CESCO Process Safety Management (PSM) 1 — Questions and Answers
Question 1: Under OSHA's Process Safety Management standard (29 CFR 1910.119), what threshold quantity of a flammable liquid with a flashpoint below 73°F triggers PSM requirements?
- 1,000 pounds
- 5,000 pounds
- 10,000 pounds (Correct answer)
- 50,000 pounds
Correct answer: 10,000 pounds
OSHA PSM requires facilities handling 10,000 pounds or more of flammable liquids at or above their normal boiling point to comply with 29 CFR 1910.119.
Question 2: Which PSM element requires employers to document the hazards associated with chemicals used in a process, including toxicity, permissible exposure limits, and physical data?
- Management of Change
- Process Hazard Analysis
- Process Safety Information (Correct answer)
- Operating Procedures
Correct answer: Process Safety Information
Process Safety Information (PSI) requires compilation of written information on chemical hazards, technology, and equipment for covered processes.
Question 3: The OSHA PSM standard requires a Process Hazard Analysis (PHA) to be revalidated at least every:
- 3 years
- 5 years (Correct answer)
- 7 years
- 10 years
Correct answer: 5 years
OSHA 29 CFR 1910.119(e)(6) requires that PHAs be updated and revalidated at least every five years after initial completion.
Question 4: Which PHA methodology uses structured guide words such as 'No,' 'More,' 'Less,' and 'Other Than' to systematically identify deviations from design intent?
- Fault Tree Analysis (FTA)
- Failure Mode and Effects Analysis (FMEA)
- Hazard and Operability Study (HAZOP) (Correct answer)
- What-If Analysis
Correct answer: Hazard and Operability Study (HAZOP)
HAZOP (Hazard and Operability Study) uses standardized guide words applied to process parameters to systematically identify potential deviations and their consequences.
Question 5: Under PSM, what does the Management of Change (MOC) element require before implementing a change to a covered process?
- A third-party audit of the change
- Review and authorization of the technical basis, safety impacts, and operating procedure updates (Correct answer)
- Immediate shutdown of the process until the change is complete
- EPA notification at least 30 days in advance
Correct answer: Review and authorization of the technical basis, safety impacts, and operating procedure updates
MOC requires review of the technical basis for the change, its impact on safety and health, modification to operating procedures, time needed, and authorization before implementation.
Question 6: The EPA's Risk Management Program (RMP) rule under Clean Air Act Section 112(r) parallels OSHA PSM. For Program 3 processes, which document must facilities submit to the EPA?
- Emergency Response Plan
- Risk Management Plan (Correct answer)
- Hazard Communication Plan
- Source Reduction Plan
Correct answer: Risk Management Plan
Facilities with Program 3 RMP-covered processes must submit a Risk Management Plan (RMP) to EPA detailing hazard assessment, prevention program, and emergency response program.
Question 7: Which PSM element focuses on ensuring that equipment used in covered processes is designed, installed, and maintained in a safe operating condition?
- Pre-Startup Safety Review
- Mechanical Integrity (Correct answer)
- Hot Work Permits
- Contractors
Correct answer: Mechanical Integrity
Mechanical Integrity requires employers to establish and implement written procedures to maintain the ongoing integrity of process equipment including inspections, testing, and quality assurance.
CESCO Process Safety Management (PSM) 1
Under OSHA's Process Safety Management standard (29 CFR 1910.119), what threshold quantity of a flammable liquid with a flashpoint below 73°F triggers PSM requirements?