4_psm_standard_operating_procedures2.ppt
- 1. Process Safety Management of Highly Hazardous & Explosive Chemicals Operating Procedures, Safety Procedures & Training
- 2. Now that the PHA’s Are Competed or Underway… Operating Operating Procedures & Safety Procedures & Safety Programs Must Be Programs Must Be Developed Developed PHA Information PHA Information Can Be Used Can Be Used
- 4. Operating Procedures & Safety Programs Must Consider: Initial start-up Initial start-up Normal operations Normal operations Temporary operations Temporary operations Emergency shutdown Emergency shutdown Emergency operations Emergency operations Normal shutdown Normal shutdown Start-up following turnaround Start-up following turnaround Consequences of deviation Consequences of deviation Steps required to correct or avoid deviation Steps required to correct or avoid deviation
- 5. Operating Procedures or Standard Operating Procedures (SOP’s) Where Did This Methodology Come From? Where Did This Methodology Come From? Answer: Answer: The Military The Military Definition: Definition: A standard A standard operating procedure operating procedure is a set of is a set of instructions having the force of a directive, covering those instructions having the force of a directive, covering those features of operations that lend themselves to a definite or features of operations that lend themselves to a definite or standardized procedure without loss of effectiveness. standardized procedure without loss of effectiveness. Standard Operating Policies and Procedures can be Standard Operating Policies and Procedures can be effective catalysts to drive performance improvement and effective catalysts to drive performance improvement and improving organizational results. Every good quality system improving organizational results. Every good quality system is based on its standard operating procedures (SOPs). is based on its standard operating procedures (SOPs).
- 6. *Readily accessible to employees Operating Procedures Develop and implement Develop and implement written operating procedures* written operating procedures* consistent with the process safety information and addresses consistent with the process safety information and addresses at least the following elements: at least the following elements: Initial start-up, normal and temporary operations Initial start-up, normal and temporary operations Normal and emergency shut-down procedures Normal and emergency shut-down procedures Operating limits and consequences of deviation Operating limits and consequences of deviation Hazards presented by the process Hazards presented by the process
- 7. Operating Procedures The operating procedures addressing The operating procedures addressing operating parameters will contain operating operating parameters will contain operating instructions about: instructions about: pressure limits pressure limits temperature ranges temperature ranges flow rates…and flow rates…and what to do when an upset condition occurs what to do when an upset condition occurs what alarms and instruments are pertinent if an what alarms and instruments are pertinent if an upset condition occurs, and other subjects. upset condition occurs, and other subjects.
- 8. Operating Procedures - Start Up…We Must Describe normal SOP's Describe normal SOP's Describe start-up SOP's Describe start-up SOP's Describe Shut-down Describe Shut-down SOP’s SOP’s
- 9. Include Sections such as: Include Sections such as: Objectives Objectives Purpose Purpose Concerns Concerns Procedures Procedures Department Department Operator Operator Equipment Involved Equipment Involved Location Location Related Documents Related Documents Operating Procedures - Start Up…We Must Let’s Look at An Example…
- 10. Objective Objective This procedure is designed to describe the Technical Operating This procedure is designed to describe the Technical Operating Specifications (TOS), and to set down the Standard Operating Specifications (TOS), and to set down the Standard Operating Procedures for the safe operation of Ammonia High Pressure Procedures for the safe operation of Ammonia High Pressure Receiver 1 (HPR-1) Receiver 1 (HPR-1) Purpose: Purpose: The purpose of the TOS is to provide a description of the High The purpose of the TOS is to provide a description of the High Pressure Receiver, to define the function of the receiver, its Pressure Receiver, to define the function of the receiver, its operating conditions and limits, and consequences of deviation operating conditions and limits, and consequences of deviation from these limits; To describe controls and instrumentation and from these limits; To describe controls and instrumentation and safety systems, and set operating alignments. The purpose of safety systems, and set operating alignments. The purpose of the Standard Operating Procedure (SOP) is to set down the the Standard Operating Procedure (SOP) is to set down the proper steps for starting, monitoring normal operation, and proper steps for starting, monitoring normal operation, and stopping and restarting the Receiver under normal and stopping and restarting the Receiver under normal and emergency conditions emergency conditions Concerns: Concerns: Very Careful attention to valve positions, temperature, and Very Careful attention to valve positions, temperature, and pressure levels is extremely important to the successful pressure levels is extremely important to the successful completion of these procedures. Deviations from normal completion of these procedures. Deviations from normal operating limits could cause