Process Safety Management Slide Show Notes Welcome to the training session on safely using, handling, moving, and storing highly hazardous chemicals. This training session is for employees and employees of contractors who work with processes that involve highly hazardous chemicals. It is designed for workplaces covered under Occupational Safety & Health Administration’s (OSHA) Process Safety Management Standard (29 CFR 1910.119). We will discuss the procedures for safely handling highly hazardous chemicals and operating a chemical process that involves such chemicals.

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 Slide Show Notes The overall goal of this training is to prevent serious chemical accidents that may cause injury to you and impact public health and the environment. By the end of the training session, you will be able to: Identify the dangers of highly hazardous chemicals present in your facility; Safely follow standard operating procedures; Avoid or correct hazards and unsafe conditions; and Respond to emergencies.

Dangers of Highly Hazardous Chemicals Millions of people live near chemical plants in the United States Bhopal, India—1984 Accidental releases can cause severe injury and death Poisoning Asphyxiation Internal or external burns Slide Show Notes What could happen at a facility that processes highly hazardous chemicals? According to the U.S. Environmental Protection Agency, or EPA, 123 chemical facilities in the United States could endanger millions of nearby residents should a catastrophic release of hazardous chemicals occur. More than 700 facilities could put at least 100,000 people at risk, and more than 3,000 facilities have at least 10,000 people nearby. The Bhopal incident of 1984, where a release of 40 tons of methyl isocyanate (MIC) initially killed 3,800 people, spurred Congress to enact legislation to regulate processes that use highly hazardous chemicals. Accidental releases have caused injuries and death to plant employees and the general public from: Poisoning; Asphyxiation; and Internal or external burns. Discuss with the participants the very real dangers associated with industrial chemical usage.

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 Slide Show Notes OSHA and other agencies have documented many incidences of accidental releases of dangerous and explosive chemicals at industrial facilities, large and small. These include: 6,500 residents of a town near a frozen pizza plant were evacuated after 45,000 pounds of ammonia were released, forming a cloud 24 city blocks long. Fifty residents were taken to hospitals. The release started at the plant when an end cap of a 16-inch suction line of the ammonia refrigeration system was knocked off. 33 people were killed and 69 injured at a propane gas distribution company when a propane gas-fueled explosion destroyed several buildings in a business district in Puerto Rico. A cracked propane pipe serving a restaurant was the source of propane fuel. The distribution company was charged with unsafe conditions and failure to strictly adhere to operating practices, and failure to provide adequate training to its employees. Minutes before the explosion, employees of the distribution company had inspected the pipe and found nothing wrong. Image Credit: Chemical Safety Board (CSB)

Highly Hazardous Chemicals Toxic Reactive Flammable Explosive Slide Show Notes It is important that you know about the highly hazardous chemicals used in our workplace. Hazardous chemicals may be: Toxic; Reactive; Flammable; and/or Explosive. Discuss the highly hazardous chemicals used in processes at your workplace, and describe some of the properties that make them so hazardous.

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 Slide Show Notes OSHA’s process safety management standard requires facilities that are operating processes with highly hazardous chemicals to have: Written safety information specific to the process; A written formal hazard assessment that looks at all potential hazards within the process; Consultation with operators on process hazards; Corrective action relative to findings; Reviews or audits using various groups to ensure that all aspects of the process are evaluated; Written operating procedures; and Training and operating information that is specific to the operation and not general in nature. Show your current written program to the class.

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 Slide Show Notes The Standard also requires: Information and training for contractors and their employees; An emergency response plan specific to chemical-related emergencies; A quality assurance system; A maintenance system to ensure system integrity; Pre-startup safety reviews; Documentation and verification of any change in a regulated process; and Incident investigation and corrective action.

Identify Hazards— The SDS Toxicity Permissible exposure limit Physical data Reactivity Corrosivity Thermal and chemical stability Hazardous effects of inadvertent mixing of materials Slide Show Notes The safety data sheet, or SDS, is essential for understanding the hazards of the chemicals involved in the processes you operate. An SDS can save your life. Make sure you read the following information on the SDS for each chemical used in the processes you operate: Toxicity; Permissible exposure limit; Physical data; Reactivity; Corrosivity; Thermal and chemical stability; and Hazardous effects of inadvertent mixing of materials. Have copies of the SDSs available for each chemical or chemical mixture used in the processes that will be operated or handled by participants.

