EXAMPLES OF PROCESS HAZARDS

FORM OF ENERGY ASSOCIATED HAZARD(S) TYPICAL ACCIDENTAL EVENT(S)

CHEMICAL ENERGY Ability to self-polymerize Uncontrolled polymerization

Shock-sensitivity Detonation of solid or liquid explosive or explosive mixture

Thermal instability Thermal explosion following bulk self-heating and runaway reaction

Rearranging ability Uncontrolled rearrangement reaction (e.g., ethylene oxide)

Pyrophoricity Fire upon atmospheric contact (e.g., triethylaluminum)

Flammability Vessel rupture following ignition of contained vapors + air

Vapor cloud explosion

Flash fire

Pool fire

Combustibility Bulk material fire

Dust explosion

Aerosol ignition and fast fire

Flash fire of vapors from heated combustible solid or liquid

Peroxidizing ability Energetic peroxide decomposition from contact with oxygen over time

Water-reactivity Release of water-reactive material and energetic reaction with water or humidity

Oxidizing or reducing ability Bulk material fire from contact of oxidizer with organic material

Uncontrolled redox reaction

Acidity or causticity Acid gas release (e.g., anhydrous HCl)

Corrosive liquid or solid spill

Uncontrolled acid/base reaction

Toxicity Toxic vapor release

Toxic liquid or solid spill

Heat, pressure, or toxic gas generation from inadvertent mixing or contact with
Other increased reactivity
incompatible material
Reduced chemical reactivity
Personnel entry into confined space with reduced oxygen level
(inert material, e.g., nitrogen)
THERMAL ENERGY Elevated temperature Hot material release

Contact with hot surface

Steam explosion or equivalent

Containment rupture from thermal expansion of blocked-in fluid

Reduced temperature Cryogenic material release

Fracture of embrittled containment

PRESSURE-VOLUME Volume of compressible fluid held
Tank or enclosure rupture
ENERGY at elevated pressure
High-velocity leak or spray
Liquefied material stored under
Rapid phase transition (Boiling Liquid Expanding Vapor Explosion or BLEVE)
pressure
Volume of compressible fluid
Tank or enclosure collapse
held under vacuum
Elevation of process material
POTENTIAL ENERGY Toppling over of stacked drums
above a reference level
Shifting of granular storage piles

Fluid surge from failed container

Falling material from spill/overflow

KINETIC ENERGY Moving process material Overpressure or overtemperature by deadheaded pumping

Impingement by process material

Water hammer damage

Elevated electromagnetic
ELECTROMAGNETIC Unshielded laser or microwave radiation associated with process
radiation levels
ELECTRICAL ENERGY Elevated voltage Electrical shock from process using electricity (e.g., electrolysis of brine)