Process Safety Management of Highly Hazardous

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Process Safety Management of Highly Hazardous
Explosive Chemicals
Hazard Assessment Equipment in the Process
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Hazards of the Process

• 1910.119(d)(1)

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The Requirements of the Standard - Hazard
Determination

• Determine
• Chemicals in Your Process
• Process Chemistry
• Quantity of Chemicals in lbs
• Compare to Appendix A List with Threshold
  Quantities (TQs)

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The Requirements of the Standard - Hazard
Determination

• How to Calculate from Gallons to lbs?
• Multiply the gallons of Liquid
• x 8.33 (How much a lb of water weighs) x
  Specific Gravity of Liquid lbs of Liquid
• Example Wt of 10,000 gallons of gasoline
• 10,000 x 8.33 x 0.739 61,559 lbs

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The Requirements of the Standard - Hazard
Determination

• Compare the lbs of Liquid or Gas to the Threshold
  Quantity in Appendix A of the Standard
• Example Anhydrous Ammonia
• TQ 10,000 lbs
• If You Exceed the Threshold Quantity, You Have a
  Covered Process Are Required to Comply

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Toxicity Information

• 1910.119(d)(1)(i)

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The Requirements of the Standard - Develop
Toxicity Information

• Obtain Toxicity Information on the Chemical(s) in
  the Process
• MSDS are Typical Resource
• You May Need Other References, NIOSH Pocket
  Guide, ACGIH TLVs

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The Requirements of the Standard - Develop
Toxicity Information

• Toxicity
• Permissible Exposure Limits
• Physical Data
• Reactivity Data
• Corrosivity Data
• Thermal and Chemical Stability Data

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Technology of the Process

• 1910.119(d)(2)

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The Requirements of the Standard - Process
Technology

• Block flow diagram or process flow diagram
• Process chemistry
• Maximum intended inventory
• Upper and lower limits
• Consequences of deviations

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The Requirements of the Standard - Process
Equipment

• Materials of construction
• Piping and instrument diagrams (PIDs)
• Electrical classification
• Relief system design
• Ventilation system design
• Design codes
• Material and energy balances
• Safety systems

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Block Diagram
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PID
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Equipment in the Process

• 1910.119(d)(3)

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The Requirements of the Standard - Process
Equipment

• Now
• Identify Each Piece of Equipment in the Covered
  Process by PID, Block Diagram and Number Them
• Remember - Must Follow Form
• Must be Able to Track Each Number Through the
  Entire Program

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Block Diagram
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PID
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Process Equipment Numbering
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Mechanical Integrity

• 1910.119(j)

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The Requirements of the Standard - Process
Equipment

• Mechanical Integrity Certificates
• Must be Obtained for Each Element of the Process
• Must be Marked with Numbering System that Follows
  Form

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The Requirements of the Standard - Process
Equipment

• Mechanical Integrity Certificates Can Be
• ASME Certificates for Vessels
• Specification Sheets

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Inspection Testing

• 1910.119(j)(4)

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The Requirements of the Standard - Process
Equipment

• Inspection/Testing/ Maintenance
• System Must be Developed to Perform These
  Functions by Part and Critical System
• Must Follow Manufacturers Recommendations
• Must be Able to Track Equipment Inspected

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Quality Assurance

• 1910.119(j)(6)

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Quality Assurance

• Construction Equipment must be suitable for the
  process application for which they will be used.
• Appropriate checks and inspections to assure that
  equipment is installed properly and consistent
  with design specifications and the manufacturer's
  instructions.
• Maintenance materials, spare parts and equipment
  are suitable for the process application for
  which they will be used

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Summary
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Hazard Assessment Equipment in the Process
Summary
Block Diagram
PID
Hazard Assessment (If over TQ, Must Proceed)
Develop information the Equipment in the Process
Develop Toxicity Information on Chemical in
Covered Process
Develop information on Technology of the Process
Obtain Mechanical Integrity Certificates
Remember Must be Able to Track Equipment
Throughout the Entire Program
Develop Inspection/Testing/Maitenance Procedures
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Whats Next?

• In the Next Session, we will Cover the Critical
  Requirements for Process Hazard Analysis (PHAs)