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Process Safety Management for Biofuels
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
3. Process Hazard Analysis
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.
Identification of individual hazards of a system, Determination of undesired events, andEvaluation of the consequences
Concept Sciences Explosion, (www.csb.gov)
Ref: Guidelines for Hazard Evaluation Procedures, 3rd edition , © 2008 by American Institute of Chemical Engineers
Hazards
Deviation
Preventive Mitigative
Regain control
or shut down
safeguards
Containment
and control safeguards
Unmitigated
Impacts
Mitigated
Loss event
PHA Regulatory Requirement
29CFR1910.119 (e) (2)
29CFR1910.119 (e) (2)
The employer shall use one or more of the following methodologies that are appropriate to determine and evaluate the hazards of the process being analyzed.
(i) What-If;
(ii) Checklist;
(iii) What-If/Checklist
(continued on next two slides)
29CFR1910.119 (e) (2)
(iv) Hazard and Operability Study (HAZOP):
(v) Failure Mode and Effects Analysis (FMEA);
(vi) Fault Tree Analysis; or(continued on next slide)
29CFR1910.119 (e) (2)
(vi) Fault Tree Analysis; or
(vii) An appropriate equivalent methodology
For more information:
OSHA
CCPS
Process Safety Information
1. Hazards of the process
2. Chemicals used or produced
3. Technology of the process
4. Equipment in the process
1. Hazards of the Process
• Previous incidents• Engineering and administrative controls• Consequence of failure of controls• Facility Siting• Human factors
CSB Video on Texas City: CSB.gov
2. Chemicals in the Process
• Toxicity
• PEL
• Reactivity
• Corrosivity data
• Chemical stability
• Inadvertent mixing
NOAA chemical reactivity worksheet
3. Technology of the Process
• Process flow diagram
• Chemistry
• Inventory
• Safe operating limits
• Consequences of deviation
29CFR1910.119 (d)
4. Equipment in the Process
A PHA is a Team Effort
PHA Team Training
Member Requirements Leader Send to training or hire
consultant
Plant expertise Plant operator
Process expertise Process Engineer
Equipment Engineer and maintenance
“Scribe” Technical and previous PHA team experience
Item Deviation Cause Consequence Safeguards Recommendation
1. Corn dust release
Leak in system
Corn dust explosion
Daily maintenance
Put corn dryer on M.I. schedule
2.
3.
4.
5.
Record of PHA Team Discussion
Plant Location Unit PHA Team Date
Anywhere, USA Corn Dryer Ann Engineer H. MaintenanceWise Operator PHA Guru
1/1/2012
Notes: M.I. = Mechanical Integrity
Human Error
People make misteaks!Calling a telephone numberMaking a PowerPoint SlideTyping a noteStopping at a red traffic light or Stop sign
Is the Risk Tolerable?
YES
Maintain Risk
Controls
Propose Risk
Reduction
No
Iterate back to “Identify Failure Mode”
Action Item Person Assigned
Due Date
Date Completed
Comments
Put corn dryer on M.I. list to prevent corn dust releases
M.I. specialist
4/15/10 4/13/10 Daily inspection by Ima Maintenance or designee; checklist
PHA Action Item List Plant Location Unit PHA Team Date
Anywhere, USA Corn Dryer Ann Engineer H. MaintenanceWise Operator PHA Specialist
4/09/’10
PHA Frequency
Every time there is a significant process change.
A minimum of every 5 years.
Retention Policy
Retain PHA records for the life of the process, regardless of your company’s record retention policy.
29CFR 1910.119(e)(7)
What-If/Checklist
Click the soybeans to go to a partial list of “What-If” questions for biodiesel.
Click the corn to go to a partial list of “What-If” questions for bioethanol.
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