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 Slide Show Notes It is important that you understand the hazards that equipment may pose to a potential accident at our workplace. Chemicals may be accidentally released or ignited as a result of: Sparks or electrical discharge from old or poorly maintained equipment; or Leaks or spills caused by: Pump or compressor failures; Loose valve connections; or Inadequate containment. Discuss the hazards that equipment may pose to a potential accident at your workplace.

PSM and Chemical Hazards—Any Questions? Any questions about the process safety management program? Any questions about the hazards or dangers of chemicals? Any questions about hazards from equipment? Slide Show Notes Do you understand our process management program, what it contains, and why it is needed? Do you understand the hazards or dangers of the chemicals used in our processes? Do you understand potential hazards from equipment? It is important for your safety and the safety of others that you understand our process safety management program.

Chemical Exposure Precautions Administrative controls Engineering controls Slide Show Notes Our workplace has specific chemical exposure precautions in place to ensure your safety. These include: Administrative controls; and Engineering controls. Discuss information about specific engineering controls at your facility such as automatic shutoff and administrative controls such as proper segregation and storage of chemical containers.

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 Slide Show Notes For PPE to do its job, it must be clean, in good condition, fit properly, and be appropriate for the hazard. Always wear PPE appropriate to the task; Ensure a good fit; Inspect PPE before use; Keep it clean; Report defective equipment to your supervisor; and Never wear defective PPE. Discuss the PPE available at your facility; show participants a PPE inventory and checklist. Provide PPE training with this lesson or during a separate training session.

Operating Phases Initial start-up Normal operations Maintenance Temporary operations Normal shutdown Emergency shutdown Restart Site security Slide Show Notes We will now discuss the following phases of our operations and how to work safety with them: Initial start-up; Normal operations; Maintenance Temporary operations; Normal shutdown Emergency shutdown Restart; and Site security.

Initial Start-Up Check storage containers Conduct pressure test and leak check Inspect equipment Slide Show Notes Before starting a chemical process or handling these chemicals, there are certain steps you must take: Check storage containers for leaks, corrosion, or other damage. Conduct pressure tests and leak checks on containers, connectors, valves, and processing equipment. And inspect all equipment before it is used to handle or process hazardous chemicals. This procedure will probably only apply to you if you only repackage or mix chemicals. If you handle the chemicals, as opposed to containers, this procedure must cover all the steps you need to take before you start a process for the first time. You should include all the steps needed to check out equipment as well as the steps needed to start the process itself. Also cover all the steps needed to inspect equipment. Image Credit: Pacific Northwest National Laboratory (PNNL)

Normal Operations— Operating Limits Capacity Pressure Temperature Weather conditions Slide Show Notes When operating a process with one or more highly hazardous chemicals, make sure the following factors that affect the process are within designated limits: The capacity of containers, tanks, process equipment, valves, connectors, and transfer equipment (for example, hoses); The pressure within containers, tanks, process equipment, and all other components of the process; The temperature of the process, equipment, and other components; and Weather conditions that may affect the process, such as storms. Distribute copies of the process operating instructions or procedures. Discuss the core procedures that you expect your operators to follow on a daily basis to run the processes safely. Use the following information to review safe operations for each process: A block-flow diagram or simplified process-flow diagram; Information on process chemistry; Maximum intended inventory of the EPA-regulated chemical; Safe upper and lower limits for such items as temperature, pressure, flows, or composition; and Steps to take should the limits be surpassed.

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 Slide Show Notes If you are responsible for loading and unloading highly hazardous chemicals, you should: Notify management if a suspicious shipment is offered. Verify that tank trucks are grounded. Inspect the tank for objects that are not bonded. Inspect valves, connections, emergency shutoff valves, and pipes. Verify that container is safe for filling. And verify that all truck electrical systems are off.

