Highly Hazardous Chemical Threshold Checker Free

PSM Highly Hazardous Chemical Threshold Checker

Enter each chemical and quantity on site.
Add multiple entries if stored in separate vessels or areas.

Chemical Name or CAS Quantity Unit (lbs/kg) Action


If you manage chemicals in any industrial, manufacturing, oil and gas, food processing, laboratory, pharmaceutical, or energy facility, you already know that one wrong calculation can trigger major regulatory consequences.

The Highly Hazardous Chemical Threshold Checker Free is a practical compliance tool designed to help safety managers, plant supervisors, environmental officers, and compliance consultants quickly determine whether the quantity of a chemical on-site meets or exceeds regulatory threshold limits for Process Safety Management (PSM).

This tool simplifies one of the most critical early steps in regulatory compliance: identifying whether your facility crosses the threshold quantity for a highly hazardous chemical (HHC).

What Is a Highly Hazardous Chemical (HHC)?

Under the Occupational Safety and Health Act of 1970, the Occupational Safety and Health Administration (OSHA) regulates certain chemicals that pose catastrophic risks if released.

These chemicals are specifically identified under:

  • 29 CFR 1910.119 – Process Safety Management of Highly Hazardous Chemicals

  • 40 CFR Part 68 – EPA Risk Management Program (RMP)

Each listed chemical has a Threshold Quantity (TQ). If your facility stores or processes an amount equal to or greater than this threshold, you may be legally required to implement a full PSM or RMP program.

Failing to identify when you exceed that threshold can result in:

  • Regulatory citations

  • Heavy financial penalties

  • Increased liability exposure

  • Shutdown orders

  • Criminal enforcement in severe cases

That’s why a reliable threshold checker matters.

What This Free Threshold Checker Does

The Highly Hazardous Chemical Threshold Checker allows you to:

1. Enter Chemical Name or CAS Number

You can input:

  • Common chemical name (e.g., chlorine, ammonia)

  • CAS number (Chemical Abstract Service number)

This ensures accurate identification of regulated substances.

2. Enter Quantity On-Site

You input the total quantity stored or processed.

3. Select Unit of Measurement

Choose between:

  • Pounds (lbs)

  • Kilograms (kg)

The tool automatically standardizes units for proper threshold comparison.

4. Add Multiple Chemical Entries

If chemicals are:

  • Stored in separate vessels

  • Located in different areas

  • Divided across units

You can add multiple entries using the Add Chemical button.

Each row can be removed individually using the Remove button.

5. Run Threshold Check

Click Check Threshold, and the system evaluates:

  • Whether your chemical exceedsthe  threshold quantity

  • Whether it potentially triggers PSM applicability

  • Whether further compliance review is required

The result is displayed clearly in the results section.

Who Should Use This Tool?

This tool is ideal for:

  • HSE Managers

  • Process Safety Engineers

  • Environmental Compliance Officers

  • Plant Managers

  • Chemical Warehouse Supervisors

  • Oil & Gas Facility Operators

  • Safety Consultants

  • Auditors

  • Engineering Students studying PSM

If you operate in a facility that stores toxic, flammable, or reactive chemicals, this tool is highly relevant to you.

Why Threshold Quantity Matters

Threshold Quantity (TQ) determines whether your facility falls under:

  • OSHA PSM requirements

  • EPA Risk Management Program

  • Local hazardous chemical storage regulations

For example:

  • Anhydrous ammonia has a specific threshold.

  • Chlorine has a different threshold.

  • Flammable liquids may have aggregate thresholds.

Exceeding the threshold triggers mandatory requirements such as:

  • Process Hazard Analysis (PHA)

  • Mechanical Integrity Programs

  • Operating Procedures

  • Employee Training

  • Management of Change (MOC)

  • Emergency Planning

  • Incident Investigation

  • Compliance Audits

This tool helps you determine whether you’re in that regulatory zone.

How the Tool Works (Step-by-Step)

Step 1: Enter Chemical Name or CAS

Type the chemical name or CAS number in the input field.

Example:

  • Chlorine

  • 7782-50-5

Using CAS numbers reduces ambiguity.

Step 2: Enter Quantity

Input the total quantity stored or processed.

Important:
Enter the maximum intended inventory — not just daily usage.

Step 3: Select Unit (lbs or kg)

Choose your unit carefully. The tool ensures consistent evaluation across measurement systems.

If your internal records are metric-based, use kilograms.
If using U.S. standard inventory systems, use pounds.

