Professional Documents
Culture Documents
1/18/2013
Nypro UK
(a joint venture between Dutch State Mines and the British National Coal Board)
Flixborough, UK (1971)
Chemical Vapor Cloud Explosion 28 deaths 36 serious injuries Cause: Rupture of a bypass pipe, releasing 40 tonnes cyclohexane
ICMESA
(subsidiary of Hoffmann-LaRoche)
Source: Kleindorfer, P., Belke, J., Elliott, M., Lee, K., Lowe, R., Feldman, H.,"Accident Epidemiology & U.S. Chemical Industry: Accident History & Worst-Case Data from RMP*Info", Risk Analysis, Vol.23, No 4, 2003, pp 865-881.
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Excluded Hydrocarbon fuels used solely as a fuel Flammable liquids stored in unrefrigerated atmospheric tanks Retail Facilities Oil or gas well drilling or servicing operations Normally unoccupied remote facilities
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Mechanical Integrity Hot Work Permit System Management of Change Incident Investigation Emergency Planning and Response Compliance Audits Trade Secret Protections
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Imperial Sugar - 2008 BP Texas City TX -2005 Deepwater Horizon Spill2010 Offshore:
Julin City, China 2005 Toulouse, France 2001
1/18/2013
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Employee Participation
Written plan of action to insure employee participation Required to consult with employees and their representatives during:
Development of process hazard analysis Development of other elements of the standard
Must provide employees access to all information developed under the standard
Toxicity Permissible Exposure Limits Physical Data Reactivity Data Corrosivity Data Thermal & Chemical Stability Data Hazardous Effects of inadvertent mixing
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Block flow diagram or process flow diagram Process chemistry Maximum intended inventory Upper and lower limits Consequences of deviations
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PHA Requirements
Appropriate Methodologies What-if, Checklist, What-lf/checklist, Hazard and operability study (HAZOP), Failure mode and effects analysis (FMEA), Fault tree analysis, or An appropriate equivalent method Analysis Must Identify
The hazards of the process; The identification of any previous incident that had a potential for catastrophic consequences; Engineering and administrative controls applicable to the hazards; Consequences of failure of engineering and administrative controls; Facility siting; Human factors; A qualitative evaluation of a range of the possible safety and health effects on employees in the workplace if there is a failure of controls
Operating Procedures
A/K/A Standard Operating Procedures (SOPs) Employer must develop and implement written operating procedures that are clear instructions for all expected phases of operations. Must cover:
Operation phase Operational limits Safety & health considerations
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SOPs must be certified annually that they are correct and accurate.
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Training
Operator training specific to the process is required Must cover:
Safety and health hazards associated with the covered process Safe work practices
Refresher training is required every 3 years or as needed to ensure employees are complying with PSM requirements
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Contractors
Contractors involved in or around a covered process must be informed of required PSM elements. Contract work includes:
Maintenance and repair Turn around Major renovations Specialty knowledge or services
Does not include support services not involved with the covered process, like laundry or vending machine supply
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Mechanical Integrity
Change maintenance philosophy:
Reduce/eliminate BREAKDOWN maintenance Promote on-going equipment, piping, and instrument integrity philosophy
Ensures that process equipment is maintained to minimize the risk of hazardous releases. A strong mechanical integrity program and proper operations forms the first line of defense against accidental releases from process equipment
Hot Work
Hot Work is frequently the source of ignition at catastrophe sites Hot work Program:
Required to implement the fire prevention requirements of 1910.252(a)
Management of Change
Procedures to manage changes to the covered process.
Exception: replacement in kind
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Incident Investigations
Must be initiated within 48 hours of an incident Team must include:
Person knowledgeable in the process involved Other persons with appropriate knowledge of the covered process Contractor if work of the contractor involved
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System must be established to promptly address recommendations and findings of report Resolutions and corrective action must be documented
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Compliance Audit
To ensure that PSM is effective, employers must certify every 3 years that they have evaluated compliance with the standard
Must be completed by at least on person knowledgeable in the process Report must be developed and documented Deficiency corrections must be documented Last two compliance audits must be kept on file
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Employers must make all necessary information required to comply with PSM, regardless of trade secrets, available to persons involved in developing or creating:
Compiling process safety information PHAs SOPs Incident investigations Emergency planning and response Compliance audits
Trade Secrets
OSHA Website
www.osha.gov
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