipment you are working on is shut down and depressurized
before beginning work.
( ) Repair or replace gauges.
( ) Repair or replace pressure relief valves.
( ) Finally, ensure that emergency shutoff valves are in good condition.
[Discuss facility-specific maintenance steps for gauges and pressure valves.]

Motors
( ) Ensure that the motor is operating according to the manufacturer’s specifications. Check
temperature, operating speed, and so forth.
( ) Check all alignments to specification.
( ) Ensure that oil systems are properly maintained and that fluids, gaskets, and other contact
parts are changed on schedule.
( ) Check all connections and terminals for tightness and contact.
( ) Monitor fluid flow.
( ) Tighten all electrical connections, and measure the voltage and current.

Hoses
( ) Ensure that hoses are operating at or below the rated working pressure.
( ) Ensure that the overfill alarm and prevention device is functioning properly.
( ) Protect hoses from severe end loads.
( ) Check hoses for loose covers, kinks, or soft spots.
( ) Replace hoses according to manufacturer’s specifications.

Electrical Equipment
Stop using and report to your supervisor:
( ) Any damaged electrical covers on electrical panels, junction boxes, and other equipment
where live electrical parts and wiring may be exposed.
( ) Damaged tools that may expose live electrical parts and wiring to a person using them.
( ) Electrical cords, which are easily damaged, exposing live wires.
( ) Any other damaged equipment.

Combustibles
To prevent fire, keep combustibles at least 10 feet away from containers. Types of combustibles
include weeds, grass, rags, paper, and wood.

Temporary Operations
For temporary operations:
( ) Conduct pre-start-up check, and
( ) Segregate incompatible containers.
[Discuss proper temporary procedures to follow when the regular process is down or when
additional capacity is needed for a limited period.]

Normal Shutdown Procedures

Make sure the pressure relief systems are functioning properly, and ensure that they are installed
according to generally accepted good engineering practices.

Emergency Shutdown
Situations that trigger an emergency shutdown include:
( ) Fire
( ) Leak
( ) Explosion
( ) Violence
Follow these procedures during an emergency shutdown:
( ) Perform the shutdown procedures only if they do not threaten your life or possibly cause
injury to yourself or others.
( ) Evacuate the area.
( ) Immediately report your shutdown actions.
[Describe the specific emergency shutdown procedures for equipment and processes at your
facility.]
[Discuss the procedures that must be taken if the process must be shut down quickly.
For warehouses: These procedures generally will apply only if you repackage regulated
substances. If you do, these procedures cover the steps you need to take if you must shut down
your process quickly. These procedures may be brief, because shutting a process down may be
no different in an emergency than in ordinary circumstances; you may simply shut off the flow or
stop any unloading or loading.]

Restart
Before beginning restart operations:
( ) Examine pressure vessels and storage tanks.
( ) Examine insulation systems for piping, vessels, and tanks.
( ) Examine drainage systems.
( ) Examine electrical motors and drives.
( ) Check valve positions.
( ) Examine all electrical equipment and wiring systems.
( ) Make sure all warning systems are operational.
( ) Check the integrity of all fire detection and suppression systems.
( ) Ensure that emergency response equipment and systems are operational.
[Describe the steps your workers should take during re-start-up to ensure that the process can
operate safely. Include the procedures outlined in the facility’s Pre-Start-Up Safety Review.
Start-up after an emergency shutdown will generally require more checks to ensure that valves
are in their proper start-up position and that they and other equipment are still functioning
properly. Be sure to include these checkpoints in the discussion.]

Security
Security is highly important at our facility, given the very real and present threats of sabotage
and terrorism. Follow these procedures to protect yourself and our facility from these threats:
( ) Make sure all doors, gates, and storage areas are locked to access from outside the facility
and sensitive work areas.
( ) Report any unlocked areas that should be secured, all suspicious packages, and any
suspicious incidents, cargo, or individuals.
( ) Don’t talk to outsiders about shipments, facilities, or any other security-related information.
( ) Display your ID badge at all times on company premises. Protect your ID badge outside of
work so that it cannot be stolen, and never lend your badge to anyone—ever.
( ) Secure hazardous materials in locked buildings or fenced areas, and sign keys out and back
in.
( ) Secure all valves and other fixtures, such as hoses and connectors on transfer and
transportation equipment, when not in use.
( ) Always verify the identity of carriers and drivers before loading a hazardous material. Ask
drivers picking up or delivering material for photo identification and their commercial driver’s
license. Compare with information provided by the carrier.
( ) Secure all rail, truck, and barge containers when stored at your location.
( ) Verify all paperwork.
( ) Handle pickups and deliveries only by appointment with known vendors.

Consequence of Deviations
Following are examples of the consequences of deviating from the chemical handling or
processing procedures:
( ) Excess pressure in containers and equipment can lead to accidental releases, leaks, fires, and
explosions.
( ) Container leaks can lead to poisoning, asphyxiation, burns, fires, and explosions.
( ) Damaged or faulty equipment can lead to accidental leaks, fires, and explosions.
[Insert the site-specific procedures for consequences of deviations.]