Process Safety Management

1
Process Safety Management
2
Session Objectives

• You will be able to
• Identify the dangers of highly hazardous
  chemicals in your facility
• Safely follow standard operating procedures
• Avoid or correct hazards and unsafe conditions
• Respond to emergencies

3
Dangers of Highly Hazardous Chemicals

• Millions of people live near chemical plants in
  the United States
• Bhopal, India1984
• Accidental releases can cause severe injury and
  death
• Poisoning
• Asphyxiation
• Internal or external burns

4
Dangers of Highly Hazardous Chemicals (cont.)

• 6,500 residents evacuated after ammonia release
• Propane gas-fueled explosion caused by unsafe
  conditions and inadequate employee training

Image Credit Chemical Safety Board (CSB)
5
Highly Hazardous Chemicals

• Toxic
• Reactive
• Flammable
• Explosive

6
Process Safety Management Overview

• Written safety information
• Written workplace hazard assessment
• Consultation with operators
• A system to respond to findings
• Periodic review of assessments and response
• Written operating procedures
• Safety training and operating information

7
Process Safety Management Overview (cont.)

• Information and training for contractors
• Emergency response training
• A quality assurance program
• Maintenance system
• Pre-startup safety reviews
• Documentation and verification of change
• Incident investigation and corrective action

8
Identify HazardsThe MSDS

• Toxicity
• Permissible exposure limit
• Physical data
• Reactivity
• Corrosivity
• Thermal and chemical stability
• Hazardous effects of inadvertent mixing of
  materials

9
Identify Hazards Equipment

• Sparks or electrical discharge from old or poorly
  maintained equipment
• Leaks or spills caused by
• Pump or compressor failures
• Loose valve connections
• Inadequate containment

10
PSM and Chemical HazardsAny Questions?

• Any questions about the process safety management
  program?
• Any questions about the hazards or dangers of
  chemicals?
• Any questions about hazards from equipment?

11
Chemical Exposure Precautions

• Administrative controls
• Engineering controls

12
Personal Protective Equipment (PPE)

• Always wear PPE appropriate to the task
• Ensure a good fit
• Inspect PPE before use
• Keep it clean
• Report defective equipment to your supervisor
• Never wear defective PPE

13
Operating Phases

• Initial start-up
• Normal operations
• Maintenance
• Temporary operations
• Normal shutdown
• Emergency shutdown
• Restart
• Site security

14
Initial Start-Up

• Check storage containers
• Conduct pressure test and leak check
• Inspect equipment

Image Credit Pacific Northwest National
Laboratory (PNNL)
15
Normal Operations Operating Limits

• Capacity
• Pressure
• Temperature
• Weather conditions

16
Normal Operations Loading and Unloading

• Notify management of suspicious shipment
• Verify tank trucks are grounded
• Inspect the tank
• Inspect all equipment before loading
• Verify container is safe for filling
• Verify truck electrical systems are off

17
Normal Operations Loading and Unloading (cont.)

• Use wheel chocks
• Check the compatibility of mixed loads
• Check the weight distribution of loads
• Verify that the cargo is properly secured
• Check the type, number, and stacking arrangement
  of load
• Conduct a walk-around inspection of transport
  vehicles

18
Normal Operations Segregation and Storage

• Never store incompatible chemicals together
• Segregate chemicals by hazard class
• Store flammable solvents in a flammable storage
  cabinet
• Store acids in their own storage cabinet
• Keep oxidizers away from organic materials
• Keep acids away from bases
• Keep cyanides and sulfides away from acids

19
MaintenanceGeneral Equipment

• Wear personal protective equipment
• Replace or repair defective or damaged power and
  hand tools
• Repair or replace damaged equipment (e.g.,
  meters, cathodic protection systems) showing
  signs of
• Leaks
• Corrosion
• Low pressure

20
MaintenanceContainers, Tanks, Foundations

• Inspect containers and tanks and repair
• Leaks
• Corrosion
• Check the condition of the foundation
• Replace footings
• Repair corrosion at container and masonry contact
  area

Image Credit Fermi National Accelerator
Laboratory (FNAL)
21
MaintenanceConnectors and Fittings

• Maintain and repair container connections
• Replace faulty flow and backflow check valves
• Abrasions or cuts on hoses
• Leaks
• Maintain and repair tank fittings
• Ensure that connectors, plugs, caps, and gaskets
  are in good condition

22
MaintenanceGauges and Pressure Valves

• Make sure equipment is shut down
• Repair or replace gauges
• Repair or replace pressure relief valves
• Ensure that emergency shut-off valves are in good
  condition

23
MaintenancePumps and Compressors

• Ensure that the motor is operating according to
  manufacturers specs
• Check all alignments to specification
• Ensure that oil systems are properly maintained
  on schedule
• Check all connections and terminals for tightness
  and contact
• Monitor fluid flow
• Tighten all electrical connections, measure
  voltage