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 Slide Show Notes Before you load or unload highly hazardous chemicals: Use wheel chocks to prevent the vehicle from moving 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. And finally, for trucks, conduct a walk-around inspection before the vehicle is driven away.

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 Slide Show Notes When storing chemicals, it is important to: Never store incompatible chemicals together. Always consult the SDS to identify incompatible chemicals. Always segregate chemicals by hazard class. For example: Store flammable solvents in a flammable storage cabinet; non-flammable solvents may be stored in the same cabinet. Store acids in a separate storage cabinet. Keep oxidizers away from organic materials. Keep acids away from bases. And keep cyanides and sulfides away from acids. Demonstrate the importance of keeping incompatible chemicals separate. Mix some vinegar with baking soda (releases bubbles of carbon dioxide gas) to show that a reaction occurs when an acid and a base mix together.

Maintenance— General 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 Slide Show Notes When conducting repairs on any equipment, make sure you: Always wear personal protective equipment. Replace or repair defective or damaged power and hand tools. Repair or replace damaged processing equipment, such as meters or cathodic protection systems, that show signs of: Leaks, Corrosion, or Low pressure. Describe the procedures for maintaining the mechanical integrity of your process equipment. You may use procedures or instructions from equipment vendors, federal or state regulations, or industry codes as the basis of your maintenance program.

Maintenance—Containers, 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 Slide Show Notes Maintenance is important in keeping equipment running safely. You should regularly: Inspect containers and tanks and repair those that show signs of: Leaks or Corrosion. Check the condition of the foundation under containers and: Replace footings that are loose or crumbling; and Repair corrosion at the container and masonry contact area. Discuss facility-specific maintenance steps for containers, tanks, and foundations. Include the items that operators and handlers should look for on a daily basis to be sure that the equipment is running safely. Image Credit: Fermi National Accelerator Laboratory (FNAL)

Maintenance— Connectors and Fittings Maintain and repair container connections Replace faulty flow and backflow check valves Abrasions or cuts on hoses Leaks Slide Show Notes To ensure that equipment is kept in good condition: To maintain and repair container connections: Replace faulty flow and backflow check valves; Check for abrasions or cuts on hoses; and Check for leaks. Discuss facility-specific maintenance steps for connectors and fittings. Include the items that operators and handlers should look for on a daily basis to be sure that the equipment is running safely.

Maintenance—Gauges 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 Slide Show Notes Follow proper procedures when repairing or replacing gauges and pressures valves. Make sure the pressurized equipment you are working on is shut down and depressurized before beginning work. Repair or replace gauges. Repair or replace pressure relief valves. Finally, ensure that emergency shut-off valves are in good condition. Discuss facility-specific maintenance steps for gauges and pressure valves. Include the items that operators and handlers should look for on a daily basis to be sure that the equipment is running safely.

Maintenance— Pumps and Compressors Ensure that the motor is operating according to manufacturer’s 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 Slide Show Notes For a smooth operation: Ensure that the motor is operating according to the manufacturer’s specifications. Check temperature, operating speed, and so forth. Check all alignments to specification. Ensure that oil systems are properly maintained and that fluids, gaskets, and other contact parts are changed on schedule. Check all connections and terminals for tightness and contact. Monitor fluid flow. Finally, tighten all electrical connections, and measure the voltage and current. Discuss equipment-specific maintenance steps for pumps and compressors. Include the items that operators and handlers should look for on a daily basis to be sure that the equipment is running safely.

Maintenance—Hoses 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 manufacturer’s specifications Slide Show Notes 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. Finally, replace hoses according to manufacturer’s specifications. Discuss facility-specific maintenance steps for hoses and liquid transfer areas.

Maintenance— Electrical Equipment Stop using and report: Broken or missing equipment covers Damaged tools Damaged cords Any other damaged equipment Slide Show Notes Stop using and report to your supervisor: Any damaged electrical covers on electrical panels, junction boxes, and other equipment where live electrical parts and wiring may be exposed; Damaged tools that may expose live electrical parts and wiring to a person using them; Electrical cords, which are easily damaged, exposing live wires; and Any other damaged equipment. Discuss facility-specific maintenance steps for electrical equipment. Include the items that operators and handlers should look for on a daily basis to be sure that the equipment is running safely.

