Process Safety Management Initial Training

Highly Hazardous Chemicals (HHCs) v A HHC is any substance that is: ToxicToxic ReactiveReactive FlammableFlammable ExplosiveExplosive 1a

v Examples of HHCs include: Anhydrous ammoniaAnhydrous ammonia Hydrogen sulfideHydrogen sulfide ChlorineChlorine 1b Highly Hazardous Chemicals (HHCs)

v When released, HHCs have the potential to cause catastrophic incidents resulting in injury/death 1c Highly Hazardous Chemicals (HHCs)

Process technology v A comprehensive assessment of a particular process v Materials used in the process v Complexity of the process 2a

Process technology v Age of the process v Past history of the process v Maximum inventory levels for process chemicals 2b

Process technology v Extent of the process hazards v Number of potentially effected employees 2c

Process equipment v Use equipment adequate for the tasks performed v Materials of construction v Piping and instrument diagrams 3a

Process equipment v Electrical classification v Relief system design v Ventilation system design 3b

Process equipment v Design codes and standards v Safety systems, such as interlocks, detection, suppression 3c

Operating procedures v Provide clear instruction for safely conducting all activities in a process 4a

Operating procedures v Operating procedures must address the following: Operating limitsOperating limits Safety and health considerationsSafety and health considerations Safety systems and their functionsSafety systems and their functions 4b

Operating procedures - phases v Initial startup v Normal operations v Temporary operations v Emergency shutdown 4c

Operating procedures - phases v Emergency operations v Normal shutdown v Startup following a turnaround v Startup following an emergency shutdown 4d

Operating limits v Be aware of the operating limits of a process v Operating limits - related issues may include: Voltage limits of the equipmentVoltage limits of the equipment Amperage limits of the equipmentAmperage limits of the equipment Phase limits of the equipmentPhase limits of the equipment 5a

Operating limits Questions regarding the process chemical limits might include: v Can the equipment handle the properties of the chemical being used in the process? v Does the process maintain the proper physical properties of the chemical? 5b

Operating limits v Does the process cause the chemical to break down? v Does the process cause the chemical to boil or freeze? 5c

Safety and health considerations v Safety and health considerations include anything that is likely to cause: Acute or chronic health problems; orAcute or chronic health problems; or Process-related injuries or accidentsProcess-related injuries or accidents 6a

Process safety systems v Provide information about safe work practices v Necessary for controlling hazards during process operations 7a

Process safety systems v Safety systems ensure that: All operating procedures reflect current operating practicesAll operating procedures reflect current operating practices Changes to processes resulting from changes in process chemicals are explainedChanges to processes resulting from changes in process chemicals are explained Changes in technology, equipment, or the facility are communicatedChanges in technology, equipment, or the facility are communicated 7b