Frequency, process hazards review

The scope, organization, format, review method, final report, and frequency are discussed as they apply to research projects. The concept of tailoring the review method to the degree of hazard involved is explained and an example of a Process Hazards Review and a Pre-Startup Review/Process Hazards Audit are given. 

Research at the Du Pont Company s Experimental Station encompasses virtually all fields of science - physics, chemistry, biochemistry, and engineering. The scope of experimentation will range from the micro-level, to the semi works-level, using from milliliter quantities to a drum lot daily. The frequency of experimentation may range from a one-time run in a hood to a round-the-clock operation in a barricade. A Process Hazards Review program must encompass all these possibilities. 

A reactive chemicals/process hazard analysis (PHA) to be completed every three years (see Reference 11). Special consideration may be given to facilities that have lower levels of process risk and which have demonstrated superior safety performance to extend this frequency up to five years. Facilities that pose higher process risk or who have lower safety performance may be recommended to have reactive chemicals/PHA reviews more frequent than every three years. In certain countries, government regulation will determine the frequency and other requirements for Process Hazard Analysis reviews. Dow will follow the government requirements where they are more stringent. 

When Hazard Studies are performed on new plants and modifications, certain inspection and test frequencies are defined. There should be a review process for changes. If equipment and instrumentation inspections reveal a pattern of failing to meet expectations, the testing or inspection should be increased and alternate equipment must be considered. 

When a facility has more than one chemical process, the PSMT develops a priority order for reviews and recommends a review frequency to the facility manager. The frequency usually ranges from once every two to three years for high-hazard-class processes such as explosives manufacture or acetylene purification, to once every five to seven years for low-hazard-class processes such as alcohol... 

Safety inspections of the jobsite will occur periodically every (Insert Frequency), when conditions change, or when a new process or procedure is implemented. These inspections should focus on the identification and correction of potential safety, health, and fire hazards. Individuals should use the site evaluation worksheet when conducting jobsite safety inspections. In addition, the safe work procedures should be reviewed by personnel conducting safety inspections of the jobsite. 

A customer satisfaction inquiry has been performed in cooperation with the Port of Kemi. Customer feedback is also gathered and possible reclamations are always processed. The daily operation of Kemi Shipping is measured using ten different indicators that have been documented in the management system and are monitored on an annual basis finked to the management s review. The indicators include HSEQ-related indicators such as work-related sick leave days, waste control, hazardous incidents and accident frequency. 

Management should establish a program for updating hazards analyses to verify that the most recent hazards analysis reflects the current process. Flazards analyses should be reviewed periodically and updated as appropriate, with typical review intervals ranging between 5 years for high-priority facilities and 10 years for low-priority facilities. The priority factors listed above and changes in the facility should be considered in establishing review frequency. 

Operating procedures shouid aiways be reviewed as part of the MOC process. There should also be a regular review of the procedures (the frequency depending on the hazards of the process covered). The standard does not specify a specific time period for routine procedure review. It su ests that one of the roles of the hazards analysis team is to help define this schedule. The communication of changes to procedures will generally be incorporated into the training program. 

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