Process Safety Management of Highly Hazardous & Explosive Chemicals

Process Safety Management of Highly Hazardous & Explosive Chemicals

Application, Exclusions & DefinitionsApplication, Exclusions & Definitions

ApplicationApplication1910.119(a)(i)

A process which involves a chemical at or above the specified threshold quantities listed in Appendix A

to this section

1910.119(a)(i)A process which involves a chemical at or above the specified threshold quantities listed in Appendix A

to this section

ApplicationApplication1910.119(a)(ii)

A process which involves a flammable liquid or gas (as defined in 1910.1200(c) of this part) on site in one location, in a quantity of 10,000 pounds

(4535.9 kg)

1910.119(a)(ii)A process which involves a flammable liquid or gas

(as defined in 1910.1200(c) of this part) on site in one location, in a quantity of 10,000 pounds

(4535.9 kg)

What Facilities are CoveredWhat Facilities are Covered

Those Who Use Chemicals in Appendix A: A List of highly hazardous chemicals, toxics and reactive (Mandatory). Contains alisting of 137 toxic and reactive highly hazardous chemicals which present a potential for a catastrophic event at or above the threshold quantity

Examples

Chemical Threshold Quantity (TQ) Anhydrous Ammonia 10,000 lbs Chlorine 1,500 lbs Hydrogen Sulfide 1,500 lbs Phosgene 100 lbs Sarin 100 lbs

Those Who Use Chemicals in Appendix A: A List of highly hazardous chemicals, toxics and reactive (Mandatory). Contains alisting of 137 toxic and reactive highly hazardous chemicals which present a potential for a catastrophic event at or above the threshold quantity

Examples

Chemical Threshold Quantity (TQ) Anhydrous Ammonia 10,000 lbs Chlorine 1,500 lbs Hydrogen Sulfide 1,500 lbs Phosgene 100 lbs Sarin 100 lbs

Important Interpretation: 2007 - 06/11/2007 - OSHA defines "on-site in one location" for Process Safety Management of Highly Hazardous Chemicals standard

OSHA interprets "on-site in one location" to mean that the standard applies when a threshold quantity of a highly hazardous chemical(HHC) exists within an area under the control of an employer or group of affiliated employers. It also applies to any group of vessels that are interconnected, or in separate vessels that are close enough in proximity that the HHC could be involved in a potential catastrophic release.

Important Interpretation: 2007 - 06/11/2007 - OSHA defines "on-site in one location" for Process Safety Management of Highly Hazardous Chemicals standard

OSHA interprets "on-site in one location" to mean that the standard applies when a threshold quantity of a highly hazardous chemical(HHC) exists within an area under the control of an employer or group of affiliated employers. It also applies to any group of vessels that are interconnected, or in separate vessels that are close enough in proximity that the HHC could be involved in a potential catastrophic release.

What Facilities are CoveredWhat Facilities are Covered

Important Interpretation: 02/01/2002 - PSM applicability to warehousing flammable liquids and other HHCs

A company has a warehouse for the storage and distribution of laboratory grade chemicals such as flammable liquids and formaldehyde. The company storage and distribution operation does not include any processing, dispensing, mixing, stirring, agitation, blending, filtering, evaporating, or drying.

PSM-covered highly hazardous chemical(s) (HHC) exists in your warehouse/process. You listed two HHCs that are covered by PSM: formaldehyde and flammable liquids. If other HHCs exist in the warehouse/process, they too would be a basis for establishing a PSM-covered process

However, when an HHC is stored in one or more cans, packages, containers, tanks, vessels, etc., the amount is aggregated if a single event such as a fire, explosion, incompatible chemical reaction, etc. could result in a release of HHC. For example, if a fire could consume an entire warehouse all the HHCs would be aggregated as either flammable liquids, flammable gasses, or by specific Appendix A chemical listing,

where applicable.