24
MaintenanceHoses

• Ensure that hoses are operating at or below the
  rated working pressure
• Ensure that the overfill alarm and prevention
  device is functioning properly
• Protect hoses from severe end loads
• Check hoses for loose covers, kinks, or soft
  spots
• Replace hoses according to manufacturers
  specifications

25
MaintenanceElectrical Equipment

• Stop using and report
• Broken or missing equipment covers
• Damaged tools
• Damaged cords
• Any other damaged equipment

26
MaintenanceRemove Combustible Materials

• Keep combustibles at least 10 feet away from
  containers
• Weeds
• Grass
• Rags
• Paper
• Wood

27
Any Questions?

• Any questions about start up, normal operations,
  and any of the maintenance procedures?

28
Temporary Operations

• Conduct a pre-startup check
• Segregate incompatible containers

29
Normal Shutdown Procedures

• Check pressure relief systems

30
Emergency Shutdown

• Situations that trigger an emergency shutdown
  include
• Fire
• Leak
• Explosion
• Workplace violence

31
Emergency Shutdown Procedure

• Perform shutdown procedures only if not
  threatening to life or injury
• Evacuate the area
• Immediately report your shutdown actions

32
Restart

• Examine pressure vessels and storage tanks
• Examine insulation systems for piping, vessels,
  and tanks
• Examine drainage systems
• Examine electrical motors and drives
• Check valve positions

33
Restart (cont.)

• Examine all electrical equipment and wiring
  systems
• Make sure all warning systems are operational
• Check the integrity of all fire detection and
  suppression systems
• Ensure that emergency response equipment and
  systems are operational

34
Site Security

• Report
• Unlocked doors, gates, and storage areas
• Suspicious packages
• Suspicious activity
• Dont talk to outsiders about the facility
• Display your ID badge on company premises
• Secure hazardous materials

35
Site Security (cont.)

• Secure all valves and other fixtures when you are
  finished using them
• Verify the identity of cargo carriers and drivers
• Secure all rail, truck, and barge containers
• Verify all paperwork
• Handle pickups and deliveries only by appointment
  with known vendors

36
Operating Procedures Any Questions?

• Any questions about
• Procedures for safely handling chemicals or
  operating a chemical process?
• Temporary operations?
• Shutdown and restart procedures?
• Site security?

37
Consequences of Deviations

• Excess pressure accidental releases, leaks,
  fires, and explosions
• Container leaks poisoning, asphyxiation, burns,
  fires, and explosions

38
Consequences of Deviations (cont.)

• Damaged or faulty equipmentaccidental leaks,
  fires, and explosions
• Change in the processaccidental releases, leaks,
  fires, and explosions

Image Credit Chemical Safety Board (CSB)
39
Emergency Response Contacts

• Fire department
• Police department
• Ambulance
• Medical clinic or hospital
• Emergency coordinator

40
Respond to Chemical Spills

• Evacuate the area
• Notify a supervisor or the emergency response
  team
• Remove ignition sources if safe to do so

41
Evacuation Preparedness

• Keep fire exits clear
• Participate in drills and provide feedback
• Become familiar with evacuation coordinators and
  headcount personnel

42
Evacuation Procedures

• Recognize the evacuation signal and listen for
  instructions
• Shut down equipment using the emergency stop
• Go directly to the nearest safe exit
• Proceed to the assembly area

43
Rescue and Medical Treatment

• Leave rescue work to trained professionals
• Designated first-aid workers perform first aid
• Follow medical emergency procedures

44
Emergency Response Any Questions?

• Any questions about responding to emergencies?

45
Management of Change

• Technical basis for the proposed change
• Impact of the change on safety and health
• Modifications of the operating procedures
• Necessary time period for the change
• Authorization requirements for the change

46
Hot Work Permit

• Hot work operations can cause catastrophic
  accidents
• A hot work permit is required for all hot work
  operations

47
Lockout/Tagout

• Qualified persons only
• Prevent machinery or equipment from being turned
  on
• Prevent a part of machinery or equipment from
  moving
• Provide means of warning (tag)

48
Permit-Required Confined Space

• Contains or has potential to contain a hazardous
  atmosphere
• Contains the potential for engulfment
• Internal configuration that can trap or
  asphyxiate entrant
• Any other serious safety or health hazards

49
Incident Investigation Reports

• Date of incident
• Date investigation began
• Description of the incident
• Factors contributing to the incident
• Recommendations resulting from the investigation

50
Key Points to Remember

• Chemical process accidents can cause severe
  injury, death, and damage to property and the
  environment
• Read MSDSs for chemicals
• Follow operating and maintenance procedures
  without deviation
• Always watch for potential unsafe conditions
• Leaks, corrosion, faulty equipment, combustibles
  near chemical processes