process safety management for biofuels 1.overview of process safety 2.compliance with standards...
TRANSCRIPT
![Page 1: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/1.jpg)
Process Safety Management for Biofuels
1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety systems9. Emergency response procedures
![Page 2: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/2.jpg)
3. Process Hazard Analysis
Process Safety Management for
Biofuels
This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.
Identification of individual hazards of a system, Determination of undesired events, andEvaluation of the consequences
![Page 3: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/3.jpg)
Concept Sciences Explosion, (www.csb.gov)
![Page 4: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/4.jpg)
Ref: Guidelines for Hazard Evaluation Procedures, 3rd edition , © 2008 by American Institute of Chemical Engineers
Hazards
Deviation
Preventive Mitigative
Regain control
or shut down
safeguards
Containment
and control safeguards
Unmitigated
Impacts
Mitigated
Loss event
![Page 5: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/5.jpg)
PHA Regulatory Requirement
29CFR1910.119 (e) (2)
![Page 6: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/6.jpg)
29CFR1910.119 (e) (2)
The employer shall use one or more of the following methodologies that are appropriate to determine and evaluate the hazards of the process being analyzed.
(i) What-If;
(ii) Checklist;
(iii) What-If/Checklist
(continued on next two slides)
![Page 7: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/7.jpg)
29CFR1910.119 (e) (2)
(iv) Hazard and Operability Study (HAZOP):
(v) Failure Mode and Effects Analysis (FMEA);
(vi) Fault Tree Analysis; or(continued on next slide)
![Page 8: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/8.jpg)
29CFR1910.119 (e) (2)
(vi) Fault Tree Analysis; or
(vii) An appropriate equivalent methodology
For more information:
OSHA
CCPS
![Page 9: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/9.jpg)
Process Safety Information
1. Hazards of the process
2. Chemicals used or produced
3. Technology of the process
4. Equipment in the process
![Page 10: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/10.jpg)
1. Hazards of the Process
• Previous incidents• Engineering and administrative controls• Consequence of failure of controls• Facility Siting• Human factors
CSB Video on Texas City: CSB.gov
![Page 11: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/11.jpg)
2. Chemicals in the Process
• Toxicity
• PEL
• Reactivity
• Corrosivity data
• Chemical stability
• Inadvertent mixing
NOAA chemical reactivity worksheet
![Page 12: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/12.jpg)
3. Technology of the Process
• Process flow diagram
• Chemistry
• Inventory
• Safe operating limits
• Consequences of deviation
29CFR1910.119 (d)
![Page 13: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/13.jpg)
4. Equipment in the Process
![Page 14: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/14.jpg)
A PHA is a Team Effort
![Page 15: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/15.jpg)
PHA Team Training
Member Requirements Leader Send to training or hire
consultant
Plant expertise Plant operator
Process expertise Process Engineer
Equipment Engineer and maintenance
“Scribe” Technical and previous PHA team experience
![Page 16: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/16.jpg)
![Page 17: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/17.jpg)
Item Deviation Cause Consequence Safeguards Recommendation
1. Corn dust release
Leak in system
Corn dust explosion
Daily maintenance
Put corn dryer on M.I. schedule
2.
3.
4.
5.
Record of PHA Team Discussion
Plant Location Unit PHA Team Date
Anywhere, USA Corn Dryer Ann Engineer H. MaintenanceWise Operator PHA Guru
1/1/2012
Notes: M.I. = Mechanical Integrity
![Page 18: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/18.jpg)
Human Error
People make misteaks!Calling a telephone numberMaking a PowerPoint SlideTyping a noteStopping at a red traffic light or Stop sign
![Page 19: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/19.jpg)
Is the Risk Tolerable?
YES
Maintain Risk
Controls
Propose Risk
Reduction
No
![Page 20: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/20.jpg)
Iterate back to “Identify Failure Mode”
![Page 21: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/21.jpg)
Action Item Person Assigned
Due Date
Date Completed
Comments
Put corn dryer on M.I. list to prevent corn dust releases
M.I. specialist
4/15/10 4/13/10 Daily inspection by Ima Maintenance or designee; checklist
PHA Action Item List Plant Location Unit PHA Team Date
Anywhere, USA Corn Dryer Ann Engineer H. MaintenanceWise Operator PHA Specialist
4/09/’10
![Page 22: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/22.jpg)
PHA Frequency
Every time there is a significant process change.
A minimum of every 5 years.
![Page 23: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/23.jpg)
Retention Policy
Retain PHA records for the life of the process, regardless of your company’s record retention policy.
29CFR 1910.119(e)(7)
![Page 24: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/24.jpg)
What-If/Checklist
Click the soybeans to go to a partial list of “What-If” questions for biodiesel.
Click the corn to go to a partial list of “What-If” questions for bioethanol.
![Page 25: Process Safety Management for Biofuels 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures](https://reader035.vdocuments.us/reader035/viewer/2022062320/56649ceb5503460f949b7218/html5/thumbnails/25.jpg)
Remaining Course Material
1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety systems9. Emergency response procedures