Important Interpretation: 02/01/2002 - PSM applicability to warehousing flammable liquids and other HHCs

A company has a warehouse for the storage and distribution of laboratory grade chemicals such as flammable liquids and formaldehyde. The company storage and distribution operation does not include any processing, dispensing, mixing, stirring, agitation, blending, filtering, evaporating, or drying.

PSM-covered highly hazardous chemical(s) (HHC) exists in your warehouse/process. You listed two HHCs that are covered by PSM: formaldehyde and flammable liquids. If other HHCs exist in the warehouse/process, they too would be a basis for establishing a PSM-covered process

However, when an HHC is stored in one or more cans, packages, containers, tanks, vessels, etc., the amount is aggregated if a single event such as a fire, explosion, incompatible chemical reaction, etc. could result in a release of HHC. For example, if a fire could consume an entire warehouse all the HHCs would be aggregated as either flammable liquids, flammable gasses, or by specific Appendix A chemical listing,

where applicable.

What Facilities are CoveredWhat Facilities are Covered

What Types of Industries?What Types of Industries?

Industries that Process Chemicals Such As:

Industrial Organics & Inorganics Paints Pharmaceuticals Adhesives Sealants and Fibers Petrochemical facilities Paper Mills (typically four covered processes) Food Processing with Anhydrous Ammonia over the

TQ (10,000 lbs)

Industries that Process Chemicals Such As:

Industrial Organics & Inorganics Paints Pharmaceuticals Adhesives Sealants and Fibers Petrochemical facilities Paper Mills (typically four covered processes) Food Processing with Anhydrous Ammonia over the

TQ (10,000 lbs)

ExclusionsExclusions1910.119(a)(1)(ii)(A)

Hydrocarbon fuels used solely for workplace consumption as a fuel (e.g., propane used for comfort heating, gasoline for vehicle refueling), if such fuels are not a part of a process containing another highly hazardous chemical covered by

this standard

1910.119(a)(1)(ii)(A)Hydrocarbon fuels used solely for workplace consumption as a fuel (e.g., propane used for comfort heating, gasoline for vehicle refueling), if such fuels are not a part of a process containing another highly hazardous chemical covered by

this standard

Retail facilities;

Oil or gas well drilling or

servicing operations; or,

Normally unoccupied

remote facilities

Retail facilities;

Oil or gas well drilling or

servicing operations; or,

Normally unoccupied

remote facilities

Exclusions1910.119(a)(2)(ii)

Exclusions1910.119(a)(2)(ii)

Affect of the “Meer” Decision:

MEER ruling and the MEER Memorandum addressed in the Secretary's letter, OSHA's enforcement policy that the Agency would not cite employers for violations of 1910.119 where stored flammable liquids in atmospheric tanks were connected to a process, unless the process outside of the amount in storage contained more than 10,000 pounds of the substance

Affect of the Affect of the ““MeerMeer”” Decision:Decision:

MEER MEER ruling and theruling and the MEERMEER Memorandum addressed in the Memorandum addressed in the Secretary's letter, Secretary's letter, OSHA's OSHA's enforcement policy that the Agency enforcement policy that the Agency would not cite employers forwould not cite employers for violations of 1910.119 where stored violations of 1910.119 where stored flammable liquids in atmospheric tanks were connected to a flammable liquids in atmospheric tanks were connected to a process, unless the process outside ofprocess, unless the process outside of the amount in storage the amount in storage contained more than 10,000 pounds of the substancecontained more than 10,000 pounds of the substance

What Facilities are CoveredWhat Facilities are Covered

DefinitionsDefinitions1910.119(b)1910.119(b)

DefinitionsDefinitions

Atmospheric tank means a storage tank which has been designed to operate at pressures from atmospheric through 0.5 p.s.i.g. (pounds per square inch gauge, 3.45 Kpa).

Boiling point means the boiling point of a liquid at a pressure of 14.7 pounds per square inch absolute (p.s.i.a.) (760 mm.).

Catastrophic release means a major uncontrolled emission, fire, or explosion, involving one or more highly hazardous chemicals, that presents serious danger to employees in the workplace.

Atmospheric tank means a storage tank which has been designed to operate at pressures from atmospheric through 0.5 p.s.i.g. (pounds per square inch gauge, 3.45 Kpa).

Boiling point means the boiling point of a liquid at a pressure of 14.7 pounds per square inch absolute (p.s.i.a.) (760 mm.).

Catastrophic release means a major uncontrolled emission, fire, or explosion, involving one or more highly hazardous chemicals, that presents serious danger to employees in the workplace.

DefinitionsDefinitions Facility means the buildings, containers or equipment

which contain a process. Highly hazardous chemical means a substance

possessing toxic, reactive, flammable, or explosive properties and specified by paragraph (a)(1) of this section.

Hot work means work involving electric or gas welding, cutting, brazing, or similar flame or spark-producing operations.

Normally unoccupied remote facility means a facility which is operated, maintained or serviced by employees who visit the facility only periodically to check its operation and to perform necessary operating or maintenance tasks. No employees are permanently stationed at the facility.

Facility means the buildings, containers or equipment which contain a process.

Highly hazardous chemical means a substance possessing toxic, reactive, flammable, or explosive properties and specified by paragraph (a)(1) of this section.

Hot work means work involving electric or gas welding, cutting, brazing, or similar flame or spark-producing operations.

Normally unoccupied remote facility means a facility which is operated, maintained or serviced by employees who visit the facility only periodically to check its operation and to perform necessary operating or maintenance tasks. No employees are permanently stationed at the facility.

DefinitionsDefinitions Process means any activity involving a highly

hazardous chemical including any use, storage, manufacturing, handling, or the on-site movement of such chemicals, or combination of these activities. For purposes of this definition, any group of vessels which are interconnected and separate vessels which are located such that a highly hazardous chemical could be involved in a potential release shall be considered a single process.

Replacement in kind" means a replacement which satisfies the design specification.

"Trade secret" means any confidential formula, pattern, process, device, information or compilation of information that is used in an employer's business

Process means any activity involving a highly hazardous chemical including any use, storage, manufacturing, handling, or the on-site movement of such chemicals, or combination of these activities. For purposes of this definition, any group of vessels which are interconnected and separate vessels which are located such that a highly hazardous chemical could be involved in a potential release shall be considered a single process.

Replacement in kind" means a replacement which satisfies the design specification.

"Trade secret" means any confidential formula, pattern, process, device, information or compilation of information that is used in an employer's business

Determining ApplicationDetermining Application

Determine:

Chemicals in Your Process Process Chemistry Quantity of Chemicals in lbs Compare to Appendix A List with

Threshold Quantities (TQ’s)

Determine:

Chemicals in Your Process Process Chemistry Quantity of Chemicals in lbs Compare to Appendix A List with

Threshold Quantities (TQ’s)

Determining ApplicationDetermining Application

How to Calculate from Gallons to lbs?

Multiply the gallons of Liquidx 8.33 (How much a gallon of water weighs) x

Specific Gravity of Liquid = lbs of Liquid

Example: Wt of 10,000 gallons of gasoline10,000 x 8.33 x 0.739 = 61,559 lbs

How to Calculate from Gallons to lbs?

Multiply the gallons of Liquidx 8.33 (How much a gallon of water weighs) x

Specific Gravity of Liquid = lbs of Liquid

Example: Wt of 10,000 gallons of gasoline10,000 x 8.33 x 0.739 = 61,559 lbs

NASA High Pressure GasPlant - Hydrogen Plant

NASA High Pressure GasPlant - Hydrogen Plant

Application & ExclusionsCase Study

Team Exercise

Application & ExclusionsCase Study

Team Exercise

Hydrogen FactsHydrogen Facts

A colorless, highly flammable gaseous element, the lightest of all gases and the most abundant element in the universe, used in the production of synthetic ammonia and methanol, in petroleum refining, in the hydrogenation of organic materials, as a reducing atmosphere, inoxyhydrogen torches, and in rocket fuels.