Maintenance—Remove Combustible Materials Keep combustibles at least 10 feet away from containers Weeds Grass Rags Paper Wood Slide Show Notes To prevent fire, keep combustibles at least 10 feet away from containers. Types of combustibles include: Weeds; Grass; Rags; Paper; and Wood. Discuss facility-specific maintenance requirements for combustibles.

Any Questions? Any questions about start up, normal operations, and any of the maintenance procedures? Slide Show Notes Do you understand initial start-up procedures, normal operations, and maintenance procedures related to chemical processes at our workplace? It is important for your safety and the safety of others that you understand the material presented so far. If you have any questions, ask your supervisor.

Temporary Operations Conduct a pre-startup check Segregate incompatible containers Slide Show Notes For temporary operations: Conduct pre-startup check, and Segregate incompatible containers. Discuss proper temporary procedures to follow when the regular process is down, or when additional capacity is needed for a limited period. Check your plan for the list of startup procedures for temporary operations at your facility; discuss.

Normal Shutdown Procedures Check pressure relief systems Slide Show Notes Make sure the pressure relief systems are functioning properly, and ensure that they are installed according to generally accepted good engineering practices. Check your written PSM plan for the list of normal shutdown procedures for your facility; discuss. Discuss all the steps needed to safely stop a process. For a complex process, or one that operates under extreme conditions, shutdown may take considerable time and may be hazardous. Discuss the complexities and hazards associated with normal shutdown of a covered process.

Emergency Shutdown Situations that trigger an emergency shutdown include: Fire Leak Explosion Workplace violence Slide Show Notes Situations that trigger an emergency shutdown include: Fire; Leak; Explosion; and Violence. Discuss the procedures that must be taken if the process must be shut down quickly. For warehouses: These procedures generally will apply only if you repackage regulated substances. If you do, these procedures cover the steps you need to take if you must shut down your process quickly. These procedures may be brief because shutting a process down may be no different in an emergency than in ordinary circumstances; you may simply shut off the flow or stop any unloading or loading.

Emergency Shutdown Procedure Perform shutdown procedures only if not threatening to life or injury Evacuate the area Immediately report your shutdown actions Slide Show Notes Follow these procedures during an emergency shutdown: Perform the shutdown procedures only if they do not threaten your life or possibly cause injury to yourself or others; Evacuate the area; and Immediately report your shutdown actions. Describe the specific emergency shutdown procedures for equipment and processes at your facility.

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 Slide Show Notes Before beginning restart operations: Examine pressure vessels and storage tanks; Examine insulation systems for piping, vessels, and tanks; Examine drainage systems; Examine electrical motors and drives; and Check valve positions. Describe the steps your workers should take during restart-up to ensure that the process can operate safely. Include the procedures outlined in the facility’s Pre-Startup Safety Review. Start-up after an emergency shutdown will generally require more checks to ensure that valves are in their proper start-up position and that they and other equipment are still functioning properly. Be sure to include these checkpoints in the discussion.

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 Slide Show Notes Before beginning start-up operations, you should also: Examine all electrical equipment and wiring systems; Make sure all warning systems are operational; Check the integrity of all fire detection and suppression systems; and Ensure that emergency response equipment and systems are operational.

Site Security Report Don’t talk to outsiders about the facility Unlocked doors, gates, and storage areas Suspicious packages Suspicious activity Don’t talk to outsiders about the facility Display your ID badge on company premises Secure hazardous materials Slide Show Notes Security is highly important at our facility, given the very real and present threats of sabotage and terrorism. Here are the procedures you must follow to protect yourself and our facility from these threats: Make sure all doors, gates, and storage areas are locked to access from outside the facility and sensitive work areas. Report: Any unlocked areas that should be secured; All suspicious packages; and Any suspicious incidents, cargo, or individuals. Don’t talk to outsiders about shipments, facilities, or any other security-related information. Display your ID badge at all times on company premises. Protect your ID badge outside of work so that it cannot be stolen, and never lend your badge to anyone—ever. And finally, secure hazardous materials in locked buildings or fenced areas, and sign keys out and back in. Describe the specific security procedures at your facility.

