B ASIC

P ROCESS

S AFETY

R EVIEW
BPSR PRESENTATION
 OBJECTIVES

WE WILL LEARN …

1. WHAT IS A BPSR?
2. WHEN CAN WE USE A BPSR?
3. HOW IS A BPSR COMPLETED?
4. HOW IS A BPSR DOCUMENTED?

PSP 491
BPSR PRESENTATION
 WHAT IS A BPSR?

 A SIMPLIFIED APPROACH TO STUDY LOWER

RISK SYSTEMS

 USES A CHECKLIST FOR EACH PIECE OF

EQUIPMENT IN THE SYSTEM

 USED IN PLACE OF PROCESS SAFETY STUDY

(BUT DO NOT REPLACE AN EXISTING PS
STUDY)

BPSR PRESENTATION
 FOR WHAT SYSTEMS?

 CLASS 3 AND CLASS 2 CHEMICALS … WITH

EXCEPTIONS
– THESE EXCEPTIONS PREVENT THE USE OF BPSRS
FOR HIGHER PRESSURE AND SERIOUS FIRE,
EXPLOSION, AND CHEMICAL RELEASE / REACTIVITY
HAZARDS

 CHEMICAL CLASSIFICATION REVIEW:

– CLASS 1 – SEE SOP 1002
– CLASS 2 – SEE HAZARDOUS CHEMICAL CBA
– CLASS 3 – NOT 1 OR 2

BPSR PRESENTATION
 FOR WHAT SYSTEMS?

 CLASS 3 EXCEPTIONS:

– SYSTEMS CONTAINING A LIQUID HEATED ABOVE

212∘F
– STEAM SYSTEMS ABOVE 175 PSIG
– COMPRESSED AIR SYSTEMS ABOVE 125 PSIG
– YANKEE DRYER SYSTEMS – PAPER
– CYROGENIC SYSTEMS

BPSR PRESENTATION
 FOR WHAT SYSTEMS?

 CLASS 2 EXCEPTIONS:

– ANY CLASS 1 CHEMICALS USED IN < CLASS 1

QUANTITIES OR CONCETRATIONS
– CAUSTICS, ACIDS, CORROSIVES
– COMBUSTIBLE DUSTS
– SYSTEMS CONTAINING A LIQUID HEATED ABOVE
212∘F
– OXIDIZERS (UNLESS SPECIFIC PSP FOR CHEMICAL)

BPSR PRESENTATION
 Is the c he m ic a l lis te d o n
the Cla s s 1 lis t, e ve n if
quantity o r c o nc e ntra tio n is
le s s tha n thre s hold (S OP
1 0 0 2 C App. C)?
y
P SS
Is t h e re a s p e c ific
P S P a va ila b le a b o u t
t h e o xid ize r?
y
BP S R + P S P
c he c klis ts
n Cla s s 2 c he mic al? n Cla s s 3 c he m ic a l?
y y
Is t h e c h e m ic a l
Is t h e re a liq u id
c o rro s ive o r c a p a b le PSS
y h e a t e d a b o ve 1 0 0 °C y
o f p ro d u c in g s e ve re
(2 1 2 °F)?
d a m a g e ? No t e 1
n n
Is it a s t e a m s ys t e m
Is it a c o m b u s t ib le y
y a b o ve 1 2 b a r (1 7 5
d u s t in a n y q u a n t it y?
p s ig )?
n n
Is t h e re a liq u id Is it a c o m p re s s e d
y h e a t e d a b o ve 1 0 0 °C a ir s ys t e m a b ove 9 y
(2 1 2 °F)? b a r (1 2 5 p s ig )?
n n
Are t h e re o xid ize r(s ) Is it a Ya n ke e Drye r
y y
in vo lve d ? s ys t e m ?
n n
is t h e re a s p e c ific
P S P a va ila b le for t h e Is it a c ryog e n ic
y y
c h e m ic a l(s )? s ys t e m ?
No t e 2
n n
BP S R
BPSR PRESENTATION
HOW IS A BPSR COMPLETED

PSP 491 “12 STEPS TO SUCCESS”:

1. OBTAIN P&ID OR MAKE ACCURATE SKETCH

2. COMPLETE CHEMICAL SAFETY DATA SHEET
3. UNDERSTAND THE PROCESS
4. COMPLETE THE FLOWCHART – APPENDIX 1
5. STUDY THE ENTIRE SYSTEM
6. COMPLETE THE CHECKLIST FOR EACH EQUIPMENT

BPSR PRESENTATION
HOW IS A BPSR COMPLETED

PSP 491 “12 STEPS TO SUCCESS”:

7. COMPLETE ANY APPLICABLE PSP CHECKLISTS

8. LIST THE PREVENTIVE OR PROTECTIVE MEASURES
AND DEVICES
9. ADD ALL “FLAGGED” SAFETY DEVICES TO THE
PLANT INSPECTION PROGRAM
10. INCLUDE OTHER SAFETY MEASURES IN THE PLANT
INSPECTION PROGRAM AS NECESSARY
11. ADD DEVICE SYMBOLS AND FLAGS TO P&ID
12. DECIDE IF ANY DEVICES NEED SIZING CALCS

BPSR PRESENTATION
HOW IS A BPSR DOCUMENTED

BPSR DOCUMENTATON INCLUDES:

1. P&ID OR SKETCH OF SYSTEM

2. CHEMICAL DATA SHEET
3. COMPLETED BPSR EQUIPMENT CHECKLISTS
4. PSP CHECKLISTS (IF APPLICABLE)
5. CALCS AND EQUIPMENT DATA (IF NEEDED)

BPSR PRESENTATION
 A LIVING DOCUMENT …

 USE AND UPDATE THE BPSR FOR CHANGES!

 REFER TO THE DOCUMENTATION REGULARLY
(DON’T SIT IT ON A SHELF)!
 USE IT FOR TRAINING!
 REVIEW EVERY 8 YEARS!

BPSR PRESENTATION
 TEAM EXERCISES

REPORT THE FOLLOWING:

EXERCISE 1:
 FLOWCHART – APPENDIX 1
 RAILCAR CHECKLIST
 PUMP 2 CHECKLIST
 TANK 1 CHECKLIST
 MARKED UP FLOWSHEET WITH FLAGS &
SYMBOLS

BPSR PRESENTATION
 TEAM EXERCISES

REPORT THE FOLLOWING:

EXERCISE 2:
 REVISED TANK 1 CHECKLIST
 MARKED UP FLOWSHEET WITH FLAGS &
SYMBOLS

BPSR PRESENTATION
 END OF BPSR PRESENTATION

 QUESTIONS ?????

BPSR PRESENTATION