personal injury or death, small to operating limits could cause personal injury or death, small to catastrophic release of ammonia or environmental damage, or catastrophic release of ammonia or environmental damage, or evacuation of, or injury to, members of the public. We seek to evacuation of, or injury to, members of the public. We seek to prevent incidents such as: prevent incidents such as: Injury to operators and others in the area. Damage to the High Injury to operators and others in the area. Damage to the High Pressure Receiver. Release of any quantity of Anhydrous Pressure Receiver. Release of any quantity of Anhydrous Ammonia refrigerant. Ammonia refrigerant. The company Lockout/Tagout program shall be followed when The company Lockout/Tagout program shall be followed when taking the receiver out of service, while maintaining the taking the receiver out of service, while maintaining the receiver, and while returning it to service. If Line-Breaking is receiver, and while returning it to service. If Line-Breaking is required, all Line-Breaking precautions described in the required, all Line-Breaking precautions described in the company Line-Break Policy shall be observed. Additionally, company Line-Break Policy shall be observed. Additionally, proper PPE shall be immediately available, or worn in response proper PPE shall be immediately available, or worn in response to the threat level posed by the work and circumstances. to the threat level posed by the work and circumstances. Process Safety Management Procedure - Revision HPR-1 Revision Date: 1-9-2009 by: SWD
- 11. Department: Department: Refrigeration Refrigeration Operator: Operator: Qualified Refrigeration Operator(s) Qualified Refrigeration Operator(s) Equipment: Equipment: Ammonia High Pressure Receiver, HPR-1 outside the south compressor Ammonia High Pressure Receiver, HPR-1 outside the south compressor room. Data from U-1-A: Vertical Receiver, Serial Number 124011, room. Data from U-1-A: Vertical Receiver, Serial Number 124011, National Board Number 8664, built in 1998, by E.L. Nickell Company. National Board Number 8664, built in 1998, by E.L. Nickell Company. MAWP: 250 psig @ 240 MAWP: 250 psig @ 240 ｡ ｡ F F Location: Location: Related Related Documents: Documents: Initial Date of Initial Date of 4/1998 4/1998 Development: Development: Authorized By: Authorized By: Previous Revision: Previous Revision: 4/1/1998 4/1/1998 Annual Review By, Annual Review By, 9/2001 plant engineer, utilities supervisor, two operators, the Process 9/2001 plant engineer, utilities supervisor, two operators, the Process and Date: and Date: Safety Management (PSM) coordinator, and an outside consultant Safety Management (PSM) coordinator, and an outside consultant
- 12. Operating Procedures Must be Developed for Each Equipment Must be Developed for Each Equipment Operation in the Covered Process Operation in the Covered Process Refer to Block Diagrams Refer to Block Diagrams Refer to P&ID Refer to P&ID Must Cover Normal Operating Conditions, Must Cover Normal Operating Conditions, Normal Operating Parameters, i.e.. Normal Operating Parameters, i.e.. Pressure/Flow/Current/ etc. Pressure/Flow/Current/ etc. Must Follow Procedures & Must Follow Procedures & Recommendations in PHA’s Recommendations in PHA’s Must Follow Form Must Follow Form
- 13. Operating Procedures For Shut-down Procedures… For Shut-down Procedures… Remember: Remember: Most operations must be shut down in a Most operations must be shut down in a specific order! specific order! Failure to follow these shut down Failure to follow these shut down procedures could results in a catastrophic procedures could results in a catastrophic release or system failure release or system failure
- 14. Ammonia Plant Explosion Caused by Improper Shut-down of Engine Room
- 15. Operating Procedures Operating Limits Operating Limits Operating Limits Operating Limits Must be Understood Must be Understood Pressures Pressures Flows Flows Electrical Potential Electrical Potential Tolerances Tolerances
- 16. Operating Procedures - Hazards of the Process Operating Operating Procedures Must Procedures Must Identify the Hazards Identify the Hazards of the Process in All of the Process in All Phases: Phases: Start Up Start Up Normal Operating Normal Operating Conditions Conditions Temporary Operating Temporary Operating Condition Condition Emergency Shut- Emergency Shut- down down
- 17. Now That We’ve Completed the Operating Procedures We Must Develop Safety Work Practices, We Must Develop Safety Work Practices, Programs & Procedures for Covered Programs & Procedures for Covered Processes Processes
- 19. •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 *These safe work practices apply to contractor employees as well
- 20. Safe Work Practices Safe Work Practices, Programs & Safe Work Practices, Programs & Procedures must: Procedures must: Be specific to the Covered Process Be specific to the Covered Process Follow Procedures & Recommendations in Follow Procedures & Recommendations in the PHA’s the PHA’s Follow Procedures in the Operating Follow Procedures in the Operating Procedures Procedures Must be Able to be Tracked Must be Able to be Tracked Follow Form Follow Form
- 22. Safe Work Practices Lockout Tagout - One of the Most Lockout Tagout - One of the Most Important Procedures in PSM Important Procedures in PSM Must be Written Carefully & Follow all Must be Written Carefully & Follow all Procedures (PHA’s, Operating Procedures (PHA’s, Operating Procedures) Procedures) Must be Followed to the Letter! Must be Followed to the Letter!