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 Slide Show Notes Secure all valves and other fixtures, such as hoses and connectors on transfer and transportation equipment, when not in use. Always verify the identity of carriers and drivers before loading a hazardous material. Ask drivers picking up or delivering material for photo identification and their commercial driver’s license. Compare with information provided by the carrier. Secure all rail, truck, and barge containers when stored at your location. Verify all paperwork. Finally, handle pickups and deliveries only by appointment with known vendors.

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? Slide Show Notes Do you understand the procedures for safely operating a chemical process or safely handling chemicals? Do you have any questions about temporary operations? Do you understand shutdown and restart procedures? Do you understand site security? It is important for your safety and the safety of others that you understand safe operating procedures and site security. .

Consequences of Deviations Excess pressure— accidental releases, leaks, fires, and explosions Container leaks— poisoning, asphyxiation, burns, fires, and explosions Slide Show Notes Here are some examples of the consequences of deviating from the chemical handling or processing procedures: Excess pressure in containers and equipment can lead to accidental releases, leaks, fires, and explosions. Container leaks can lead to poisoning, asphyxiation, burns, fires, and explosions. Discuss the consequences of deviations from proper procedures for the process, and the steps required to correct or avoid deviations. Your operating procedures should tell the workers what will happen if something starts to go wrong and should be consistent with the safety information you develop. For example, if the pressure in your storage tanks rises, your operator must know at what point higher pressure poses a hazard and the steps to take to address the problem. You should include this information in each of the other procedures (start-up, normal operations, shutdowns), rather than as separate documents.

Consequences of Deviations (cont.) Damaged or faulty equipment—accidental leaks, fires, and explosions Change in the process—accidental releases, leaks, fires, and explosions Slide Show Notes Damaged or faulty equipment can lead to accidental leaks, fires, and explosions. Any unauthorized change in the operating process or handling procedures can lead to accidental releases, leaks, fires, and explosions. Image Credit: Chemical Safety Board (CSB)

Emergency Response— Contacts Fire department Police department Ambulance Medical clinic or hospital Emergency coordinator Slide Show Notes Emergency phone numbers are readily available in our workplace. Make sure you know the procedure to follow in an emergency and where to find the numbers for: Fire, Police, Ambulance, Medical clinic or hospital, and The emergency coordinator. Tell trainees where they can find emergency notification numbers and describe the procedures for notification. If emergency response is provided by employees, discuss the facility’s emergency response plan. If emergency response is provided through contract services, discuss emergency contact and evacuation information.

Respond to Chemical Spills Evacuate the area Notify a supervisor or the emergency response team Remove ignition sources if safe to do so Slide Show Notes If a chemical spill occurs, don’t attempt to clean it up unless you’re part of an emergency response team. Immediately evacuate the area and help others get out, Notify a supervisor or the emergency response team, and Remove ignition sources only if it is safe to do so. Discuss your company’s specific emergency response plan and the procedures to spot a spill, report a spill, and evacuate. Describe the process for spotting a spill or leak, how to report it, and how to evacuate the area. Discuss what types of spills or leaks might occur at your company.

Evacuation Preparedness Keep fire exits clear Participate in drills and provide feedback Become familiar with evacuation coordinators and headcount personnel Slide Show Notes Evacuations are successful when you are prepared for them. It is essential to keep all fire exits clear. Regular drills will be conducted. It is important for you to provide feedback on drills when asked. Did you hear the alarm? Were exits clear? Are there any other important details? Make sure you know who the evacuation coordinators are, and respond to personnel responsible for accounting for everyone after the evacuation. Provide an evacuation map and go over the assembly areas with employees. If possible, insert a slide here with the map scanned in or a picture showing the assembly area.

