Process Safety Management Plan — OSHA 29 CFR 1910.119 Compliant
The PSM program for facilities with highly hazardous chemicals above threshold quantities. Covers all 14 PSM elements — employee participation, PSI, PHA, operating procedures, training, contractors, MOC, pre-startup safety review, mechanical integrity, hot work, incident investigation, emergency planning, compliance audits, and trade secrets.
When this template is required
Required of facilities with 'highly hazardous chemicals' above the threshold quantities listed in 1910.119 Appendix A, or processes involving flammable liquids/gases ≥10,000 lb on-site. Approximately 12,000 PSM-covered facilities in the US — refineries, chemical plants, large-scale food and pharmaceutical, certain bulk storage.
Why this template
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All 14 PSM elements covered
PSM has exactly 14 required elements per 1910.119. The plan has one section per element with the regulatory citation, required content, and template procedure. No gaps.
PHA worksheet supports multiple methodologies
1910.119(e) requires Process Hazard Analysis but doesn't mandate a specific methodology. The worksheet supports What-If, HAZOP, FMEA, and Checklist methodologies — pick what fits your process.
MOC procedure (highest-cited PSM element)
Management of Change (MOC) is consistently the most-cited PSM element in OSHA inspections. The MOC procedure walks through change classification, hazard review, sign-off, and training before changes are implemented.
What you receive
- PSM Plan master document (Word .docx) — covers all 14 PSM elements
- Process Safety Information (PSI) compilation template
- Process Hazard Analysis (PHA) worksheet (PHA, HAZOP, What-If formats)
- Standard Operating Procedures (SOP) template framework
- PSM training matrix and recordkeeping
- Contractor program — qualification, training, audits
- Management of Change (MOC) procedure with worksheet
- Pre-Startup Safety Review (PSSR) procedure
- Mechanical Integrity program with inspection schedules
- Hot Work Permit procedure (PSM-context, cross-references HW family)
- Incident Investigation procedure with root-cause analysis
- Emergency Planning cross-reference (with EAP)
- Compliance Audit procedure (every 3 years)
How you get it
This document is written and reviewed against the standard it cites, and it is ready now. The download link is emailed as soon as your payment clears.
Revisions included — if something about your operation changes what the document should say, reply to the delivery email and we will amend it.
Who buys this
- Petroleum refineries
- Chemical and petrochemical plants
- Pharmaceutical manufacturing (with highly hazardous chemicals)
- Bulk gas distributors (chlorine, ammonia, etc.)
- Large-scale food manufacturing (refrigeration ammonia)
- Pulp and paper (chemical processes)
- Engineering consultants serving PSM-covered facilities
Frequently asked
Who is covered by PSM?
29 CFR 1910.119(a) covers two categories: (1) A process containing a 'highly hazardous chemical' at or above the threshold quantity listed in Appendix A (e.g. chlorine ≥1,500 lb, ammonia anhydrous ≥10,000 lb, hydrogen ≥10,000 lb, dozens of others); (2) A process involving flammable liquids/gases ≥10,000 lb on-site in one location (excluding fuel for plant use, hydrocarbon fuels for sale, atmospheric liquid storage). Approximately 12,000 facilities US-wide are PSM-covered.
What are the 14 PSM elements?
Per 1910.119: (1) Employee Participation; (2) Process Safety Information; (3) Process Hazard Analysis; (4) Operating Procedures; (5) Training; (6) Contractors; (7) Pre-Startup Safety Review; (8) Mechanical Integrity; (9) Hot Work Permit; (10) Management of Change; (11) Incident Investigation; (12) Emergency Planning and Response; (13) Compliance Audits; (14) Trade Secrets. The plan has a section for each.
What's the difference between PSM and EPA RMP?
PSM (OSHA 1910.119) protects workers from chemical accidents. EPA RMP (40 CFR 68) protects the public and environment from chemical accidents. Many facilities are subject to both, with substantial overlap in requirements — PHA, MOC, emergency planning, etc. The plan focuses on PSM; companies subject to RMP also need RMP-specific content (offsite consequence analysis, accidental release prevention programs) which is a separate engineering deliverable.
What is a PHA?
Process Hazard Analysis — a systematic analysis of the hazards of a process. 1910.119(e) requires PHA using an appropriate methodology (What-If, HAZOP, FMEA, Checklist, Fault Tree, etc.). The PHA identifies process hazards, potential incidents, and the controls in place; gaps are addressed via MOC. PHA must be revalidated every 5 years. The worksheet supports the common methodologies.
Is $699 a typical price for a PSM plan?
Internal/engineered PSM plans typically run $25,000-$250,000+ to develop from scratch when prepared by engineering consultants. The template provides the foundation framework that an in-house safety engineer or PSM-qualified consultant can complete — likely saving $20,000+ vs. starting from scratch. For very large or complex facilities, an engineering consultant is still recommended for PHA execution and engineering analysis.