- 24. Safe Work Practices Lockout/Tagout in Lockout/Tagout in PSM PSM Why not Use Digital Why not Use Digital Imaging in Your Imaging in Your Procedures to Identify Procedures to Identify Critical Lockout /Tagout Critical Lockout /Tagout Positions Positions
- 25. Line Opening Line Opening Permits Permits Identify Procedures Identify Procedures for Opening any for Opening any Process Line in a Process Line in a Covered Process Covered Process Must Include Must Include Hazards of the Line Hazards of the Line Opening Opening PPE Required PPE Required Safe Work Practices
- 26. Safe Work Practices Line & Equipment Opening A Hazard Review Must Completed for All A Hazard Review Must Completed for All Line/Equipment Hazards Including: Line/Equipment Hazards Including: HAZARDOUS MATERIALS IN SYSTEM HAZARDOUS MATERIALS IN SYSTEM POTENTIAL PHYSICAL HAZARDS POTENTIAL PHYSICAL HAZARDS BARRICADING AS REQUIRED BARRICADING AS REQUIRED FIRST AID IF EXPOSED FIRST AID IF EXPOSED LOCATION OF SAFETY EQUIPMENT LOCATION OF SAFETY EQUIPMENT PPE REQUIRED FOR LINE OPENING PPE REQUIRED FOR LINE OPENING
- 30. Safe Work Practices- Hot Work A Program Must be Developed for the Covered Process A Program Must be Developed for the Covered Process That Requires: That Requires: A Hot Work Permit be Issued for ALL Hot Work A Hot Work Permit be Issued for ALL Hot Work Performed in the Plant by Employees or Contractors Performed in the Plant by Employees or Contractors A Permit must be Posted at the Location of the Hot A Permit must be Posted at the Location of the Hot Work Work A Fire Watch Is Required A Fire Watch Is Required A Fire Extinguisher or Other Appropriate Fire A Fire Extinguisher or Other Appropriate Fire Fighting Equipment Must Be Present, Fire Watch Fighting Equipment Must Be Present, Fire Watch must be Trained in its use must be Trained in its use
- 31. Paper Mill Explosion & Fire Caused by Failure to Follow Hot Work Procedures
- 32. Must be Specific for the Covered Must be Specific for the Covered Process Process May Require Additional Program other May Require Additional Program other than Lockout Tagout, Line Opening & than Lockout Tagout, Line Opening & Hot Work…such as Confined Space, Hot Work…such as Confined Space, Electrical Safe Work Practices, Electrical Safe Work Practices, Combustible Dust Combustible Dust Safe Work Practices
- 33. Now That We’ve Developed Safe Work Practices We Have to Train We Have to Train
- 35. PSM 29CFR1910.119(g) Requires (G) (G) Training (Initial, Refresher, and Documentation) Training (Initial, Refresher, and Documentation) (paragraphs (g)(1), (g)(2), and (g)(3)). (paragraphs (g)(1), (g)(2), and (g)(3)). Paragraph (g)(1) requires employers to train Paragraph (g)(1) requires employers to train employees operating dangerous process. Paragraph employees operating dangerous process. Paragraph (g)(2) requires that the employer provide refresher (g)(2) requires that the employer provide refresher training at least every three years. Paragraph (g)(3) training at least every three years. Paragraph (g)(3) requires the employer to prepare a record that requires the employer to prepare a record that contains the name of employee, the date of training, contains the name of employee, the date of training, and the means used to verify that the employee and the means used to verify that the employee understood the training understood the training
- 36. PSM Training PSM Training Programs Must be Developed PSM Training Programs Must be Developed for: for: Affected Employees - Those not Directly Involved Affected Employees - Those not Directly Involved in the Process Operation in the Process Operation Authorized Employees - Those Directly Involved in Authorized Employees - Those Directly Involved in the Process Operation the Process Operation Contractors Who May Perform Work on a Covered Contractors Who May Perform Work on a Covered Process Process Vendors/Visitors who May Visit the Facility Vendors/Visitors who May Visit the Facility and and May Potentially be Exposed to the Covered May Potentially be Exposed to the Covered Process Process
- 37. PSM Training Training Must Be Performed as Follows: Training Must Be Performed as Follows: Initial training Initial training Prior to work assignment Prior to work assignment Waved for those already in a process Waved for those already in a process Refresher training Refresher training Every three years Every three years All Training Must be Documented All Training Must be Documented
- 38. PSM Training Training Subjects Must Include at Least: Training Subjects Must Include at Least: Lockout Tagout Lockout Tagout Hot Work Hot Work Line & Equipment Opening Line & Equipment Opening Confined Space (if applicable) Confined Space (if applicable) Emergency Response Emergency Response
- 39. Examples of Training PSM training example including the PSM training example including the means used to verify that the means used to verify that the employee understood the training. employee understood the training.
