Chemical Process Safety

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Chemical Process Safety

• Ana Brjetchkova
• Renee Bryner
• Hilary McQuiston-Fall

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What is Chemical Process Safety?

• The prevention of accidents by the use of
  appropriate technologies to identify the hazards
  of a chemical plant and to eliminate them before
  an accident occurs

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OSHA

• Occupational Safety and Health Administration
• Created by an act of Congress on December 28,
  1970
• Mission Assure the safety and health of
  Americas workers by setting and enforcing
  standards, providing training and education,
  establishing partnerships and encouraging
  continual improvement in workplace safety and
  health
• Guidelines exist for ALL areas of process safety

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Process Safety Management

• Process Safety Information
• Material Safety Data Sheets (MSDS)
• Process Technology Information
• Process Block Flow Diagrams

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Process Safety Management

• Process Equipment Information
• P IDs (Piping and Instrumentation Diagrams)

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Process Safety Management

• Relief System Design and Basis
• There are several types of relief valves

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Process Safety Management
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Process Safety Management

• Safety System Interlocks
• Agitation Interlock
• High Temperature Interlock
• Low Temperature Interlock
• High Pressure Interlock

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Process Safety Management

• Process Hazard Analysis
• Identify possible problems in the process
• Identify possible causes and results
• Develop prevention techniques
• Evaluate the current system and operations

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Process Safety Management

• Operating Procedures
• Initial Startup
• Normal Operations
• Emergency shutdown
• Emergency operations
• Safety and Health Considerations
• Precautions to prevent exposure
• Control measures if exposure occurs

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Process Safety Management

• Training
• Initial Training
• Refresher Training
• Training Documentation
• Pre-Startup Safety Review
• Walk through the completed facilities to make
  sure the building looks like the design and to
  look for safety hazards

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Process Safety Management

• Mechanical Integrity
• Inspection and Testing
• Preventative Maintenance
• Safe Work Practices
• Hot Work Permits, Confined Space Training/Permit,
  Lockout/Tagout

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Process Safety Management

• Management of Change
• Outlines the minimum requirements for making
  changes
• Evaluation must occur before any change
• EVERYTHING must be updated and approved
• Employee training

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Process Safety Management

• Incident Investigation
• Procedure to follow if one of the guidelines is
  breached or chemical safety is compromised
• PROMPT, no longer then 24 hrs.
• Report must be submitted

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Process Safety Management

• Emergency Planning and Response
• Plant-wide Program
• Procedure for small releases
• Provisions for hazardous waste
• Compliance Audits
• Evaluate procedures and practices to make sure
  they apply to OSHA standards every three years

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Process Safety Management

• Trade Secrets
• Information necessary to comply with all
  guidelines must be released to all individuals
  for whom they are necessary without regard to
  the possible trade secret status of such
  information

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Without Process Safety
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Without Process Safety

• Bhopal- December 2-3, 1984
• Union Carbide
• Release of methyl iso-cyanate
• Killed 2,000
• Injured 150,000

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Works Cited

• www.osha.gov
• Chemical Process Safety Fundamentals with
  Applications, Daniel A. Crowl and Joseph F.
  Louvar
• Henry Brinker, Sr. Safety Engineer, Mallinckrodt
  Group
• Mr. V. Boyen, Corporate Safety Director,
  Mallinckrodt Chemical Inc.
• Judy A. Perry, Sr. Safety Engineer, Mallinckrodt
  Chemical Inc.