CESCO Process Safety Management (PSM) 2 — Questions and Answers
Question 1: Under OSHA PSM, a Pre-Startup Safety Review (PSSR) is required before introducing a highly hazardous chemical to a process when:
- Any employee requests one
- A new facility is started up or a significant modification has been made to an existing process (Correct answer)
- An OSHA inspection is scheduled
- The chemical inventory exceeds 50% of the threshold quantity
Correct answer: A new facility is started up or a significant modification has been made to an existing process
PSSR is required for new facilities and when modifications are significant enough to require a change in the process safety information, ensuring all elements are in place before startup.
Question 2: OSHA PSM requires employers to investigate incidents that resulted in or could reasonably have resulted in a catastrophic release. The investigation must begin:
- Within 24 hours of the incident
- Within 48 hours of the incident (Correct answer)
- Within 5 business days
- Within 30 days
Correct answer: Within 48 hours of the incident
29 CFR 1910.119(m) requires that incident investigations be initiated as promptly as possible, but no later than 48 hours following the incident.
Question 3: Which of the following is NOT one of the 14 elements of OSHA's Process Safety Management standard?
- Employee Participation
- Hot Work Permits
- Environmental Impact Assessment (Correct answer)
- Compliance Audits
Correct answer: Environmental Impact Assessment
Environmental Impact Assessment is an NEPA requirement for federal actions, not an element of OSHA's PSM standard, which focuses on preventing catastrophic chemical releases at fixed facilities.
Question 4: Under PSM, how long must employers retain the five most recent compliance audit reports?
- Until the next audit is completed (Correct answer)
- 3 years
- 5 years
- 10 years
Correct answer: Until the next audit is completed
29 CFR 1910.119(o)(3) requires employers to retain the two most recent compliance audit reports, not a set number of years — they must be kept until replaced by newer audits.
Question 5: The 'consequence analysis' component of a PSM hazard assessment typically evaluates which of the following?
- Worker compensation costs from past incidents
- The potential impacts of a release including toxic cloud dispersion and blast overpressure zones (Correct answer)
- Insurance premium changes after an incident
- Training hours spent on emergency response
Correct answer: The potential impacts of a release including toxic cloud dispersion and blast overpressure zones
Consequence analysis models the physical effects of accidental releases, such as vapor cloud dispersion, explosion blast zones, and thermal radiation, to understand potential harm to workers and the public.
Question 6: In PSM, the term 'highly hazardous chemical' refers to:
- Any chemical listed on OSHA's Hazard Communication standard SDS requirement
- A substance with toxic, reactive, flammable, or explosive properties listed in Appendix A or B of 29 CFR 1910.119 (Correct answer)
- Any chemical with an IDLH value established by NIOSH
- Chemicals regulated exclusively by the EPA under TSCA
Correct answer: A substance with toxic, reactive, flammable, or explosive properties listed in Appendix A or B of 29 CFR 1910.119
Under PSM, highly hazardous chemicals are those listed in 29 CFR 1910.119 Appendix A (with threshold quantities) or flammable liquids/gases in Appendix B that pose significant hazards.
Question 7: Which PSM element requires employers to develop written safety and health procedures for each task involving highly hazardous chemicals and make them accessible to employees?
- Operating Procedures (Correct answer)
- Employee Participation
- Training
- Mechanical Integrity
Correct answer: Operating Procedures
Operating Procedures under PSM must cover steps for each phase of operation, operating limits, safety and health considerations, and safety systems, and must be readily accessible to employees.
CESCO Process Safety Management (PSM) 2
Under OSHA PSM, a Pre-Startup Safety Review (PSSR) is required before introducing a highly hazardous chemical to a process when: