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Process Safety Management

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Report. Unlocked doors, gates, and storage areas. Suspicious packages. Suspicious activity ... Police department. Ambulance. Medical clinic or hospital ... – PowerPoint PPT presentation

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Title: Process Safety Management


1
Process Safety Management
2
Session Objectives
  • You will be able to
  • Identify the dangers of highly hazardous
    chemicals in your facility
  • Safely follow standard operating procedures
  • Avoid or correct hazards and unsafe conditions
  • Respond to emergencies

3
Dangers of Highly Hazardous Chemicals
  • Millions of people live near chemical plants in
    the United States
  • Bhopal, India1984
  • Accidental releases can cause severe injury and
    death
  • Poisoning
  • Asphyxiation
  • Internal or external burns

4
Dangers of Highly Hazardous Chemicals (cont.)
  • 6,500 residents evacuated after ammonia release
  • Propane gas-fueled explosion caused by unsafe
    conditions and inadequate employee training

Image Credit Chemical Safety Board (CSB)
5
Highly Hazardous Chemicals
  • Toxic
  • Reactive
  • Flammable
  • Explosive

6
Process Safety Management Overview
  • Written safety information
  • Written workplace hazard assessment
  • Consultation with operators
  • A system to respond to findings
  • Periodic review of assessments and response
  • Written operating procedures
  • Safety training and operating information

7
Process Safety Management Overview (cont.)
  • Information and training for contractors
  • Emergency response training
  • A quality assurance program
  • Maintenance system
  • Pre-startup safety reviews
  • Documentation and verification of change
  • Incident investigation and corrective action

8
Identify HazardsThe MSDS
  • Toxicity
  • Permissible exposure limit
  • Physical data
  • Reactivity
  • Corrosivity
  • Thermal and chemical stability
  • Hazardous effects of inadvertent mixing of
    materials

9
Identify Hazards Equipment
  • Sparks or electrical discharge from old or poorly
    maintained equipment
  • Leaks or spills caused by
  • Pump or compressor failures
  • Loose valve connections
  • Inadequate containment

10
PSM and Chemical HazardsAny Questions?
  • Any questions about the process safety management
    program?
  • Any questions about the hazards or dangers of
    chemicals?
  • Any questions about hazards from equipment?

11
Chemical Exposure Precautions
  • Administrative controls
  • Engineering controls

12
Personal Protective Equipment (PPE)
  • Always wear PPE appropriate to the task
  • Ensure a good fit
  • Inspect PPE before use
  • Keep it clean
  • Report defective equipment to your supervisor
  • Never wear defective PPE

13
Operating Phases
  • Initial start-up
  • Normal operations
  • Maintenance
  • Temporary operations
  • Normal shutdown
  • Emergency shutdown
  • Restart
  • Site security

14
Initial Start-Up
  • Check storage containers
  • Conduct pressure test and leak check
  • Inspect equipment

Image Credit Pacific Northwest National
Laboratory (PNNL)
15
Normal Operations Operating Limits
  • Capacity
  • Pressure
  • Temperature
  • Weather conditions

16
Normal Operations Loading and Unloading
  • Notify management of suspicious shipment
  • Verify tank trucks are grounded
  • Inspect the tank
  • Inspect all equipment before loading
  • Verify container is safe for filling
  • Verify truck electrical systems are off

17
Normal Operations Loading and Unloading (cont.)
  • Use wheel chocks
  • Check the compatibility of mixed loads
  • Check the weight distribution of loads
  • Verify that the cargo is properly secured
  • Check the type, number, and stacking arrangement
    of load
  • Conduct a walk-around inspection of transport
    vehicles

18
Normal Operations Segregation and Storage
  • Never store incompatible chemicals together
  • Segregate chemicals by hazard class
  • Store flammable solvents in a flammable storage
    cabinet
  • Store acids in their own storage cabinet
  • Keep oxidizers away from organic materials
  • Keep acids away from bases
  • Keep cyanides and sulfides away from acids

19
MaintenanceGeneral Equipment
  • Wear personal protective equipment
  • Replace or repair defective or damaged power and
    hand tools
  • Repair or replace damaged equipment (e.g.,
    meters, cathodic protection systems) showing
    signs of
  • Leaks
  • Corrosion
  • Low pressure

20
MaintenanceContainers, Tanks, Foundations
  • Inspect containers and tanks and repair
  • Leaks
  • Corrosion
  • Check the condition of the foundation
  • Replace footings
  • Repair corrosion at container and masonry contact
    area

Image Credit Fermi National Accelerator
Laboratory (FNAL)
21
MaintenanceConnectors and Fittings
  • Maintain and repair container connections
  • Replace faulty flow and backflow check valves
  • Abrasions or cuts on hoses
  • Leaks
  • Maintain and repair tank fittings
  • Ensure that connectors, plugs, caps, and gaskets
    are in good condition

22
MaintenanceGauges and Pressure Valves
  • Make sure equipment is shut down
  • Repair or replace gauges
  • Repair or replace pressure relief valves
  • Ensure that emergency shut-off valves are in good
    condition

23
MaintenancePumps and Compressors
  • Ensure that the motor is operating according to
    manufacturers specs
  • Check all alignments to specification
  • Ensure that oil systems are properly maintained
    on schedule
  • Check all connections and terminals for tightness
    and contact
  • Monitor fluid flow
  • Tighten all electrical connections, measure
    voltage

24
MaintenanceHoses
  • Ensure that hoses are operating at or below the
    rated working pressure
  • Ensure that the overfill alarm and prevention
    device is functioning properly
  • Protect hoses from severe end loads
  • Check hoses for loose covers, kinks, or soft
    spots
  • Replace hoses according to manufacturers
    specifications

25
MaintenanceElectrical Equipment
  • Stop using and report
  • Broken or missing equipment covers
  • Damaged tools
  • Damaged cords
  • Any other damaged equipment

26
MaintenanceRemove Combustible Materials
  • Keep combustibles at least 10 feet away from
    containers
  • Weeds
  • Grass
  • Rags
  • Paper
  • Wood

27
Any Questions?
  • Any questions about start up, normal operations,
    and any of the maintenance procedures?

28
Temporary Operations
  • Conduct a pre-startup check
  • Segregate incompatible containers

29
Normal Shutdown Procedures
  • Check pressure relief systems

30
Emergency Shutdown
  • Situations that trigger an emergency shutdown
    include
  • Fire
  • Leak
  • Explosion
  • Workplace violence

31
Emergency Shutdown Procedure
  • Perform shutdown procedures only if not
    threatening to life or injury
  • Evacuate the area
  • Immediately report your shutdown actions

32
Restart
  • Examine pressure vessels and storage tanks
  • Examine insulation systems for piping, vessels,
    and tanks
  • Examine drainage systems
  • Examine electrical motors and drives
  • Check valve positions

33
Restart (cont.)
  • Examine all electrical equipment and wiring
    systems
  • Make sure all warning systems are operational
  • Check the integrity of all fire detection and
    suppression systems
  • Ensure that emergency response equipment and
    systems are operational

34
Site Security
  • Report
  • Unlocked doors, gates, and storage areas
  • Suspicious packages
  • Suspicious activity
  • Dont talk to outsiders about the facility
  • Display your ID badge on company premises
  • Secure hazardous materials

35
Site Security (cont.)
  • Secure all valves and other fixtures when you are
    finished using them
  • Verify the identity of cargo carriers and drivers
  • Secure all rail, truck, and barge containers
  • Verify all paperwork
  • Handle pickups and deliveries only by appointment
    with known vendors

36
Operating Procedures Any Questions?
  • Any questions about
  • Procedures for safely handling chemicals or
    operating a chemical process?
  • Temporary operations?
  • Shutdown and restart procedures?
  • Site security?

37
Consequences of Deviations
  • Excess pressure accidental releases, leaks,
    fires, and explosions
  • Container leaks poisoning, asphyxiation, burns,
    fires, and explosions

38
Consequences of Deviations (cont.)
  • Damaged or faulty equipmentaccidental leaks,
    fires, and explosions
  • Change in the processaccidental releases, leaks,
    fires, and explosions

Image Credit Chemical Safety Board (CSB)
39
Emergency Response Contacts
  • Fire department
  • Police department
  • Ambulance
  • Medical clinic or hospital
  • Emergency coordinator

40
Respond to Chemical Spills
  • Evacuate the area
  • Notify a supervisor or the emergency response
    team
  • Remove ignition sources if safe to do so

41
Evacuation Preparedness
  • Keep fire exits clear
  • Participate in drills and provide feedback
  • Become familiar with evacuation coordinators and
    headcount personnel

42
Evacuation Procedures
  • Recognize the evacuation signal and listen for
    instructions
  • Shut down equipment using the emergency stop
  • Go directly to the nearest safe exit
  • Proceed to the assembly area

43
Rescue and Medical Treatment
  • Leave rescue work to trained professionals
  • Designated first-aid workers perform first aid
  • Follow medical emergency procedures

44
Emergency Response Any Questions?
  • Any questions about responding to emergencies?

45
Management of Change
  • Technical basis for the proposed change
  • Impact of the change on safety and health
  • Modifications of the operating procedures
  • Necessary time period for the change
  • Authorization requirements for the change

46
Hot Work Permit
  • Hot work operations can cause catastrophic
    accidents
  • A hot work permit is required for all hot work
    operations

47
Lockout/Tagout
  • Qualified persons only
  • Prevent machinery or equipment from being turned
    on
  • Prevent a part of machinery or equipment from
    moving
  • Provide means of warning (tag)

48
Permit-Required Confined Space
  • Contains or has potential to contain a hazardous
    atmosphere
  • Contains the potential for engulfment
  • Internal configuration that can trap or
    asphyxiate entrant
  • Any other serious safety or health hazards

49
Incident Investigation Reports
  • Date of incident
  • Date investigation began
  • Description of the incident
  • Factors contributing to the incident
  • Recommendations resulting from the investigation

50
Key Points to Remember
  • Chemical process accidents can cause severe
    injury, death, and damage to property and the
    environment
  • Read MSDSs for chemicals
  • Follow operating and maintenance procedures
    without deviation
  • Always watch for potential unsafe conditions
  • Leaks, corrosion, faulty equipment, combustibles
    near chemical processes
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