Process Safety

Management
Initial
Training
Highly Hazardous
Chemicals (HHCs)
 A HHC is any substance that is:
• Toxic
• Reactive
• Flammable
• Explosive

1a
Highly Hazardous
Chemicals (HHCs)
 Examples of HHCs include:
• Anhydrous ammonia
• Hydrogen sulfide
• Chlorine

1b
Highly Hazardous
Chemicals (HHCs)
 When released, HHCs have the
potential to cause
catastrophic
incidents
resulting in
injury/death

1c
Process technology
 A comprehensive assessment of
a particular process

 Materials used in the process

 Complexity of the process

2a
Process technology
 Age of the process

 Past history of the process

 Maximum inventory levels for

process chemicals

2b
Process technology
 Extent of the process hazards

 Number of potentially effected

employees

2c
Process equipment
 Use equipment adequate for the
tasks performed

 Materials of construction

 Piping and instrument diagrams

3a
Process equipment
 Electrical classification

 Relief system design

 Ventilation system design

3b
Process equipment
 Design codes and standards

 Safety systems, such as

interlocks, detection,
suppression

3c
Operating procedures
 Provide clear instruction for
safely conducting all
activities in a
process

4a
Operating procedures
 Operating procedures must
address the following:
• Operating limits
• Safety and health
considerations
• Safety systems and
their functions

4b
Operating procedures -
phases
 Initial startup

 Normal operations

 Temporary operations

 Emergency shutdown
4c
Operating procedures -
phases
 Emergency operations

 Normal shutdown

 Startup following a turnaround

 Startup following an emergency

shutdown
4d
Operating limits
 Be aware of the operating limits
of a process

 Operating limits - related issues

may include:
• Voltage limits of the equipment
• Amperage limits of the equipment
• Phase limits of the equipment
5a
Operating limits
Questions regarding the process
chemical limits might include:
 Can the equipment handle the
properties of the chemical being
used in the process?

 Does the process maintain the

proper physical properties of the
chemical?

5b
Operating limits
 Does the process cause the
chemical to break down?

 Does the process cause the

chemical to boil or freeze?

5c
Safety and health
considerations
 Safety and health
considerations include anything
that is likely to cause:
• Acute or chronic health problems;
or
• Process-related injuries or
accidents

6a
Process safety systems
 Provide information about safe
work practices

 Necessary for controlling

hazards during process
operations

7a
Process safety systems
 Safety systems ensure that:
• All operating procedures reflect
current operating practices
• Changes to processes resulting
from changes in process
chemicals are explained
• Changes in technology, equipment,
or the facility are communicated

7b