Process Safety Management of Highly Hazardous & Explosive Chemicals
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Transcript of Process Safety Management of Highly Hazardous & Explosive Chemicals
Process Safety Management of Highly Hazardous & Explosive Chemicals
Hazard Assessment & Equipment in the Hazard Assessment & Equipment in the ProcessProcess
Hazards of the Process
1910.119(d)(1)1910.119(d)(1)
The Requirements of the Standard - Hazard Determination
Determine:Determine:
Chemicals in Your ProcessChemicals in Your ProcessProcess ChemistryProcess ChemistryQuantity of Chemicals in lbsQuantity of Chemicals in lbsCompare to Appendix A List with Compare to Appendix A List with
Threshold Quantities (TQ’s)Threshold Quantities (TQ’s)
The Requirements of the Standard - Hazard Determination
How to Calculate from Gallons to lbs?How to Calculate from Gallons to lbs?
Multiply the gallons of LiquidMultiply the gallons of Liquid x 8.33 (How much a lb of water weighs) x x 8.33 (How much a lb of water weighs) x
Specific Gravity of Liquid = lbs of LiquidSpecific Gravity of Liquid = lbs of Liquid
Example: Wt of 10,000 gallons of gasolineExample: Wt of 10,000 gallons of gasoline10,000 x 8.33 x 0.739 = 61,559 lbs 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 Compare the lbs of Liquid or Gas to the Threshold Quantity in Appendix A of the Threshold Quantity in Appendix A of the StandardStandard
Example: Anhydrous AmmoniaExample: Anhydrous AmmoniaTQ = 10,000 lbsTQ = 10,000 lbs
If You Exceed the Threshold Quantity, You If You Exceed the Threshold Quantity, You Have a “Covered Process” & Are Required to Have a “Covered Process” & Are Required to ComplyComply
Toxicity Information
1910.119(d)(1)(i)1910.119(d)(1)(i)
The Requirements of the Standard - Develop Toxicity Information
Obtain Toxicity Obtain Toxicity Information on the Information on the Chemical(s) in the Chemical(s) in the ProcessProcess
MSDS are Typical MSDS are Typical ResourceResource
You May Need You May Need Other References, Other References, NIOSH Pocket NIOSH Pocket Guide, ACGIH TLV’sGuide, ACGIH TLV’s
ToxicityToxicity Permissible Permissible
Exposure LimitsExposure Limits Physical DataPhysical Data Reactivity DataReactivity Data Corrosivity DataCorrosivity Data Thermal and Thermal and
Chemical Chemical Stability DataStability Data
The Requirements of the Standard - Develop Toxicity Information
Technology of the Process
1910.119(d)(2)1910.119(d)(2)
The Requirements of the Standard - Process Technology
Block flow diagram Block flow diagram or process flow or process flow diagramdiagram
Process chemistryProcess chemistry Maximum intended Maximum intended
inventoryinventory Upper and lower Upper and lower
limitslimits Consequences of Consequences of
deviationsdeviations
The Requirements of the Standard - Process Equipment
Materials of constructionMaterials of construction Piping and instrument Piping and instrument
diagrams (P&ID’s)diagrams (P&ID’s) Electrical classificationElectrical classification Relief system designRelief system design Ventilation system Ventilation system
designdesign Design codesDesign codes Material and energy Material and energy
balancesbalances Safety systemsSafety systems
Block Diagram
P&ID
Equipment in the Process
1910.119(d)(3)1910.119(d)(3)
The Requirements of the Standard - Process Equipment
Now:Now: Identify Each Piece of Identify Each Piece of
Equipment in the Equipment in the Covered Process by Covered Process by P&ID, Block Diagram P&ID, Block Diagram and Number Themand Number Them
Remember - Must Remember - Must Follow Form Follow Form
Must be Able to Track Must be Able to Track Each Number Through Each Number Through the Entire Programthe Entire Program
Block Diagram
P&ID
Process Equipment Numbering
Mechanical Integrity
1910.119(j)1910.119(j)
Mechanical Integrity Mechanical Integrity CertificatesCertificates Must be Obtained for Must be Obtained for
Each Element of the Each Element of the ProcessProcess
Must be Marked with Must be Marked with Numbering System Numbering System that Follows Formthat Follows Form
The Requirements of the Standard - Process Equipment
Mechanical Integrity Mechanical Integrity Certificates Can Be:Certificates Can Be: ASME Certificates ASME Certificates
for Vesselsfor Vessels Specification SheetsSpecification Sheets
The Requirements of the Standard - Process Equipment
Inspection & Testing
1910.119(j)(4)1910.119(j)(4)
Inspection/Testing/ Inspection/Testing/ MaintenanceMaintenance System Must be System Must be
Developed to Developed to Perform These Perform These Functions by Part Functions by Part and Critical Systemand Critical System
Must Follow Must Follow Manufacturer’s Manufacturer’s RecommendationsRecommendations
Must be Able to Must be Able to Track Equipment Track Equipment InspectedInspected
The Requirements of the Standard - Process Equipment
Quality Assurance
1910.119(j)(6)1910.119(j)(6)
Quality Assurance
Construction & Equipment must be suitable Construction & Equipment must be suitable for the process application for which they will for the process application for which they will be used.be used.
Appropriate checks and inspections to assure Appropriate checks and inspections to assure that equipment is installed properly and that equipment is installed properly and consistent with design specifications and the consistent with design specifications and the manufacturer's instructions.manufacturer's instructions.
Maintenance materials, spare parts and Maintenance materials, spare parts and equipment are suitable for the process equipment are suitable for the process application for which they will be usedapplication for which they will be used
Summary
Hazard Assessment & Equipment in the Process: Summary
Hazard Assessment
(If over TQ, Must Proceed)
Develop Toxicity Information on Chemical in Covered Process
Develop information on Technology of the Process
Develop information the Equipment in the Process
Block Diagram P&ID
Obtain Mechanical Integrity Certificates
Develop Inspection/Testing/Maitenance Procedures
Remember: Must be Able to Track Equipment Throughout the Entire Program
What’s Next?
In the Next Session, In the Next Session, we will Cover the we will Cover the Critical Requirements Critical Requirements for Process Hazard for Process Hazard Analysis (PHA’s)Analysis (PHA’s)