Regulated Chemicals Under Process Safety Management (PSM)

The Process Safety Management (PSM) standard mandates specific guidelines for the safe handling, use, and storage of highly hazardous chemicals. The following list details these chemicals and their respective threshold quantities (TQ) in pounds, which, if equaled or exceeded, trigger PSM requirements.

List of Highly Hazardous Chemicals, Toxics, and Reactives

This table lists chemicals regulated under PSM, including their CAS numbers and threshold quantities (TQ) in pounds. * Chemical Abstract Service Number. ** Threshold Quantity in Pounds (Amount necessary to be covered by this standard.)

CHEMICAL NAME	CAS*	TQ**
Methyl Isocyanate	624-83-9	250
Methyl Mercaptan	74-93-1	5000
Methyl Vinyl Ketone	79-84-4	100
Methyltrichlorosilane	75-79-6	500
Nickel Carbonyl (Nickel Tetracarbonyl)	13463-39-3	150
Nitric Acid (94.5% by weight or greater)	7697-37-2	500
Nitric Oxide	10102-43-9	250
Nitroaniline (para Nitroaniline)	100-01-6	5000
Nitromethane	75-52-5	2500
Nitrogen Dioxide	10102-44-0	250
Nitrogen Oxides (NO; NO(2); N204; N203)	10102-44-0	250
Nitrogen Tetroxide (also called Nitrogen Peroxide)	10544-72-6	250
Nitrogen Trifluoride	7783-54-2	5000
Nitrogen Trioxide	10544-73-7	250
Oleum (65% to 80% by weight; also called Fuming Sulfuric Acid)	8014-94-7	1000
Osmium Tetroxide	20816-12-0	100
Oxygen Difluoride (Fluorine Monoxide)	7783-41-7	100
Ozone	10028-15-6	100
Pentaborane	19624-22-7	100
Peracetic Acid (concentration greater 60% Acetic Acid; also called Peroxyacetic Acid)	79-21-0	1000
Perchloric Acid (concentration greater than 60% by weight)	7601-90-3	5000
Perchloromethyl Mercaptan	594-42-3	150
Perchloryl Fluoride	7616-94-6	5000
Peroxyacetic Acid (concentration greater than 60% Acetic Acid; also called Peracetic Acid)	79-21-0	1000
Phosgene (also called Carbonyl Chloride)	75-44-5	100
Phosphine (Hydrogen Phosphide)	7803-51-2	100
Phosphorus Oxychloride (also called Phosphoryl Chloride)	10025-87-3	1000
Phosphorus Tricloride	7719-12-2	1000
Phosphoryl Chloride (also called Phosphoryl Chloride)	10025-87-3	1000
Propargyl Bromide	106-96-7	100
Ethyleneimine	151-56-4	1000
Fluorine	7782-41-4	1000
Formaldehyde (Formalin)	50-00-0	1000
Furan	110-00-9	500
Hexafluoroacetone	684-16-2	5000
Hydrochloric Acid, Anhydrous	7647-01-0	5000
Hydrofluoric Acid, Anhydrous	7664-39-3	1000
Hydrogen Bromide	10035-10-6	5000
Hydrogen Chloride	7647-01-0	5000
Hydrogen Cyanide, Anhydrous	74-90-8	1000
Hydrogen Fluoride	7664-39-3	1000
Hydrogen Peroxide (52% by weight or greater)	7722-84-1	7500
Hydrogen Selenide	7783-07-5	150
Hydrogen Sulfide	7783-06-4	1500
Hydroxylamine	7803-49-8	2500
Iron, Pentacarbonyl	13463-40-6	250
Isopropylamine	75-31-0	5000
Ketene	463-51-4	100
Methacrylaldehyde	78-85-3	1000
Methacryloyl Chloride	920-46-7	150
Methacryloyloxyethyl Isocyanate	30674-80-7	100
Methyl Acrylonitrile	126-98-7	250
Methylamine, Anhydrous	74-89-5	1000
Methyl Bromide	74-83-9	2500
Methyl Chloride	74-87-3	15000
Methyl Chloroformate	79-22-1	500
Methyl Ethyl Ketone Peroxide (concentration greater than 60%)	1338-23-4	5000
Methyl Fluoroacetate	453-18-9	100
Methyl Fluorosulfate	421-20-5	100
Methyl Hydrazine	60-34-4	100
Methyl lodide	74-88-4	7500
Propyl Nitrate	627-3-4	2500
Sarin	107-44-8	100
Selenium Hexafluoride	7783-79-1	1000
Stibine (Antimony Hydride)	7803-52-3	500
Sulfur Dioxide (liquid)	7446-09-5	1000
Sulfur Pentafluoride	5714-22-7	250
Sulfur Tetrafluoride	7783-60-0	250
Sulfur Trioxide (also called Sulfuric Anhydride)	7446-11-9	1000
Sulfuric Anhydride (also called Sulfur Trioxide)	7446-11-9	1000
Tellurium Hexafluoride	7783-80-4	250
Tetrafluoroethylene	116-14-3	5000
Tetrafluorohydrazine	10036-47-2	5000
Tetramethyl Lead	75-74-1	1000
Thionyl Chloride	7719-09-7	250
Trichloro (chloromethyl) Silane	1558-25-4	100
Trichloro (dichlorophenyl) Silane	27137-85-5	2500
Trichlorosilane	10025-78-2	5000
Trifluorochloroethylene	79-38-9	10000
Trimethyoxysilane	2487-90-3	1500

[1] [2] [3] [4] [5] [6] Emergency Preparedness

Preplanning is crucial for managing releases of highly hazardous chemicals. Employers must determine in advance the actions employees should take during a serious release, including evacuation procedures. Plant personnel involved in emergency response, such as fire brigades or hazardous materials teams, are covered by the Hazardous Waste Operations and Emergency Response (HAZWOPER) standard (1910.120). Cooperation and coordination between plant and local community emergency preparedness managers is essential for better preparedness and compliance with the Environmental Protection Agency's Risk Management Plan criteria. [7] [7] [7] [7]

Emergency Control Center

Establishing and equipping an emergency control center is an effective way to enhance coordination and communication during emergencies. The center should be located in a safe zone and equipped with communication equipment, plant layouts, community maps, utility drawings, reference materials, emergency plans, and access to weather data and dispersion modeling data. A backup communication network is vital in case of power failure. [7] [7] [7] [7] [7] [7]

Compliance Audits

Employers must conduct regular audits of their process safety management system. These audits should be performed by a trained individual or team and include an evaluation of the PSM system's design and effectiveness, as well as a field inspection of safety and health conditions and practices. The audit should be conducted by someone knowledgeable in audit techniques and impartial to the facility being audited. Essential elements of an audit program include planning, staffing, conducting the audit, evaluation and corrective action, follow-up, and documentation. [7] [7] [7] [7]

Audit Team and Planning

Planning is essential for a successful audit. Employers need to establish the format, staffing, scheduling, and verification methods before conducting the audit. Audit team members should be selected for their experience, knowledge, and training, and should be familiar with the processes and auditing techniques. The size of the team will vary depending on the size and complexity of the process. For large, complex plants, team members with expertise in process engineering, chemistry, instrumentation, electrical hazards, safety and health, maintenance, and emergency preparedness may be necessary. [7] [7] [7] [7] [7]

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