Process safety analysis reactivity hazards

Complete and accurate written documentation of chemicals properties, process teclinology, and process equipment is essential to the PSM program and to a process hazards analysis (PrHA). This information serves many users including the PrHA team. The needed chemical information includes fire and explosion characteristics, reactivity hazards, safety and health hazards and the corrosion and erosion effects. Current material safety data sheet (MSDS ) information helps meet this requirement, but must be supplemented with process chemistry information regarding runaway reactions, and over-pressure hazards. 

Document Chemical Reactivity Risks and Management Decisions Process Knowledge and Documentation Process Risk Management Process Safety Information Process Hazard Analysis Operating Procedures Operational Control... 

Analysis and Safeguards Lees, Loss Prevention in the Process Industries ISBN 0750615478 Guidelines for Safe Storage and Handling of Reactive Materials Guidelines for Process Safety in Batch Reaction Systems Guidelines for Hazard Evaluation Procedures, Second Edition with Worked Examples... 

As supported by the CSB incident data, two elements are particularly relevant to reactive hazards-Process Safety Information (PSI 29 CFR 1910.119 [d]) and Process Hazard Analysis (PHA 29 CFR 1910.119... 

The concept of a safety case comes from the requirements of the European Union/European Community (EU/EC) Seveso Directive (82/501/EC) and, in particular, regulations that the United Kingdom and other member states used to implement that directive. United Kingdom regulations (Control of Industrial Major Accident Hazards [CIMAH], 1984 replaced by Control of Major Accident Hazards Involving Dangerous Substances [COMAH] in 1999) require that major hazardous facilities produce a safety report or safety case.64 The requirement for a safety case is initiated by a list of chemicals and a class of flammables. Like the hazard analysis approach (Section 8.1.2), experts identify the reactive hazards of the process if analysis shows that the proposed process is safe, it may be excluded from additional regulatory requirements. 

Reactive chemical hazard management is one element of an overall process safety program, but is emphasized through thermal hazards analysis. 

As can be seen from the Global Reactive Chemicals Standard, all existing chemical processes will have a Reactive Chemicals/Process Hazard Analysis review on a predefined periodic basis. In addition, every new plant Production Leader should review their process with the Reactive Chemicals Committee within 90 days of assuming responsibility for a pilot or production plant. Prior to the review, the Leader should acquire training on the chemistry and processes that they are working with. This should include an evaluation of raw materials, processes, products and waste to understand any potential reactive chemical hazards. They should review and be prepared to answer questions from the completed and updated RC/PHA protocol questionnaire as well as other relevant materials in their plant Process Safety Folder, such as F EI, CEI, etc. The review should cover all auxiliary operations to the process such as raw material and product storage drum, tank car and truck loading. 

As a part of an effective Health, Safety, and Environment (HSE) program, a Job Safety Analysis (JSA) has proved to be an effective accident and occupational illness prevention tool in many industries. The JSA, also known as a Job Hazard Analysis (JHA), is a safety management tool in which the risks or hazards of a specific job in the workplace are identified and measures to eliminate or control those hazards are determined and implemented. Most safety programs are considered reactive, an action in response to an incident. A JSA is considered a proactive approach to workplace safety. A JSA is a process of systematically evaluating certain jobs, identifying the hazards or potential hazard associated with each step of the job, and finding effective control measures to eliminate or reduce the risk of hazards and make the workplace as safe as possible, before those hazards have a chance to become accidents. 

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. 

CHAZOP a Computer Hazard and Operability study. A structured qualitative study of control and safety systems to access and minimize the effect of failures of its subsystems impacting the plant or affecting the ability of an operator to take corrective action Chemical Hazard Analysis (CHA) a formal process for identifying and quantifying reactive chemical hazards... 

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