Process Safety Management of Highly Hazardous & Explosive Chemicals. Safe Work Practices

Full text

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Process Safety Management

of Highly Hazardous &

Explosive Chemicals

Process Safety Management

of Highly Hazardous &

Explosive Chemicals

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Safe Work Practices

Safe Work Practices

1910.119(f)(1)

The employer shall develop and implement safe work practices to provide for the control

of hazards during operations such as

lockout/tagout; confined space entry; opening process equipment or piping; and control over

entrance into a facility by maintenance, contractor, laboratory, or other support personnel. These safe work practices shall

apply to employees and contractor employees.

1910.119(f)(1)

The employer shall develop and implement safe work practices to provide for the control

of hazards during operations such as

lockout/tagout; confined space entry; opening process equipment or piping; and control over

entrance into a facility by maintenance, contractor, laboratory, or other support personnel. These safe work practices shall

apply to employees and contractor employees.

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Safe Work Practices

Safe Work Practices

Are They Really Important

Video…

Are They Really Important

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•Develop and implement safe work practices* to provide for the control of hazards during operations such as:

–Lockout/tagout;

–Confined space entry;

–Line Opening process equipment or piping; and

–Control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel

Safe Work Practices

Safe Work Practices

(5)

Safe Work Practices

Safe Work Practices

Safe Work Practices, Programs &

Procedures must:

Be specific to the Covered Process

Follow Procedures & Recommendations in

the PHA’s

Follow Procedures in the Operating

Procedures

Must be Able to be Tracked

Follow Form

Safe Work Practices, Programs &

Procedures must:

Be specific to the Covered Process

Follow Procedures & Recommendations in

the PHA’s

Follow Procedures in the Operating

Procedures

Must be Able to be Tracked

Follow Form

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First,

How do We Control Who Enters the

Covered Process?

What Type of Security Controls are in

Place

What Training is Required Before Entry?

First,

How do We Control Who Enters the

Covered Process?

What Type of Security Controls are in

Place

What Training is Required Before Entry?

Safe Work Practices

Control Over Entrance into the Facility

Safe Work Practices

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Remember

 ” and control over

entrance into a facility by maintenance,

contractor, laboratory, or other support

personnel” 

Remember

 ” and control over

entrance into a facility by maintenance,

contractor, laboratory, or other support

personnel”

Safe Work Practices

Control Over Entrance into the Facility

Safe Work Practices

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NASA Security Gate

& Why…

NASA Security Gate

& Why…

Safe Work Practices

Control Over Entrance into the Facility

Safe Work Practices

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Safe Work Practices

General Hazardous Materials &

Fire Prevention

Safe Work Practices

General Hazardous Materials &

Fire Prevention

 Many Times, when

covered process hazards include flammable liquids or gases, the control of ignition sources becomes critical. This may require testing of the atmosphere before any device not

deemed “intrinsically

safe” are introduced into the covered process area

 Many Times, when

covered process hazards include flammable liquids or gases, the control of ignition sources becomes critical. This may require testing of the atmosphere before any device not

deemed “intrinsically

safe” are introduced into the covered process area

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Safe Work Practices

General Hazardous Materials & Fire Prevention

Safe Work Practices

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Simple Safety

Procedures that

Become Critical Near

a Covered Process

Such as Cylinder

Storage

Simple Safety

Procedures that

Become Critical Near

a Covered Process

Such as Cylinder

Storage

Safe Work Practices

General Hazardous Materials & Fire Prevention

Safe Work Practices

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Ensuring the Correct

Gas is Marked &

Secured

Ensuring the Correct

Gas is Marked &

Secured

Safe Work Practices

General Hazardous Materials & Fire Prevention

Safe Work Practices

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And A Procedure for

Marking Historical

Areas of Minor Gas

Leaks

And A Procedure for

Marking Historical

Areas of Minor Gas

Leaks

Safe Work Practices

General Hazardous Materials & Fire Prevention

Safe Work Practices

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Lockout Tagout - One of the Most

Important Procedures in PSM

Must be Written Carefully & Follow all

Procedures (PHA’s, Operating

Procedures)

Must be Followed to the Letter!

Lockout Tagout - One of the Most

Important Procedures in PSM

Must be Written Carefully & Follow all

Procedures (PHA’s, Operating

Procedures)

Must be Followed to the Letter!

Safe Work Practices

The Control of Hazardous Energy - Lockout Tagout

Safe Work Practices

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Lockout/Tagout in PSM

 Why not Use Digital Imaging in Your

Procedures to Identify Critical Lockout /Tagout Positions

Lockout/Tagout in PSM

 Why not Use Digital

Imaging in Your

Procedures to Identify Critical Lockout /Tagout Positions

Safe Work Practices

The Control of Hazardous Energy - Lockout Tagout

Safe Work Practices

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The Mirror Standard

to Lockout Tagout

No Mistakes Allowed

Here

Must be Specific to

the Covered Process

The Mirror Standard

to Lockout Tagout

No Mistakes Allowed

Here

Must be Specific to

the Covered Process

Safe Work Practices

Permit Confined Space Entry Program

Safe Work Practices

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 A Confined Space is

Defined as A Space That :  Has limited or restricted

means of entry or exit  Is large enough for an

employee to enter and perform assigned work,

and

 Is not designed for

continuous occupancy by the employee.

