Process Safety Management of Highly Hazardous & Explosive Chemicals

Hazard Assessment & Equipment in the Process

Hazards of the Process

1910.119(d)(1)

The Requirements of the Standard - Hazard Determination

Determine:
Chemicals in Your Process Process Chemistry Quantity of Chemicals in lbs Compare to Appendix A List with Threshold Quantities (TQs)

The Requirements of the Standard - Hazard Determination

How to Calculate from Gallons to lbs?

Multiply the gallons of Liquid x 8.33 (How much a lb of water weighs) x Specific Gravity of Liquid = lbs of Liquid Example: Wt of 10,000 gallons of gasoline 10,000 x 8.33 x 0.739 = 61,559 lbs

The Requirements of the Standard - Hazard Determination

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

Example: Anhydrous Ammonia TQ = 10,000 lbs

If You Exceed the Threshold Quantity, You Have a Covered Process & Are Required to Comply

Toxicity Information
1910.119(d)(1)(i)

The Requirements of the Standard - Develop Toxicity Information

Obtain Toxicity Information on the Chemical(s) in the Process MSDS are Typical Resource You May Need Other References, NIOSH Pocket Guide, ACGIH TLVs

The Requirements of the Standard - Develop Toxicity Information

Toxicity Permissible Exposure Limits Physical Data Reactivity Data Corrosivity Data Thermal and Chemical Stability Data

Technology of the Process

1910.119(d)(2)

The Requirements of the Standard - Process Technology

Block flow diagram or process flow diagram Process chemistry Maximum intended inventory Upper and lower limits Consequences of deviations

The Requirements of the Standard - Process Equipment

Materials of construction Piping and instrument diagrams (P&IDs) Electrical classification Relief system design Ventilation system design Design codes Material and energy balances Safety systems

Block Diagram

P&ID

Equipment in the Process

1910.119(d)(3)

The Requirements of the Standard - Process Equipment

Now: Identify Each Piece of Equipment in the Covered Process by P&ID, Block Diagram and Number Them Remember - Must Follow Form Must be Able to Track Each Number Through the Entire Program

Block Diagram

P&ID

Process Equipment Numbering

Mechanical Integrity
1910.119(j)

The Requirements of the Standard - Process Equipment

Mechanical Integrity Certificates

Must be Obtained for Each Element of the Process Must be Marked with Numbering System that Follows Form

The Requirements of the Standard - Process Equipment

Mechanical Integrity Certificates Can Be:

ASME Certificates for Vessels Specification Sheets

Inspection & Testing

1910.119(j)(4)

The Requirements of the Standard - Process Equipment

Inspection/Testing/ Maintenance

System Must be Developed to Perform These Functions by Part and Critical System Must Follow Manufacturers Recommendations Must be Able to Track Equipment Inspected

Quality Assurance
1910.119(j)(6)

Quality Assurance

Construction & Equipment must be suitable for the process application for which they will be used. Appropriate checks and inspections to assure that equipment is installed properly and consistent with design specifications and the manufacturer's instructions. Maintenance materials, spare parts and equipment are suitable for the process application for which they will be used

Summary

Hazard Assessment & Equipment in the Process: Summary

Block Diagram Hazard Assessment (If over TQ, Must Proceed) Develop information the Equipment in the Process P&ID

Develop Toxicity Information on Chemical in Covered Process

Develop information on Technology of the Process

Obtain Mechanical Integrity Certificates

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

Develop Inspection/Testing/ Maitenance Procedures

Whats Next?

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