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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