Process_Safety_Management_Initial_Training.ppt

Process safety management

1. Process Safety Process Safety
ManagementManagement
Initial Initial
TrainingTraining

2. Highly Hazardous Highly Hazardous
Chemicals (HHCs)Chemicals (HHCs)

A HHC is any substance that is:A HHC is any substance that is:
•ToxicToxic
•ReactiveReactive
•FlammableFlammable
•ExplosiveExplosive
1a

3. 
Examples of HHCs include:Examples of HHCs include:
•Anhydrous ammoniaAnhydrous ammonia
•Hydrogen sulfideHydrogen sulfide
•ChlorineChlorine
1b
Highly Hazardous Highly Hazardous
Chemicals (HHCs)Chemicals (HHCs)

4. 
When released, HHCs have the When released, HHCs have the
potential to cause potential to cause
catastrophic catastrophic
incidents incidents
resulting in resulting in
injury/deathinjury/death
1c
Highly Hazardous Highly Hazardous
Chemicals (HHCs)Chemicals (HHCs)

5. Process technologyProcess technology

A comprehensive assessment of A comprehensive assessment of
a particular processa particular process

Materials used in the processMaterials used in the process

Complexity of the processComplexity of the process
2a

6. Process technologyProcess technology

Age of the processAge of the process

Past history of the processPast history of the process

Maximum inventory levels for Maximum inventory levels for
process chemicalsprocess chemicals
2b

7. Process technologyProcess technology

Extent of the process hazardsExtent of the process hazards

Number of potentially effected Number of potentially effected
employeesemployees
2c

8. Process equipmentProcess equipment

Use equipment adequate for the Use equipment adequate for the
tasks performedtasks performed

Materials of constructionMaterials of construction

Piping and instrument diagramsPiping and instrument diagrams
3a

9. Process equipmentProcess equipment

Electrical classificationElectrical classification

Relief system designRelief system design

Ventilation system designVentilation system design
3b

10. Process equipmentProcess equipment

Design codes and standardsDesign codes and standards

Safety systems, such as Safety systems, such as
interlocks, detection, interlocks, detection,
suppressionsuppression
3c

11. Operating proceduresOperating procedures

Provide clear instruction for Provide clear instruction for
safely conducting all safely conducting all
activities in a activities in a
processprocess
4a

12. Operating proceduresOperating procedures

Operating procedures must Operating procedures must
address the following:address the following:
•Operating limitsOperating limits
•Safety and health Safety and health
considerationsconsiderations
•Safety systems and Safety systems and
their functionstheir functions
4b

13. Operating procedures - Operating procedures -
phasesphases

Initial startupInitial startup

Normal operationsNormal operations

Temporary operationsTemporary operations

Emergency shutdownEmergency shutdown
4c

14. Operating procedures - Operating procedures -
phasesphases

Emergency operationsEmergency operations

Normal shutdownNormal shutdown

Startup following a turnaroundStartup following a turnaround

Startup following an emergency Startup following an emergency
shutdownshutdown
4d

15. Operating limitsOperating limits

Be aware of the operating limits Be aware of the operating limits
of a processof a process

Operating limits - related issues Operating limits - related issues
may include: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

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

17. Operating limitsOperating limits

Does the process cause the Does the process cause the
chemical to break down?chemical to break down?

Does the process cause the Does the process cause the
chemical to boil or freeze?chemical to boil or freeze?
5c

18. Safety and health Safety and health
considerationsconsiderations

Safety and health Safety and health
considerations include anything considerations include anything
that is likely to cause:that is likely to cause:
•Acute or chronic health problems; Acute or chronic health problems;
oror
•Process-related injuries or Process-related injuries or
accidentsaccidents
6a

19. Process safety systemsProcess safety systems

Provide information about safe Provide information about safe
work practiceswork practices

Necessary for controlling Necessary for controlling
hazards during process hazards during process
operationsoperations
7a

20. Process safety systemsProcess safety systems

Safety systems ensure that:Safety systems ensure that:
•All operating procedures reflect All operating procedures reflect
current operating practicescurrent operating practices
•Changes to processes resulting Changes to processes resulting
from changes in process from changes in process
chemicals are explained chemicals are explained
•Changes in technology, equipment, Changes in technology, equipment,
or the facility are communicatedor the facility are communicated
7b