Operating Procedures
Validated normal, abnormal, and emergency procedures kept current right at the workstation
What this element is and why it matters
Operating Procedures are the codified instructions for running every process, covering normal operation, startup, shutdown, abnormal situation response, and emergency response. The element maps to OSHA 1910.119(f) and is the most operator visible PSM artefact of all. Texas City, Tesoro Anacortes, and BP Macondo each surfaced findings against PSM (f) in their CSB investigations, and our team writes and validates procedures so the people on shift can trust what is in front of them.
Individual significance for organisations
Operating procedures are the daily operating language of the plant. An organisation with current, validated, workstation accessible procedures runs operations with consistency and guards against the drift between procedure and reality that drives incidents. Operators who trust their procedures follow them, and those who do not fall back on personal notebooks, at which point the management system quietly collapses into hope.
Contribution to Risk Based Process Safety (RBPS)
Operating Procedures convert the output of Hazard Analysis (Element 7) and Process Knowledge (Element 6) into actionable instructions for the workforce. They directly enable Conduct of Operations (Element 15), Training (Element 12), and Operational Readiness through PSSR (Element 14). MOC (Element 13) keeps them current and Auditing (Element 19) verifies their accuracy. Without the discipline of Element 8, the rest of the operational pillar runs from the wrong baseline.
What compliant execution looks like
How we implement this element
A focused six step methodology calibrated to deliver operating procedures as a working capability rather than a documented compliance artefact.
We catalogue your existing procedures, map them against the required scope under OSHA PSM (f), and identify gaps in coverage, currency, and accessibility.
We conduct task analysis with operator input and author each procedure on a consistent template covering purpose, scope, safety, steps, troubleshooting, and references.
We walk each procedure through with the operating team, capture the practical corrections they raise, and obtain formal signoff before issue.
We integrate procedures with the DCS HMI, mobile tablet delivery, or paper at the workstation, make sure the shift team can see them, and place safety critical warnings prominently.
We run the annual procedure walk down per OSHA PSM (f)(3), capture operator signoff that procedures match current operation, and reconcile any MOC backlog.
We monitor procedure compliance through observation, behavioural audit, and post incident root cause analysis, and trigger a refresh wherever systematic deviation appears.
Element implementation flow chart
A decision gated workflow that shows the actual sequence of activities from initiation through steady state operation, with key decision points highlighted.
What we produce
- A procedure inventory and gap register
- An authoring template with safety, scope, steps, and troubleshooting sections
- Operator validation signoff records
- A workstation delivery system spanning DCS, tablet, and paper backup
- An annual accuracy certification protocol per OSHA PSM (f)(3)
- A compliance monitoring and refresh trigger framework
Where execution fails
- Procedures that describe an idealised process which does not match the plant
- Missing MOC discipline, where procedures are not updated when something changes
- Operators working from personal notebooks rather than the authoritative documents
- Annual certification done as a paper exercise rather than a real field walk down
Codes this element is built on
Explore related elements in this framework
Risk Based Process Safety (RBPS) full element index
Talk to us about implementing Operating Procedures
We can scope this element implementation against your facility, regulatory context, and existing management system maturity, then integrate it with the other Risk Based Process Safety (RBPS) elements you already operate.