Procedures

Module from the Process Safety Management Curriculum curriculum.

Module 6 - Operating Procedures and Training · Learning Objectives · 1. Develop written SOPs for startup, shutdown, normal, emergency, and TA · 2. Include process limits (safe operating envelope) · 3. Require operator initial certification + 3-year refresher · 4. Simulator training for complex units (crude, FCC, hydrocracker) · 5. Certify SOPs annually and after any procedure change · SOP Minimum Content (29 CFR 1910.119(f))

Section	Content	Notes	Required?	Typical Length	Ref
Initial startup	Step-by-step from cold	After TA or new unit	Yes	50+ steps	1910.119(f)(1)(i)
Normal operations	Ongoing running	Day-to-day	Yes	Checklist form	(f)(1)(i)
Normal shutdown	Planned	Orderly	Yes	20-50 steps	(f)(1)(i)
Emergency shutdown	Rapid isolation	Safety critical	Yes	5-20 steps	(f)(1)(i)
Temporary operations	Abnormal + limits	With MOC	Yes	Per change	(f)(1)(i)
Startup after emergency	Post-ESD or incident	Safety check	Yes	50+ steps	(f)(1)(i)
Safe operating limits	Min/max for each parameter	Critical	Yes	Tabular	(f)(1)(ii)
Safety and health considerations	Hazards of chemicals	PPE, exposure	Yes	Reference SDS	(f)(1)(iii)
Safety systems and function	PSVs, SIS, alarms	Overview	Yes	Tabular	(f)(1)(iv)

Source: Process_Safety_Management_Curriculum_v1.xlsx · Sheet: Procedures

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