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BLR’s

Safety Training Presentations

Process Safety Management of Highly Hazardous Chemicals 29 CFR 1910.119

(PSM)

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Disasters That Led to

Process Safety Management Bhopal, India (1984)

2,000 deaths Isocyanate release

Pasadena, Tex. (1989) 23 deaths, 132 injuries

Petroleum explosion Cincinnati, Ohio (1990)

2 deaths Explosion

Sterlington, La. (1991) 8 deaths, 128 injuries

Chemical release

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Clean Air Act

Amendments—1990 Required secretary of labor to promulgate a PSM

standard

PSM standard must include a list of highly hazardous chemicals

Highly hazardous chemicals list must include: toxics, flammables, highly reactive and explosive materials

Required EPA to establish RMP standard

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Minimum Program Requirements

Written safety information

Workplace hazard assessment

Consult with employees

Establish a system to respond to findings

Periodic review of assessments and response

Written operating procedures

Safety training and operating information

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Minimum Program Requirements (cont.)

Appropriate information and training for contractors

Train and educate employees in emergency response

Establish a quality assurance program

Establish maintenance systems

Prestart-up safety reviews

Management of change

Incident investigation

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Application of PSM

Companies that process highly hazardous materials

Flammable liquids and gases in quantities in excess of 10,000 pounds

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Initial Process

Hazard Analysis Deadlines 25% complete by May 26, 1994

50% complete by May 26, 1995

75% complete by May 26, 1996

100% complete by May 26, 1997

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Process Safety Information

Toxicity

Permissible Exposure Limits

Physical Data

Reactivity Data

Corrosivity Data

Thermal and Chemical Stability Data

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Process Technology

Block flow diagram or process flow diagram

Process chemistry

Maximum intended inventory

Upper and lower limits

Consequences of deviations

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Information on

Process Equipment Materials of construction

Piping and instrument diagrams (PIDs)

Electrical classification

Relief system design

Ventilation system design

Design codes

Material and energy balances

Safety systems

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Items the PHA Must Address

Hazards of the process

Identification of previous incidents

Engineering and administrative controls

Consequences of failure

Facility siting

Human factors

Qualitative evaluation of safety and health effects

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Operating Phases

Initial start-up

Normal operations

Temporary operations

Emergency shutdown

Emergency operations

Normal shutdown

Start-up following turnaround

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Operating Limits

Consequences of deviation

Steps required to correct or avoid deviation

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Safety and Health Considerations

Properties and hazards of the chemicals

Precautions to prevent exposures

Control measures to be taken

Quality control for raw materials/control of inventory

Special or unique hazards

Safety systems and their functions

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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

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Training Requirements

Initial training Prior to work

assignment Waved for those

already in a process

Refresher training Every three years

Training documentation

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Contractor Requirements

PSM applies to contractors in or adjacent to a process performing Maintenance Repair Turnaround Major renovation Specialty work

PSM does not apply to incidental contractors Food service Laundry Delivery, etc.

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Incident Investigation Reports

Date of incident

Date investigation began

Description of the incident

Factors contributing to the incident

Recommendations resulting from the investigation

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Quiz Review

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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

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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 _________________.

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Quiz Answers

1. True. The PSM standard was drafted as a result of the Clean Air Act Amendments of 1990.

2. 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.

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Quiz Answers

1. True. The PSM standard was drafted as a result of the Clean Air Act Amendments of 1990.

2. 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.

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Training