Course Material

1. Overview of Process Safety

2. Compliance with standards
3. Process Hazard Analysis
4. Standard Operating Procedures
5. Safe Work Procedures
6. Mechanical Integrity
7. Management of Change
8. Auditing Process Safety systems
9. Emergency response procedures
 Process Safety
Management for
Biofuels

5. Safe Work Procedures

29 CFR 1910.119 (f)(4)
This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health
Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S.
Department of Labor, nor does mention of trade names, commercial products, or organizations imply
endorsement by the U.S. Government.
 Process Safety
Management for
Biofuels

5. Safe Work Procedures

29 CFR 1910.119 (f)(4)
This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health
Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S.
Department of Labor, nor does mention of trade names, commercial products, or organizations imply
endorsement by the U.S. Government.
Piper Alpha Oil Platform
Explosion
Failure of Lock out / Tag out
Procedure
Permit-To-Work System

Safe Work Permit

Safe Work Procedures
Lock out / Tag out
Each Craft Should have
Their Own Lock
 Lock out / tag out

Safe Work Permit

OSHA 29 CFR 1910.147

 Try the Lock Out

OSHA 29 CFR 1910.147

 Additional
Information

Additional information on Lock out / Tag out

procedures can be found in the document
referenced in the below link.
 Hot Work Permit

29 CFR 1910.119 (k)

 Hot Work Permit
Requirements

OSHA 29 CFR
1910.252
Hot Work Permit Failure
 Closing the Permit
Joint inspection when the nonroutine work is complete
1. Valve alignment
2. Blinds removed
3. Sewer drains
reopened
4. Vents
5. Rotating equipment
6. Locks and tags
7. Utilities
8. Barricades removed
Confined Space Fatalities
CSB Bulletin
 Safe Work
Procedures

Confined Space Entry Permit

Permit-Required Confined Spaces (PRCS) standard 29 CFR 1910.146

http://www.osha.gov/
pls/oshaweb/
owadisp.show_documen
t?p_table=STANDARDS
 “Opening Process
Equipment” Fatalities

29 CFR 1910.119 (f)(4)

www.csb.gov
 “Opening Process
Equipment” Fatalities

29 CFR 1910.119 (f)(4)

www.csb.gov
BP Amoco Incident; Georgia; March, 2001
www.csb.gov

CSB Video on BP Amoco Incident

Can be viewed from video time 6:45 – 10:20
 BP Amoco Incident; Georgia; March, 2001
www.csb.gov

Fact: Three maintenance workers were fatally injured.

1. Why?
The workers were working on the “Polymer Catch Tank”.

The polymer catch tank was still pressurized.

The workers partially removed the cover.

 BP Amoco Incident; Georgia; March, 2001
www.csb.gov

Fact: The polymer catch tank was still pressurized

2. Why?
Loss of gas venting capability by catch tank.
Decomposition generating gas in core of vessel.
Pressure gauge was inoperative.
No de-energizing procedure for vessel.
 BP Amoco Incident; Georgia; March, 2001
www.csb.gov

Fact: There was no de-energizing procedure for tank.

3. Why?
Pressure gauge and drain used as indication of de-
energized status.
Process had been shut down, was not operative.
Outdated vessel cleaning procedure was being used.
 BP Amoco Incident; Georgia; March, 2001
www.csb.gov

Fact: Outdated vessel cleaning procedure was being

used.
4. Why?
Foaming of the polymer product was not well
understood by operations.

The plugging capacity of the foaming polymer

was not well understood by operations.
 BP Amoco Incident; Georgia; March, 2001
www.csb.gov

Foaming and plugging of product was not well

understood by operations.
5. Why?
Operations had not taken advantage of opportunities to
learn from near misses on product foaming and plugging.

Operations’ safe work procedures had not been

modified to consider foaming of polymer material.
 Applicability of
Previous Material
1. Overview of Process Safety
2. Compliance with standards
3. Process Hazard Analysis
4. Standard Operating Procedures
5. Safe Work Procedures
 
 Remaining Course
Material
1. Overview of Process Safety
2. Compliance with standards
3. Process Hazard Analysis
4. Standard Operating Procedures
5. Safe Work Procedures
6. Mechanical Integrity
7. Management of Change
8. Auditing Process Safety systems
9. Emergency response procedures