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 (TQ’s)
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 TLV’s
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
Materials of
construction
construction
 Piping and
Piping and instrument
instrument
diagrams (P&ID’s)
diagrams (P&ID’s)
 Electrical classification
Electrical classification
 Relief system design
 Ventilation system
Ventilation system
design
 Design codes
Design codes
 Material and
Material and energy
energy
balances
balances
 Safety systems
Safety systems
Block Diagram
P&ID
Equipment in the Process

1910.119(d)(3)
The Requirements of the Standard
- Process Equipment
 Now:
Now:
 Identify Each
Identify Each Piece
Piece of
of
Equipment in
Equipment in the
the
Covered Process
Covered Process byby
P&ID, Block
P&ID, Block Diagram
Diagram
and Number Them
 Remember - Must
Follow Form
Follow Form
 Must be
Must be Able
Able to
to Track
Track
Each Number Through
the Entire
the Entire Program
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
Each Element of
of the
the
Process
Process
Must be
 Must be Marked
Marked with
with
Numbering System
Numbering System
that Follows
that Follows Form
Form
The Requirements of the Standard
- Process Equipment
 Mechanical Integrity
Certificates Can Be:
 ASME Certificates
ASME Certificates
for Vessels
Specification Sheets
 Specification Sheets
Inspection & Testing

1910.119(j)(4)
The Requirements of the Standard
- Process Equipment
 Inspection/Testing/
Maintenance
 System Must
System Must bebe
Developed to
Developed to
Perform These
Functions by Part
and Critical
and Critical System
System
 Must Follow
Manufacturer’s
Manufacturer’s
Recommendations
Recommendations
Must be
 Must be Able
Able toto
Track Equipment
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 P&ID
Hazard Develop
Assessment information the
(If over TQ, Must Equipment in the
Proceed) Process

Develop Toxicity
Information on Develop information
Chemical in on Technology of
the Process Obtain Mechanical
Covered Process
Integrity
Certificates

Remember: Must be Able to Develop

Inspection/Testing/
Track Equipment Throughout Maitenance
the Entire Program Procedures
What’s Next?

 In the Next Session,

we will Cover the
Critical Requirements
for Process Hazard
Analysis (PHA’s)