 A Confined Space is

Defined as A Space That :

 Has limited or restricted

means of entry or exit

 Is large enough for an

employee to enter and perform assigned work,

and

 Is not designed for

continuous occupancy by the employee.

Safe Work Practices

Permit Confined Space Entry Program

Safe Work Practices

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A Permitted Confined

Space is A Confined

Space with a Serious

Hazard of Any Kind

Or a Space That a

Serious Hazard of

Any Kind is

Introduced into the

Space

A Permitted Confined

Space is A Confined

Space with a Serious

Hazard of Any Kind

Or a Space That a

Serious Hazard of

Any Kind is

Introduced into the

Space

Safe Work Practices

Permit Confined Space Entry Program

Safe Work Practices

Permit Confined Space Entry Program

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 Program Element Summary:

 Written Program  Worksite Hazard

Evaluation

 Marking of Permit Spaces  Space Specific Entry

Procedures

 Entry Permit Procedure  Training  Demonstration of Competency  Rescue Procedures  Periodic Inspections  Program Element Summary:  Written Program  Worksite Hazard Evaluation

 Marking of Permit Spaces  Space Specific Entry

Procedures

 Entry Permit Procedure  Training

 Demonstration of

Competency

 Rescue Procedures  Periodic Inspections

Safe Work Practices

Permit Confined Space Entry Program

Safe Work Practices

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 A Hazard Review Must Completed for All Line/Equipment Hazards Including:

HAZARDOUS MATERIALS IN SYSTEMPOTENTIAL PHYSICAL HAZARDS

BARRICADING AS REQUIRED FIRST AID IF EXPOSED

LOCATION OF SAFETY EQUIPMENTPPE REQUIRED FOR LINE OPENING

 A Hazard Review Must Completed for All

Line/Equipment Hazards Including:

HAZARDOUS MATERIALS IN SYSTEMPOTENTIAL PHYSICAL HAZARDS

BARRICADING AS REQUIRED FIRST AID IF EXPOSED

LOCATION OF SAFETY EQUIPMENTPPE REQUIRED FOR LINE OPENING

Safe Work Practices

Line Opening or Breaking Procedures

Safe Work Practices

(23)

Special PPE may

Required

 Example - NASA Hydrogen Gas & Nitrogen High

Pressure Gas Plant  Cryogenic Gas

Special PPE may

Required

 Example - NASA

Hydrogen Gas & Nitrogen High

Pressure Gas Plant

 Cryogenic Gas

Safe Work Practices

Line Opening or Breaking Procedures

Safe Work Practices

Line Opening or Breaking Procedures

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Safe Work Practices

Line Opening or Breaking Procedures

Safe Work Practices

Line Opening or Breaking Procedures

 Cryogenic Protective Footwear  Hardhat  Face shield  Safety Glasses  Protective Clothing  Special Gloves  Cryogenic Protective Footwear  Hardhat  Face shield  Safety Glasses  Protective Clothing  Special Gloves

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LOP Program May Take the Form of Many

Types

A Combination of Written Procedures and

Graphic Illustrations Work Well

Let’s review an example…

LOP Program May Take the Form of Many

Types

A Combination of Written Procedures and

Graphic Illustrations Work Well

Let’s review an example…

Safe Work Practices

Line Opening or Breaking Procedures

Safe Work Practices

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Line Opening Permits

 Identify Procedures for Opening any Process Line in a Covered

Process

 Must Include Hazards of the Line Opening  PPE Required

Line Opening Permits

 Identify Procedures for

Opening any Process Line in a Covered

Process

 Must Include Hazards

of the Line Opening

 PPE Required

(30)

Safe Work Practices

Hot Work Program

Safe Work Practices

(31)

Hot Work is any work involving burning, welding,

or similar operations that are capable of initiating

fires or explosions. This program shall cover the

following hot work processes:

 Welding and Allied Processes  Heat Treating

 Grinding

 Thawing Pipe

 Powder-Driven Fasteners  Hot Riveting

 Any Other Spark, Flame or Heat

Hot Work is any work involving burning, welding,

or similar operations that are capable of initiating

fires or explosions. This program shall cover the

following hot work processes:

 Welding and Allied Processes  Heat Treating

 Grinding

 Thawing Pipe

 Powder-Driven Fasteners  Hot Riveting

 Any Other Spark, Flame or Heat

Safe Work Practices

Hot Work Program

Safe Work Practices

(32)

