Process Safety Management of Highly Hazardous & Explosive Chemicals

Process Safety Management of Highly Hazardous & Explosive Chemicals

Hazard Assessment & Equipment in the Hazard Assessment & Equipment in the ProcessProcess

Hazards of the Process

1910.119(d)(1)1910.119(d)(1)

The Requirements of the Standard - Hazard Determination

Determine:Determine:

Chemicals in Your ProcessChemicals in Your ProcessProcess ChemistryProcess ChemistryQuantity of Chemicals in lbsQuantity of Chemicals in lbsCompare to Appendix A List with Compare to Appendix A List with

Threshold Quantities (TQ’s)Threshold Quantities (TQ’s)


How to Calculate from Gallons to lbs?How to Calculate from Gallons to lbs?

Multiply the gallons of LiquidMultiply the gallons of Liquid x 8.33 (How much a lb of water weighs) x x 8.33 (How much a lb of water weighs) x

Specific Gravity of Liquid = lbs of LiquidSpecific Gravity of Liquid = lbs of Liquid

Example: Wt of 10,000 gallons of gasolineExample: Wt of 10,000 gallons of gasoline10,000 x 8.33 x 0.739 = 61,559 lbs 10,000 x 8.33 x 0.739 = 61,559 lbs


Compare the lbs of Liquid or Gas to the Compare the lbs of Liquid or Gas to the Threshold Quantity in Appendix A of the Threshold Quantity in Appendix A of the StandardStandard

Example: Anhydrous AmmoniaExample: Anhydrous AmmoniaTQ = 10,000 lbsTQ = 10,000 lbs

If You Exceed the Threshold Quantity, You If You Exceed the Threshold Quantity, You Have a “Covered Process” & Are Required to Have a “Covered Process” & Are Required to ComplyComply

Toxicity Information

1910.119(d)(1)(i)1910.119(d)(1)(i)

The Requirements of the Standard - Develop Toxicity Information

Obtain Toxicity Obtain Toxicity Information on the Information on the Chemical(s) in the Chemical(s) in the ProcessProcess

MSDS are Typical MSDS are Typical ResourceResource

You May Need You May Need Other References, Other References, NIOSH Pocket NIOSH Pocket Guide, ACGIH TLV’sGuide, ACGIH TLV’s

ToxicityToxicity Permissible Permissible

Exposure LimitsExposure Limits Physical DataPhysical Data Reactivity DataReactivity Data Corrosivity DataCorrosivity Data Thermal and Thermal and

Chemical Chemical Stability DataStability Data

The Requirements of the Standard - Develop Toxicity Information

Technology of the Process

1910.119(d)(2)1910.119(d)(2)

The Requirements of the Standard - Process Technology

Block flow diagram Block flow diagram or process flow or process flow diagramdiagram

Process chemistryProcess chemistry Maximum intended Maximum intended

inventoryinventory Upper and lower Upper and lower

limitslimits Consequences of Consequences of

deviationsdeviations

The Requirements of the Standard - Process Equipment

Materials of constructionMaterials of construction Piping and instrument Piping and instrument

diagrams (P&ID’s)diagrams (P&ID’s) Electrical classificationElectrical classification Relief system designRelief system design Ventilation system Ventilation system

designdesign Design codesDesign codes Material and energy Material and energy

balancesbalances Safety systemsSafety systems

Block Diagram

P&ID

Equipment in the Process

1910.119(d)(3)1910.119(d)(3)


Now:Now: Identify Each Piece of Identify Each Piece of

Equipment in the Equipment in the Covered Process by Covered Process by P&ID, Block Diagram P&ID, Block Diagram and Number Themand Number Them

Remember - Must Remember - Must Follow Form Follow Form

Must be Able to Track Must be Able to Track Each Number Through Each Number Through the Entire Programthe Entire Program

Block Diagram

P&ID

Process Equipment Numbering

Mechanical Integrity

1910.119(j)1910.119(j)

Mechanical Integrity Mechanical Integrity CertificatesCertificates Must be Obtained for Must be Obtained for

Each Element of the Each Element of the ProcessProcess

Must be Marked with Must be Marked with Numbering System Numbering System that Follows Formthat Follows Form


Mechanical Integrity Mechanical Integrity Certificates Can Be:Certificates Can Be: ASME Certificates ASME Certificates

for Vesselsfor Vessels Specification SheetsSpecification Sheets


Inspection & Testing

1910.119(j)(4)1910.119(j)(4)

Inspection/Testing/ Inspection/Testing/ MaintenanceMaintenance System Must be System Must be

Developed to Developed to Perform These Perform These Functions by Part Functions by Part and Critical Systemand Critical System

Must Follow Must Follow Manufacturer’s Manufacturer’s RecommendationsRecommendations

Must be Able to Must be Able to Track Equipment Track Equipment InspectedInspected


Quality Assurance

1910.119(j)(6)1910.119(j)(6)

Quality Assurance

Construction & Equipment must be suitable Construction & Equipment must be suitable for the process application for which they will for the process application for which they will be used.be used.

Appropriate checks and inspections to assure Appropriate checks and inspections to assure that equipment is installed properly and that equipment is installed properly and consistent with design specifications and the consistent with design specifications and the manufacturer's instructions.manufacturer's instructions.

Maintenance materials, spare parts and Maintenance materials, spare parts and equipment are suitable for the process equipment are suitable for the process application for which they will be usedapplication for which they will be used

Summary

Hazard Assessment & Equipment in the Process: Summary

Hazard Assessment

(If over TQ, Must Proceed)

Develop Toxicity Information on Chemical in Covered Process

Develop information on Technology of the Process

Develop information the Equipment in the Process

Block Diagram P&ID

Obtain Mechanical Integrity Certificates

Develop Inspection/Testing/Maitenance Procedures

Remember: Must be Able to Track Equipment Throughout the Entire Program

What’s Next?

In the Next Session, In the Next Session, we will Cover the we will Cover the Critical Requirements Critical Requirements for Process Hazard for Process Hazard Analysis (PHA’s)Analysis (PHA’s)

Documents

Process Safety Management of Highly Hazardous & Explosive Chemicals