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

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

Concept Sciences Explosion, (www.csb.gov)

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

PHA Regulatory Requirement

29CFR1910.119 (e) (2)

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)

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)

29CFR1910.119 (e) (2)

   (vi)  Fault Tree Analysis; or

(vii) An appropriate equivalent methodology

For more information:

OSHA

CCPS

Process Safety Information

1. Hazards of the process

2. Chemicals used or produced

3. Technology of the process

4. Equipment in the process

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

2. Chemicals in the Process

• Toxicity

• PEL

• Reactivity

• Corrosivity data

• Chemical stability

• Inadvertent mixing

NOAA chemical reactivity worksheet

3. Technology of the Process

• Process flow diagram

• Chemistry

• Inventory

• Safe operating limits

• Consequences of deviation

29CFR1910.119 (d)

4. Equipment in the Process

A PHA is a Team Effort

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

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

Human Error

People make misteaks!Calling a telephone numberMaking a PowerPoint SlideTyping a noteStopping at a red traffic light or Stop sign

Is the Risk Tolerable?

YES

Maintain Risk

Controls

Propose Risk

Reduction

No

Iterate back to “Identify Failure Mode”

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

PHA Frequency

Every time there is a significant process change.

A minimum of every 5 years.

Retention Policy

Retain PHA records for the life of the process, regardless of your company’s record retention policy.

29CFR 1910.119(e)(7)

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.

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