Management Responsibilities

 providing employees with adequate training including the inherent risks involved, the emergency

procedures in the event of a fire, instructions on all equipment and processes, as well as the provisions of this program

 recognizing responsibility for the safe usage of cutting and welding equipment on Covered Process

Equipment and ensuring only approved equipment is used

Management Responsibilities

 providing employees with adequate training including the inherent risks involved, the emergency

procedures in the event of a fire, instructions on all equipment and processes, as well as the provisions of this program

recognizing responsibility for the safe usage of cutting

and welding equipment on Covered Process

Equipment and ensuring only approved equipment is used

Safe Work Practices

Hot Work Program

Safe Work Practices

(33)

Remember…Hot

Work Program Could

be Used to Control

the Introduction of

Non-Intrinsically Safe

Devices into a

Covered Process

Remember…Hot

Work Program Could

be Used to Control

the Introduction of

Non-Intrinsically Safe

Devices into a

Covered Process

Safe Work Practices

Hot Work Program

Safe Work Practices

(34)

Controlling all Other

Ignitions Sources is

also Difficult Such As:

 Electrical

 Static Electricity  Lightning

 Truck/Cars

Controlling all Other

Ignitions Sources is

also Difficult Such As:

 Electrical

 Static Electricity  Lightning

 Truck/Cars

Safe Work Practices

Hot Work Program

Safe Work Practices

(35)

Safe Work

Practices-Hot Work

Safe Work

Practices-Hot Work

A Program Must be Developed for the Covered Process That Requires:

 A Hot Work Permit be Issued for ALL Hot Work

Performed in the Plant by Employees or Contractors

 A Permit must be Posted at the Location of the Hot Work  A Fire Watch Is Required

 A Fire Extinguisher or Other Appropriate Fire Fighting Equipment Must Be Present, Fire Watch must be

Trained in its use

A Program Must be Developed for the Covered Process That Requires:

 A Hot Work Permit be Issued for ALL Hot Work

Performed in the Plant by Employees or Contractors

 A Permit must be Posted at the Location of the Hot Work  A Fire Watch Is Required

 A Fire Extinguisher or Other Appropriate Fire Fighting

Equipment Must Be Present, Fire Watch must be Trained in its use

(36)

Paper Mill Explosion & Fire Caused by Failure to Follow Hot Work

(37)

Must be Specific for the Covered Process

May Require Additional Program other

than Lockout Tagout, Line Opening & Hot

Work…such as Confined Space, Electrical

Safe Work Practices, Combustible Dust

Must be Specific for the Covered Process

May Require Additional Program other

than Lockout Tagout, Line Opening & Hot

Work…such as Confined Space, Electrical

Safe Work Practices, Combustible Dust

Safe Work Practices

Safe Work Practices

(38)

NASA High Pressure Gas

Plant

NASA High Pressure Gas

Plant

Operating Procedures & Safe

Work Practices

Case Study

Team Exercise

Operating Procedures & Safe

Work Practices

Case Study

Team Exercise

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Team Exercise

Team Exercise

With the Information to Follow in The

NASA Case Study Video, Presentation &

Notebook,

With Your Team Members, Perform the

Following Exercises & Answer the

Following Questions:

With the Information to Follow in The

NASA Case Study Video, Presentation &

Notebook,

With Your Team Members, Perform the

Following Exercises & Answer the

Following Questions:

(48)

Case Study Exploration

Case Study Exploration

1. List the Hazards Present in the NASA High Pressure Gas Plant

that Handles Liquid Nitrogen, Helium, Liquid Hydrogen & Gaseous Hydrogen.

2. What are Potential Ignition Sources to Control at the Hydrogen

Gas Plant?

3. What are the hazards of Cryogenic Gas?

4. What PPE is required to work around Cryogenic Gas? 5. Why can’t you use your cell phone near the gas plant?

6. Why are Vehicles Kept at least 100 ft. away from the Hydrogen

Gas Plant?

7. List the Safe Work Practices Required in the PSM Standard? 8. With the information learned, write a simple one page hot work

program for the Hydrogen Gas Plant.

We will Discuss the Findings of Each Team in Class

1. List the Hazards Present in the NASA High Pressure Gas Plant

that Handles Liquid Nitrogen, Helium, Liquid Hydrogen & Gaseous Hydrogen.

2. What are Potential Ignition Sources to Control at the Hydrogen

Gas Plant?

3. What are the hazards of Cryogenic Gas?

4. What PPE is required to work around Cryogenic Gas? 5. Why can’t you use your cell phone near the gas plant?

6. Why are Vehicles Kept at least 100 ft. away from the Hydrogen

Gas Plant?

7. List the Safe Work Practices Required in the PSM Standard? 8. With the information learned, write a simple one page hot work

program for the Hydrogen Gas Plant.

(49)

Now That We’ve Developed

Operating Procedures & Safe

Work Practices

Now That We’ve Developed

Operating Procedures & Safe

Work Practices

We Have to Train

We Have to Train

What’s Next

What’s Next

Figure

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References

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