Step 4: Add Additional Chemicals (If Needed)

If you have multiple regulated chemicals, click Add Chemical to create additional rows.

Each row operates independently.

You can remove any entry using the Remove button.

Step 5: Click “Check Threshold”

Once all chemicals are entered, click the button.

The system evaluates:

  • Each chemical

  • Quantity against known threshold values

  • Possible regulatory applicability

The result appears clearly in bold for easy interpretation.

Key Features of the Tool

1. Multi-Entry Capability

Supports multiple chemicals in a single review session.

2. Unit Flexibility

Accepts both pounds and kilograms.

3. Simple Interface

No complex software training required.

4. Fast Assessment

Immediate feedback — no manual calculations.

5. Compliance-Oriented Design

Built specifically to support PSM threshold review.

6. No Cost

Fully free to use.

Common Chemicals Typically Checked

Although this tool can evaluate multiple chemicals, common PSM-regulated chemicals include:

  • Chlorine

  • Anhydrous ammonia

  • Hydrogen sulfide

  • Propylene oxide

  • Hydrogen fluoride

  • Formaldehyde

  • Ethylene oxide

  • Flammable liquids above threshold amounts

Always verify the chemical against OSHA’s Appendix A list.

Important Compliance Notes

This tool provides a screening-level evaluation.

It does NOT:

  • Replace a formal legal determination

  • Substitute professional safety consultation

  • Account for aggregation rules across interconnected processes

  • Automatically generate PSM documentation

Final applicability decisions should be reviewed against:

  • 29 CFR 1910.119

  • 40 CFR Part 68

  • State-specific regulations

  • Local authority requirements

If you are close to the threshold, consult a qualified Process Safety professional.

When You Should Immediately Perform a Check

Use this tool whenever:

  • You install new storage tanks

  • You increase chemical inventory capacity

  • You receive bulk shipments

  • You redesign a process

  • You combine two chemical systems

  • You expand facility operations

  • You acquire a new plant

Threshold exceedance can happen unintentionally during expansion projects.

Practical Example

Let’s say your facility stores:

  • 9,500 lbs of chlorine

  • 12,000 lbs of anhydrous ammonia

If chlorine threshold is 10,000 lbs, you are below.

If ammonia threshold is 10,000 lbs, you exceed.

The tool highlights this instantly — helping you prioritize compliance.

Why Manual Calculations Are Risky

Without a tool:

  • Unit conversion errors occur

  • Staff forget to include the maximum inventory

  • Separate vessels are overlooked

  • Aggregate quantities are miscalculated

  • Regulatory applicability is assumed incorrectly

Even experienced safety managers can miss threshold triggers during expansion.

This tool reduces that risk.

Limitations to Understand

While powerful, the tool:

  • Assumes accurate input from the user

  • Relies on current regulatory threshold values

  • Does not account for chemical mixtures unless properly entered

  • Does not perform consequence modeling

  • Does not generate full PSM compliance plans

It is a decision-support screening tool, not a compliance substitute.

Best Practice for Using This Tool

  1. Maintain updated chemical inventory logs

  2. Cross-check CAS numbers

  3. Use the maximum intended inventory

  4. Review results annually

  5. Re-check whenever process changes occur

  6. Document your evaluation for audit purposes

Why This Tool Matters for Audits

During OSHA or EPA inspections, inspectors often ask:

  • Do you exceed any PSM threshold quantities?

  • How do you determine applicability?

  • When was your last threshold evaluation conducted?

Having documented threshold checks strengthens your compliance posture.

Benefits for Small and Medium Facilities

Large corporations typically have compliance departments.
Small facilities often do not.

This free tool provides:

  • Immediate regulatory screening

  • Reduced need for costly initial consultation

  • Faster internal safety reviews

  • Better expansion planning

It empowers smaller operations to make informed safety decisions.

Final Thoughts

The Highly Hazardous Chemical Threshold Checker Free is a practical compliance support tool for facilities that handle regulated chemicals.

It helps you:

  • Identify regulatory exposure

  • Prevent costly compliance violations

  • Strengthen your safety management system

  • Improve audit readiness

  • Support responsible chemical management

Process Safety Management begins with knowing whether you are covered.

This tool helps you answer that question — quickly, clearly, and accurately.

If your facility handles hazardous chemicals, don’t guess.

Check your thresholds.
Document your findings.
Protect your people.
Stay compliant.

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