- 40. Let’s Use Hot Work Procedures
- 41. Safe Work Practices Hot Work Program Hot Work Program
- 43. Safe Work Practices Hot Work Burning, Welding, Grinding Our Program Requires Our Program Requires A Hot Work Permit be Issued for ALL Hot A Hot Work Permit be Issued for ALL Hot work Performed in the Plant by Employees or work Performed in the Plant by Employees or Contractors Contractors Permit must be Posted at the Location of the Permit must be Posted at the Location of the Hot Work Hot Work Fire Watch Is Required Fire Watch Is Required Fire Extinguisher Must Be Present, Fire Fire Extinguisher Must Be Present, Fire Watch must be Trained in its use Watch must be Trained in its use
- 44. Safe Work Practices HOT WORK PERMIT MUST BE PERMIT MUST BE COMPLETED PRIOR TO COMPLETED PRIOR TO BEGINNING WORK BEGINNING WORK INVOLVIING INVOLVIING ANY HOT ANY HOT WORK WORK PERMIT SHALL BE PERMIT SHALL BE DISPLAYED AT THE DISPLAYED AT THE LOCATION OF THE LOCATION OF THE ACTUAL ACTUAL HOT HOT WORK WORK OPERATION OPERATION
- 46. VERIFICATION OF UNDERSTANDING WORKSHEET HOT WORK CIRCLE THE CORRECT ANSWER 1. A HOT WORK permit must be obtained prior to beginning HOT.work by welders and contractors before beginning a job. TRUE 2. A HOT WORK permit is not necessary if just burning and grinding is being done on a job. FALSE 3. Contractors are not required to obtain HOT WORK permits. FALSE 4. The employee or contractor will obtain a HOT WORK permit from his supervisor and must determine if conditions are safe and have a fire watch if necessary. TRUE
- 47. 5. HOT WORK is permitted in explosive atmospheres, around hazardous tanks and equipment. FALSE 6. The following protective measures can be used: damp sand on floors, protective shields, or fire resistant coverings while Hot Work is taking place. TRUE 7. 35 feet is a good safe distance for covered combustibles to be away from HOT WORK. TRUE 8. Fully charged and operable fire extinguishers and/or hose lines shall be available and ready. TRUE 9. The HOT WORK permit shall be posted at the job site, and the supervisor shall retain the permits for three (3) days. TRUE 10. The fire watch does not have to be trained in fire extinguishing and is not responsible for sounding an alarm in the event of a fire.
- 48. PSM Operating Procedures Summary You Must Develop and implement You Must Develop and implement written operating written operating procedures procedures consistent with the process safety consistent with the process safety information and addresses at least the following information and addresses at least the following elements: elements: Initial start-up, normal and temporary operations Initial start-up, normal and temporary operations Normal and emergency shut-down procedures Normal and emergency shut-down procedures Operating limits and consequences of deviation Operating limits and consequences of deviation Hazards presented by the process Hazards presented by the process
- 49. PSM Safe Work Practices Summary Safe Work Practices, Programs & Safe Work Practices, Programs & Procedures must: Procedures must: Be specific to the Covered Process(s) Be specific to the Covered Process(s) Follow Procedures & Recommendations in Follow Procedures & Recommendations in the PHA’s the PHA’s Follow Procedures in the Operating Follow Procedures in the Operating Procedures Procedures Must be Able to be Tracked Must be Able to be Tracked Follow Form Follow Form
- 50. PSM Training Summary PSM Training Programs Must be Developed PSM Training Programs Must be Developed for All Necessary Workers and Contractors for All Necessary Workers and Contractors Verification of Understanding is Required Verification of Understanding is Required Training Must Be Performed as Follows: Training Must Be Performed as Follows: Initial training Initial training Prior to work assignment Prior to work assignment Waved for those already in a process Waved for those already in a process Refresher training Refresher training Every three years Every three years All Training Must be Documented All Training Must be Documented
- 51. What’s Next? In the Last Session, we will Cover Contractor Pre-Qualification, Emergency Planning & Response Audits, and EPA Risk Management Plans (RMP)
Editor's Notes
- #45: Blurry slide