Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe work Procedures 6.Mechanical Integrity 7.Management of Change 8.Auditing Process Safety systems 9.Emergency response procedures

3. Process Hazard Analysis Process Safety Management for Biofuels This material was produced under grant SH F-36 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government. Identification of individual hazards of a system, Determination of undesired events, and Evaluation of the consequences

Concept Sciences Explosion, ( (

Ref: Guidelines for Hazard Evaluation Procedures, 3 rd edition, © 2008 by American Institute of Chemical Engineers Hazards Deviation PreventiveMitigative Regain control or shut down safeguards Containment and controlsafeguards Unmitigated Impacts Mitigated Loss event

PHA Regulatory Requirement 29CFR (e) (2)

The employer shall use one or more of the following methodologies that are appropriate to determine and evaluate the hazards of the process being analyzed. (i) What-If; (ii) Checklist; (iii) What-If/Checklist (continued on next two slides)

29CFR (e) (2) (iv) Hazard and Operability Study (HAZOP): (v) Failure Mode and Effects Analysis (FMEA); (vi) Fault Tree Analysis; or (continued on next slide)

29CFR (e) (2) (vi) Fault Tree Analysis; or (vii) An appropriate equivalent methodology For more information: OSHA CCPS

Process Safety Information 1.Hazards of the process 2.Chemicals used or produced 3.Technology of the process 4.Equipment in the process

1. Hazards of the Process Previous incidents Engineering and administrative controls Consequence of failure of controls Facility Siting Human factors CSB Video on Texas City: CSB.govCSB.gov

2. Chemicals in the Process Toxicity PEL Reactivity Corrosivity data Chemical stability Inadvertent mixing NOAA chemical reactivity worksheet

3. Technology of the Process Process flow diagram Chemistry Inventory Safe operating limits Consequences of deviation 29CFR (d)

4. Equipment in the Process

A PHA is a Team Effort

PHA Team Training MemberRequirements LeaderSend to training or hire consultant Plant expertise Plant operator Process expertiseProcess Engineer EquipmentEngineer and maintenance “Scribe”Technical and previous PHA team experience

Is Risk Tolerable? Estimate Risk Evaluate ConsequencesEvaluate Likelihood Identify Failure Modes EquipmentHuman Identify “Hazard of Interest” ProcessChemicalsEquipment

ItemDeviationCauseConsequenceSafeguardsRecommendatio n 1.Corn dust release Leak in system Corn dust explosion Daily maintenance Put corn dryer on M.I. schedule Record of PHA Team Discussion Plant LocationUnitPHA TeamDate Anywhere, USACorn DryerAnn Engineer H. Maintenance Wise Operator PHA Guru 1/1/2012 Notes: M.I. = Mechanical Integrity

Human Error People make misteaks! Calling a telephone number Making a PowerPoint Slide Typing a note Stopping at a red traffic light or Stop sign

Is the Risk Tolerable? YES Maintain Risk Controls Propose Risk Reduction No

Is Risk Tolerable? Estimate Risk Evaluate ConsequencesEvaluate Likelihood Identify Failure Modes EquipmentHuman Identify “Hazard of Interest” ProcessChemicalsEquipment Iterate back to “Identify Failure Mode”

Action ItemPerson Assigned Due Date Date Completed Comments Put corn dryer on M.I. list to prevent corn dust releases M.I. specialist 4/15/104/13/10Daily inspection by Ima Maintenance or designee; checklist PHA Action Item List Plant LocationUnitPHA TeamDate Anywhere, USACorn DryerAnn Engineer H. Maintenance Wise Operator PHA Specialist 4/09/’10

PHA Frequency Every time there is a significant process change. A minimum of every 5 years.

Retention Policy Retain PHA records for the life of the process, regardless of your company’s record retention policy. 29CFR (e)(7)

What-If/Checklist Click the soybeans to go to a partial list of “What-If” questions for biodiesel. Click the corn to go to a partial list of “What- If” questions for bioethanol.

Remaining Course Material 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe work Procedures 6.Mechanical Integrity 7.Management of Change 8.Auditing Process Safety systems 9.Emergency response procedures