Presentation on theme: "1 BLRs Safety Training Presentations Process Safety Management of Highly Hazardous Chemicals 29 CFR 1910.119 (PSM)"— Presentation transcript:
1 BLRs Safety Training Presentations Process Safety Management of Highly Hazardous Chemicals 29 CFR (PSM)
2 Disasters That Led to Process Safety Management n Bhopal, India (1984) 2,000 deaths Isocyanate release n Pasadena, Tex. (1989) 23 deaths, 132 injuries Petroleum explosion n Cincinnati, Ohio (1990) 2 deaths Explosion n Sterlington, La. (1991) 8 deaths, 128 injuries Chemical release
3 Clean Air Act Amendments1990 n Required secretary of labor to promulgate a PSM standard n PSM standard must include a list of highly hazardous chemicals n Highly hazardous chemicals list must include: toxics, flammables, highly reactive and explosive materials n Required EPA to establish RMP standard
4 Minimum Program Requirements n Written safety information n Workplace hazard assessment n Consult with employees n Establish a system to respond to findings n Periodic review of assessments and response n Written operating procedures n Safety training and operating information
5 Minimum Program Requirements (cont.) n Appropriate information and training for contractors n Train and educate employees in emergency response n Establish a quality assurance program n Establish maintenance systems n Prestart-up safety reviews n Management of change n Incident investigation
6 Application of PSM n Companies that process highly hazardous materials n Flammable liquids and gases in quantities in excess of 10,000 pounds
7 Initial Process Hazard Analysis Deadlines n 25% complete by May 26, 1994 n 50% complete by May 26, 1995 n 75% complete by May 26, 1996 n 100% complete by May 26, 1997
8 Process Safety Information n Toxicity n Permissible Exposure Limits n Physical Data n Reactivity Data n Corrosivity Data n Thermal and Chemical Stability Data
9 Process Technology n Block flow diagram or process flow diagram n Process chemistry n Maximum intended inventory n Upper and lower limits n Consequences of deviations
10 Information on Process Equipment n Materials of construction n Piping and instrument diagrams (PIDs) n Electrical classification n Relief system design n Ventilation system design n Design codes n Material and energy balances n Safety systems
11 Items the PHA Must Address n Hazards of the process n Identification of previous incidents n Engineering and administrative controls n Consequences of failure n Facility siting n Human factors n Qualitative evaluation of safety and health effects
12 Operating Phases n Initial start-up n Normal operations n Temporary operations n Emergency shutdown n Emergency operations n Normal shutdown n Start-up following turnaround
13 Operating Limits n Consequences of deviation n Steps required to correct or avoid deviation
14 Safety and Health Considerations n Properties and hazards of the chemicals n Precautions to prevent exposures n Control measures to be taken n Quality control for raw materials/control of inventory n Special or unique hazards n Safety systems and their functions
15 Management of Change n Technical basis for the proposed change n Impact of the change on safety and health n Modifications of the operating procedures n Necessary time period for the change n Authorization requirements for the change
16 Training Requirements n Initial training Prior to work assignment Waved for those already in a process n Refresher training Every three years n Training documentation
17 Contractor Requirements n PSM applies to contractors in or adjacent to a process performing Maintenance Repair Turnaround Major renovation Specialty work n PSM does not apply to incidental contractors Food service Laundry Delivery, etc.
18 Incident Investigation Reports n Date of incident n Date investigation began n Description of the incident n Factors contributing to the incident n Recommendations resulting from the investigation
19 Quiz Review
20 Quiz 1.The PSM standard was drafted as a requirement of the Clean Air Act. True or False 2.The PSM program must include a list of highly hazardous chemicals. True or False 3.The initial start-up of a process is not included as an operating phase under the PSM standard. True or False 4.List three items that the process hazard analysis must address: ___________, __________, and __________. 5.PSM does not apply to contractors, regardless of the work they are doing. True or False
21 Quiz (cont.) 6.The PSM standard applies to companies that either process highly _____________ materials or use _____________ liquids and gases in excess of 10,000 pounds. 7.Process safety information includes: ______________, _____________, and _____________. 8.Fault tree analysis is one form of an approved method of performing a process hazard analysis. True or False 9.A technical basis is not required to change a process covered by the PSM standard. True or False 10.Two types of training required by the PSM standard are _____________ and _________________.
22 Quiz Answers 1.True. The PSM standard was drafted as a result of the Clean Air Act Amendments of True. 3.False. The initial start-up of a process is an operating phase that must be included. 4.The items that a process hazard analysis must address include hazards of the process, identification of previous accidents, engineering and administrative controls, consequences of failure, facility siting, human factors, and qualitative evaluation of S and H effects. 5.False. PSM does apply to contractors who work on or adjacent to a process.
23 Quiz Answers 1.True. The PSM standard was drafted as a result of the Clean Air Act Amendments of True. 3.False. The initial start-up of a process is an operating phase that must be included. 4.The items that a process hazard analysis must address include hazards of the process, identification of previous accidents, engineering and administrative controls, consequences of failure, facility siting, human factors, and qualitative evaluation of S and H effects. 5.False. PSM does apply to contractors who work on or adjacent to a process.