Process Safety Management of Highly Hazardous & Explosive Chemicals

1. Process Safety Management of Highly Hazardous & Explosive Chemicals Hazard Assessment & Equipment in the Process

2. Hazards of the Process 1910.119(d)(1)

3. 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)

4. 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

5. 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

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

7. 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

9. The Requirements of the Standard - Develop Toxicity Information • Toxicity • Permissible Exposure Limits • Physical Data • Reactivity Data • Corrosivity Data • Thermal and Chemical Stability Data

11. Technology of the Process 1910.119(d)(2)

12. 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

14. The Requirements of the Standard - Process Equipment • Materials of construction • Piping and instrument diagrams (P&ID’s) • Electrical classification • Relief system design • Ventilation system design • Design codes • Material and energy balances • Safety systems

15. Block Diagram

16. P&ID

17. Equipment in the Process 1910.119(d)(3)

18. 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

19. Block Diagram

20. P&ID

21. Process Equipment Numbering

22. Mechanical Integrity 1910.119(j)

23. 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

24. The Requirements of the Standard - Process Equipment • Mechanical Integrity Certificates Can Be: • ASME Certificates for Vessels • Specification Sheets

25. Inspection & Testing 1910.119(j)(4)

26. 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 Manufacturer’s Recommendations • Must be Able to Track Equipment Inspected

27. Quality Assurance 1910.119(j)(6)

28. 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

29. Summary

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

31. What’s Next? • In the Next Session, we will Cover the Critical Requirements for Process Hazard Analysis (PHA’s)