Highly hazardous chemical

Chemicals, highly hazardous process safety management... 

The third of the major hazards and the one with the greatest disaster potential is the release of toxic chemicals. The hazard posed by toxic release depends not only on the chemical species but also on the conditions of exposure. The high disaster potential from toxic release arises in situations where large numbers of people are briefly exposed to high concentrations of toxic material, i.e., acute exposure. However, the long-term health risks associated with prolonged exposure at low concentrations, i.e., chronic exposure, also present serious hazards. 

Process safety management of highly hazardous chemicals... 

Process Safety Management of Highly Hazardous Chemicals Tide 29, Subtitie B, Chapt. XVII, Part 1910, Subpart H, Paragraph 119, of the Code ofFederal Regulations (29 CER 1910.119), FederalRegisterhl >()) 6403, U.S. Department of Labor, Occupational Safety and Health Administration (Feb. 24, 1992). 

Explosibility and Fire Control. As in the case of many other reactive chemicals, the fire and explosion hazards of ethylene oxide are system-dependent. Each system should be evaluated for its particular hazards including start-up, shut-down, and failure modes. Storage of more than a threshold quantity of 5000 lb (- 2300 kg) of the material makes ethylene oxide subject to the provisions of OSHA 29 CER 1910 for "Highly Hazardous Chemicals." Table 15 summarizes relevant fire and explosion data for ethylene oxide, which are at standard temperature and pressure (STP) conditions except where otherwise noted. 

IRI 1990. Guiding Principals for Protection of High-Hazard Chemical and Petrochemical Plants. IRInformation Manual 17.2.1. Industrial Risk Insurers, Hartford, CT. 

Process Safety Management of Highly Hazardous Chemicals (PSM) OSHA 29 CFR 1910.119... 

Are there industrial and/or commercial neighbors that have highly hazardous chemicals, such that a release of one of these chemicals could have an affect on the facility and its people ... 

Catastrophic release Under OS HA PSM and EPA RMP, it means a major uncontrolled emission, fire, or explosion, involving one or more highly hazardous chemical substances (per OSHA) or regulated substances (per EPA) that presents serious danger to employees in the workplace (per OSHA) or imminent and substantial endangerment to public health and the environment (per EPA). 

Critical Equipment Equipment, instrumentation, controls, or systems whose malfunction or failure would likely result in a catastrophic release of highly hazardous chemicals, or whose proper operation is required to mitigate the consequences of such release. (Examples are most safety systems, such as area LEL monitors, fire protection systems such as deluge or underground systems, and key operational equipment usually handling high pressures or large volumes.)... 

Chemical reaction hazards must be considered in assessing whether a process can be operated safely on the manufacturing scale. Furthermore, the effect of scale-up is particularly important. A reaction, which is innocuous on the laboratory or pilot plant scale, can be disastrous in a full-scale manufacturing plant. For example, the heat release from a highly exothermic process, such as the reduction of an aromatic nitro compound, can be easily controlled in laboratory glassware. Flowever,... 

Qccupational Safety and Health Administration (QSHA) (1992). 29 CFR Part 1910. Process Safety Management of Highly Hazardous Chemicals Explosives and Blasting Agents Final Rule. Federal Register 57, 36 (February 24), 6356-417. 

PSM was created to help the management of hazards associated with processes using highly hazardous chemicals. In an appendix to the rule, OSHA discussed several methods of process hazard analysis. That... 

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... 

Each employer must address what actions employees are to take when there is an unwanted release of highly hazardous chemicals. Emergency preparedness is the employer s third line of defense that will be relied on along with the second line of defense, which is to control the release of chemicals. Control releases and emergency preparedness will take place when the first line of defense to operate and maintain the process and contain the chemicals fails to stop the release. In preparing for an emergency chemical release, employers will need to decide the following ... 

Employers, at a minimum, must have an emergency action plan that will facilitate the prompt evacuation of employees when there is an unwanted release of a highly hazardous chemical. This means that the employer s plan will be activated by an alarm system to alert employees when to evacuate, and that employees who are physically impaired will have the necessary support and assistance to get them to a safe zone. The intent of these requirements is to alert and move employees quickly to a safe zone. The use of process control centers or buildings as safe areas is discouraged. Recent catastrophes indicate that lives are lost in these structures because of their location and because they are not necessarily designed to withstand over-pressures from shock waves resulting from explosions in the process area. 

Wlien there are unwanted incidental releases of highly hazardous chemicals in the process area, the employer must inform employees of the actions/procedures to take. If the employer wants employees to evacuate the area, then the emergency action plan will be activated. Eor outdoor processes, where wind direction is important for selecting the safe route to a refuge area, the employers should place a wind direction indicator, such as a wind sock or pennant, at the highest point visible... 

Table 1.9-1 List of Highly-Hazardous Chemicals, Toxics, and Reactives (Mandatoty)...

The employer investigates incidents that result in, or could result in, a catastrophic release of highly hazardous chemicals. An incident investigation is initiated as soon as possible, but before 48 hours following the incident. An incident investigation team is established to consist of one or more experts in the process involved, and accident investigation. The report prepared at the conclusion of the investigation includes at a minimum ... 

All employees, working with highly hazardous chemicals must understand the safety and health hazards (29CFR1910.1200 - the Hazard Communication Standard) by knowing the properties of the chemicals with which they work, safe operating procedures, work practices, and emergency action. 

Equipment used to process, store, or handle highly hazardous chemicals must be designed constructed, installed and maintained to minimize the risk of release. A systematic, scheduled, test and maintenance program is preferred over "breakdown" maintenance " that could compromise safety. Elements of a mechanical integrity program include 1) identification and categorization of equipment and instrumentation, 2) documentation of manufacturer data on mean time to failure, 3 ) test and inspection frequencies, 4) maintenance procedures, 5) training of maintenance personnel, 6) test criteria, and 7) documentation of test and inspection results. 

Employee - According to 29CFR1910.119, Process Safety Management of Highly Hazardous Chemicals," an hourly, salaried, or contract person who works at a facility and is subject to I he process hazards. 

Highly Hazardous Chemical - Toxic, reactive, flammable, or explosive substances, as defined in Appendix A of 29 CFR 1910.119, "Process Safety Management of Highly Hazardous Chemicals."... 

Process - An activity that involves highly hazardous materials reacting chemically, their use, storage, manufacturing, handling, or movement... 

DOE, 1996, Process Safety Manaagement for Highly Hazardous Chemicals, DOE-HDBK-1101-96, February. 

Monitors and deluge sets-Many chemical plants use monitors for general use and for high hazard locations in order to provide maximum water supply with a minimum of manpower exposure. Deluge sets supported by ample hose streams are preferred for some protection uses. 

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