Course Material

Course Material

1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe Work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety systems9. Emergency response procedures

5. Safe Work Procedures

Process Safety Management for

Biofuels

This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

29 CFR 1910.119 (f)(4)

5. Safe Work Procedures

Process Safety Management for

Biofuels

This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

29 CFR 1910.119 (f)(4)

Piper Alpha Oil Platform Explosion

Failure of Lock out / Tag out Procedure

Permit-To-Work System

Safe Work Permit

Safe Work Procedures Lock out / Tag out

Each Craft Should have Their Own Lock

Lock out / tag out

Safe Work Permit

OSHA 29 CFR 1910.147

Try the Lock Out

OSHA 29 CFR 1910.147

Additional Information

Additional information on Lock out / Tag out procedures can be found in the document

referenced in the below link.

Hot Work Permit

29 CFR 1910.119 (k)

Hot Work Permit Requirements

OSHA 29 CFR 1910.252

Hot Work Permit Failure

Closing the PermitJoint inspection when the nonroutine work is complete

1. Valve alignment2. Blinds removed3. Sewer drains

reopened4. Vents5. Rotating equipment6. Locks and tags7. Utilities8. Barricades removed

Confined Space Fatalities

CSB Bulletin

Confined Space Entry Permit

Safe Work Procedures

http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS

Permit-Required Confined Spaces (PRCS) standard 29 CFR 1910.146

“Opening Process Equipment” Fatalities

29 CFR 1910.119 (f)(4)

www.csb.gov

“Opening Process Equipment” Fatalities

29 CFR 1910.119 (f)(4)

www.csb.gov

BP Amoco Incident; Georgia; March, 2001www.csb.gov

CSB Video on BP Amoco IncidentCan be viewed from video time 6:45 – 10:20

BP Amoco Incident; Georgia; March, 2001www.csb.gov

Fact: Three maintenance workers were fatally injured.

1. Why?The workers were working on the “Polymer Catch Tank”.

The polymer catch tank was still pressurized.

The workers partially removed the cover.

BP Amoco Incident; Georgia; March, 2001www.csb.gov

Fact: The polymer catch tank was still pressurized

2. Why?Loss of gas venting capability by catch tank.

Decomposition generating gas in core of vessel.

Pressure gauge was inoperative.

No de-energizing procedure for vessel.

BP Amoco Incident; Georgia; March, 2001www.csb.gov

Fact: There was no de-energizing procedure for tank.

3. Why?Pressure gauge and drain used as indication of de-

energized status.

Process had been shut down, was not operative.

Outdated vessel cleaning procedure was being used.

BP Amoco Incident; Georgia; March, 2001www.csb.gov

Fact: Outdated vessel cleaning procedure was being used.

4. Why?Foaming of the polymer product was not well understood by operations.

The plugging capacity of the foaming polymer was not well understood by operations.

BP Amoco Incident; Georgia; March, 2001www.csb.gov

Foaming and plugging of product was not well understood by operations.

5. Why?

Operations’ safe work procedures had not been modified to consider foaming of polymer material.

Operations had not taken advantage of opportunities to learn from near misses on product foaming and plugging.

Applicability of Previous Material

1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe Work Procedures

Remaining Course Material

1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe Work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety systems9. Emergency response procedures