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 Slide Show Notes Follow these steps during an evacuation: Recognize the evacuation signal and listen for instructions; Shut down equipment using the emergency stop; Go directly to the nearest safe exit; and Finally, proceed to the assembly area. Describe your workplace evacuation procedures.

Rescue and Medical Treatment Leave rescue work to trained professionals Designated first-aid workers perform first aid Follow medical emergency procedures Slide Show Notes If a worker is trapped or badly injured, leave the rescue work to trained and certified first responders. If you or a coworker is injured, only provide medical help for which you are trained. Whenever possible, alert designated first-aid providers or medical personnel to your needs or the needs of coworkers. Follow the company’s written medical emergency procedures. Describe your company’s medical emergencies procedures.

Emergency Response— Any Questions? Any questions about responding to emergencies? Slide Show Notes Now it is time to ask yourself if you understand how to respond to emergencies. It is important for your safety and the safety of others that you understand our workplace emergency procedures.

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 Slide Show Notes OSHA regulations require us to implement written procedures whenever changes occur that affect a process. If a process is regulated under the process safety management standard, we will justify and document any minor or typical change that affects the process. Documentation will verify whether the change will have an impact on your safety and health. We will tell you about any modifications to the operating procedures. We will let you know when and how long the change will take. No change will be implemented without the proper authorization of management officials. The authorization will not just be a management signature. The official signer of the change will be responsible for verifying that the change has been adequately implemented.

Hot Work Permit Hot work operations can cause catastrophic accidents A hot work permit is required for all hot work operations Slide Show Notes Hot work operations are a significant cause of catastrophic accidents involving highly hazardous chemicals and chemical processes. Hot work operations will be permitted only when a hot work permit has been issued for the operation.

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) Slide Show Notes It’s a qualified person’s job to know how to control hazardous energy. Here are some ways to do this: Only qualified persons may work on energized parts or equipment. First, follow lockout and tagout procedures—that is, use devices that prevent access to hazardous energy or that warn others to avoid it; Prevent machinery or equipment from being turned on during servicing and maintenance; Prevent parts of machinery and equipment from moving, usually by using locking devices; and Provide means of warning others, usually with warning tags, when it is not possible to lock out controls or parts. Have you ever been in a situation when a machine started up or an equipment part moved unexpectedly? It can be pretty frightening, and it shows why preventing it is so important. Discuss the types of equipment in your workplace that may need to be locked out.

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” Slide Show Notes A confined space requires a permit for entry by workers if any of these four conditions exist in the space: Hazardous atmospheres, including oxygen-deficient atmosphere, or toxic levels of chemical vapors. Engulfment hazards, including grain, sand, and water. Inwardly converging walls or other configuration that can trap or asphyxiate the entrant. Finally, “any other serious safety or health hazard” is the catchall phrase in the standard that prevents any dangerous confined spaces from slipping through unintended regulatory loopholes. Discuss confined spaces in your workplace that have at least one of these characteristics and that would require a permit. Bring a list of permit-required confined spaces that have been identified in your workplace.

Incident Investigation Reports Date of incident Date investigation began Description of the incident Factors contributing to the incident Recommendations resulting from the investigation Slide Show Notes The final element of an effective process safety management program is incident investigation. If the unfortunate incident does happen, the investigation is the key to providing lessons learned so that a recurrence can be avoided. Most safety professionals can use their standard accident investigation skills to handle a process safety management incident. It is important to document the incident as well as all corrective action planned as a result of the incident. Documentation should include: Date of incident; Date investigation began; Description of the incident; Factors contributing to the incident; and Recommendations resulting from the investigation.

Key Points to Remember Chemical process accidents can cause severe injury, death, and damage to property and the environment Read SDSs for chemicals Follow operating and maintenance procedures without deviation Always watch for potential unsafe conditions Leaks, corrosion, faulty equipment, combustibles near chemical processes Slide Show Notes Chemical process accidents can cause severe injury, death, and damage to property and the environment; Read SDSs for chemicals; Follow operating and maintenance procedures without deviation; and Always watch for potential unsafe conditions, such as: Leaks, corrosion, faulty equipment, and combustibles near chemical processes.