Atomic number: 1 atomic weight: 1.00794 melting point −259.14ｰC boiling point −252.8ｰC density at 0ｰC 0.08987 gram per liter valence 1

A colorless, highly flammable gaseous element, the lightest of all gases and the most abundant element in the universe, used in the production of synthetic ammonia and methanol, in petroleum refining, in the hydrogenation of organic materials, as a reducing atmosphere, inoxyhydrogen torches, and in rocket fuels.

Atomic number: 1 atomic weight: 1.00794 melting point −259.14ｰC boiling point −252.8ｰC density at 0ｰC 0.08987 gram per liter valence 1

Hydrogen FactsHydrogen Facts

How much does a gallon of liquid hydrogen weigh? 1 liter of liquid hydrogen weighs only 0.07 kg. That is

a density of 70.8 kg/mｳ (at 20 K) There are 3.7854 liters per gallon, so 1 gallon of liquid H2 weighs 0.268 kg. There are 2.2046 lbs per kilogram, so 1 gallon of liquid H2 weighs 0.5908 lbs. Compare that with the weight of 1 gallon of water: 8.3454 lbs (more than 14 times heavier!)

How much does a gallon of liquid hydrogen weigh? 1 liter of liquid hydrogen weighs only 0.07 kg. That is

a density of 70.8 kg/mｳ (at 20 K) There are 3.7854 liters per gallon, so 1 gallon of liquid H2 weighs 0.268 kg. There are 2.2046 lbs per kilogram, so 1 gallon of liquid H2 weighs 0.5908 lbs. Compare that with the weight of 1 gallon of water: 8.3454 lbs (more than 14 times heavier!)

Nitrogen & Helium Plant

NASA High Pressure Gas Plant

Hydrogen Piping to Engine Test Stands

Team ExerciseTeam Exercise

With the Information to Follow in The NASA Case Study Video, Presentation & Notebook

With Your Team Members, Answer the Following Questions:

With the Information to Follow in The NASA Case Study Video, Presentation & Notebook

With Your Team Members, Answer the Following Questions:

Case Study FactsCase Study Facts

The High Pressure Gas Plant Uses Helium Nitrogen Hydrogen

The Nitrogen & Helium Plant is one Section of the Plant The Hydrogen Plant is remotely located from the

Nitrogen & Helium Plant The Hydrogen is Piped from the Hydrogen Plant to the

Engine Test Stands through a valved system There are approximately 100 miles of pipe at the NASA

Stennis Space Center

The High Pressure Gas Plant Uses Helium Nitrogen Hydrogen

The Nitrogen & Helium Plant is one Section of the Plant The Hydrogen Plant is remotely located from the

Nitrogen & Helium Plant The Hydrogen is Piped from the Hydrogen Plant to the

Engine Test Stands through a valved system There are approximately 100 miles of pipe at the NASA

Stennis Space Center

Case Study ExplorationCase Study Exploration

1. Are the Nitrogen & Helium sections of the plant a covered process? Yes or No & Why

2. Is the Hydrogen Plant a covered process? Why?

3. How Much Hydrogen is in the Hydrogen Plant - Find in the PSM Documentation?

4. How is the amount of Hydrogen Calculated?5. Is that All the Hydrogen in the covered

process?

We will discuss the Team Findings

1. Are the Nitrogen & Helium sections of the plant a covered process? Yes or No & Why

2. Is the Hydrogen Plant a covered process? Why?

3. How Much Hydrogen is in the Hydrogen Plant - Find in the PSM Documentation?

4. How is the amount of Hydrogen Calculated?5. Is that All the Hydrogen in the covered

process?

We will discuss the Team Findings

What’s NextWhat’s Next

Process Information &

Toxicity

Process Information &

Toxicity