Process Safety Management

of Highly Hazardous &

Explosive Chemicals

Hazard Assessment & Equipment in the

Process

Hazards of the Process

1910.119(d)(1)

The Requirements of the

Standard - Hazard Determination
Determine:
Chemicals in Your Process
Process Chemistry
Quantity of Chemicals in lbs
Compare to Appendix A List with
Threshold Quantities (TQs)

The Requirements of the Standard

- Hazard Determination

How to Calculate from Gallons to lbs?

Multiply the gallons of Liquid

x 8.33 (How much a lb of water weighs) x
Specific Gravity of Liquid = lbs of Liquid
Example: Wt of 10,000 gallons of gasoline
10,000 x 8.33 x 0.739 = 61,559 lbs

The Requirements of the

Standard - Hazard Determination

Compare the lbs of Liquid or Gas to the

Threshold Quantity in Appendix A of the
Standard

Example: Anhydrous Ammonia

TQ = 10,000 lbs
If You Exceed the Threshold Quantity, You
Have a Covered Process & Are Required to
Comply

Toxicity Information
1910.119(d)(1)(i)

The Requirements of the Standard

- Develop Toxicity Information

Obtain Toxicity
Information on the
Chemical(s) in the
Process
MSDS are Typical
Resource
You May Need
Other References,
NIOSH Pocket
Guide, ACGIH TLVs

The Requirements of the Standard

- Develop Toxicity Information

Toxicity
Permissible
Exposure Limits
Physical Data
Reactivity Data
Corrosivity Data
Thermal and
Chemical
Stability Data

Technology of the Process

1910.119(d)(2)

The Requirements of the Standard

- Process Technology

Block flow diagram

or process flow
diagram
Process chemistry
Maximum intended
inventory
Upper and lower
limits
Consequences of
deviations

The Requirements of the

Standard - Process Equipment

Materials of
construction
Piping and instrument
diagrams (P&IDs)
Electrical classification
Relief system design
Ventilation system
design
Design codes
Material and energy
balances
Safety systems

Block Diagram

P&ID

Equipment in the Process

1910.119(d)(3)

The Requirements of the Standard

- Process Equipment

Now:
Identify Each Piece of
Equipment in the
Covered Process by
P&ID, Block Diagram
and Number Them
Remember - Must
Follow Form
Must be Able to Track
Each Number Through
the Entire Program

Block Diagram

P&ID

Process Equipment
Numbering

Mechanical Integrity
1910.119(j)

The Requirements of the Standard

- Process Equipment

Mechanical Integrity
Certificates

Must be Obtained for

Each Element of the
Process
Must be Marked with
Numbering System
that Follows Form

The Requirements of the Standard

- Process Equipment

Mechanical Integrity
Certificates Can Be:

ASME Certificates
for Vessels
Specification Sheets

Inspection & Testing

1910.119(j)(4)

The Requirements of the Standard

- Process Equipment

Inspection/Testing/
Maintenance

System Must be
Developed to
Perform These
Functions by Part
and Critical System
Must Follow
Manufacturers
Recommendations
Must be Able to
Track Equipment
Inspected

Quality Assurance
1910.119(j)(6)

Quality Assurance

Construction & Equipment must be suitable

for the process application for which they will
be used.
Appropriate checks and inspections to assure
that equipment is installed properly and
consistent with design specifications and the
manufacturer's instructions.
Maintenance materials, spare parts and
equipment are suitable for the process
application for which they will be used

Summary

Hazard Assessment & Equipment

in the Process: Summary
Block Diagram
Hazard
Assessment
(If over TQ, Must
Proceed)

Develop Toxicity
Information on
Chemical in
Covered Process

P&ID

Develop
information the
Equipment in the
Process

Develop information
on Technology of the
Process

Remember: Must be Able to

Track Equipment Throughout
the Entire Program

Obtain Mechanical
Integrity Certificates

Develop
Inspection/Testing/
Maitenance
Procedures

Whats Next?

In the Next Session,

we will Cover the
Critical Requirements
for Process Hazard
Analysis (PHAs)