Process Safety Information

1 Information About Highly Hazardous Process Chemicals 

Information about the chemicals used in a process, as well as chemical intermediates, must be comprehensive enough for an accurate assessment of fire and explosion characteristics, reactivity hazards, safety and health hazards to workers, and corrosion and erosion effects on process equipment and monitoring tools. Information must include, at a minimum  

Process equipment information must include at least (1) materials of construction  

Process equipment design and materials must be documented by identifying the applicable codes and standards (e.g., ASME, ASTM, API). If the codes and standards are not current, the DOE contractor must document that the design, construction, testing, inspection, and operation are still suitable for the intended use. If the process technology requires a design that departs from the applicable codes and standards, the contractor must document that the design and construction are suitable for the intended purpose. 

The purpose of this handbook is to facilitate, within the DOE, the performance of chemical process hazards analyses (PrHAs) as required under the PSM Rule. It provides basic information for the performance of PrHAs, and should not be considered a complete resource on PrHA methods. Likewise, to determine if a facility is covered by the PSM rule, the reader should refer to the handbook, Process Safety Management for Highly Hazardous Chemicals (DOE-HDBK-1101-96). 

Promulgation of the PSM Rule has heightened the awareness of chemical safety management issues whithin the DOE. This handbook is intended for use by DOE facilities and processes covered by the PSM rule to facilitate contractor implementation of the PrHA element of the PSM Rule. However, contractors whose facilities and processes not covered by the PSM Rule may also use this handbook as a basis for conducting process hazards analyses as part of their good management practices. 

This handbook explains the minimum requirements for PrHAs outlined in the PSM Rule. Nowhere have requirements been added beyond what is specifically required by the rule. 

The U S. Department of Energy (DOE) wishes to thank all persons who commented on this handbook for their help in clarifying and focusing this guidance. Ms. Pamela Sutherland of Battelle-Columbus managed the preparation of this handbook by Battelle Memorial Institute staff in Columbus and at Pacific Northwest Laboratories (PNL). 

0 PROCESS HAZARD ANALYSIS METHODS WITH EXAMPLES. 23 

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Provide system to maintain process safety information (PSI)... 

Maintain Process Safety Information (PSI) related to chemistry such as ... 

This guideline describes methods to help the chemical processing industry apply the CCPS chemical process safety concepts to outsourced manufacturing operations, specifically the tolling vendor-client relationship. In addition to the focus on process safety, information and examples provided in this text foster good practices relative to community and worker health, and environmental responsibility. 

The combination of the contributions should result in complete process safety information for the toll. As you can see in this definition, there are many facets to both sides of the tolling contract that can be impacted by either party s philosophy of process safety. 

Examining the lists above makes it clear that a good toller-client relationship with open and honest communication of process safety information, process hazard analysis input and early recognition of issues can help avoid potential problems. 

Specific titles within each of the operating phases can be determined using a job task analysis in concert with the technology package and process safety information. Appendix D, ISD Model and Job Task Analysis Techniques, provides basic guidance in this useful method. 

Operators with previous experience in similar tolls teamed with engineers using the process safety information can identify the specific procedures needed within each subcategoiy. Whenever possible, tiy to use experience from duplicate tolls or similar processes. 

With the PHA methodology selected, the team assembled and the process safety information gathered, the analysis of chemical and process hazards, and the consequences and deviations associated with those hazards are identified. 

Process safety information information identified and complete... 

Did the Process Safety Information Change O YES O NO ( items indicates PSI) (If YES, initiate PSM-ADM-08, Pre-Startup Safety Review)... 

Have appropriate revisions been made to process safety information, P IDs, and operating procedures ... 

Process Safety Information Physical, chemical, and toxicological information related to the chemicals, process, and equipment. It is used to document the configuration of a process, its characteristics, its limitations, and as data for process hazard analyses. 

Technology package Information typically provided to a toller by their client delineating specifications for the equipment, chemicals, processing and quality control for a toll. Process safety information is a subset of the technology package. 

Process technology information will be a part of the process safety information package and should include employer-established criteria for maximum inventory levels for process chemicals limits beyond which would be considered upset conditions and a qualitative estimate of the consequences or results of deviation that could occur if operating beyond the established process limits. Employers are encouraged to use diagrams that will help users understand the process. 

The written process safety information shall be prepared by the employer before conducting process hazard analysis. It shall include information on hazards of the hazardous chemicafs used or produced by the process, information pertaining to the technology of the process, and information pertaining to the equipment in the process. 

The employer is responsible for developing and implementing written operating procedures that provide dear instructions for safely conducting activities involved in each covered process consistent with the process safety information by addressing requirements, responsibilities, and procedures for ... 

Equipment deficiencies that are outside acceptable limits (defined by the process safety information) are corrected before further use or in a safe and timely manner. 

The audit includes a review of the process safety information, inspection of the physical facilities, and interviews with all levels of plant personnel. Using the procedures and checklist, the team systematically analyzes compliance with the PSM Rule and any other relevant corporate policies. The training program is reviewed for adequacy of content, frequency and effectiveness of training. Interviews determine employee knowledge and awareness ofthe safety procedures, duties, rules, and emergency response assignments. The team identifies deficiencies in the application of safety and health policies, procedures, and work authorization practices to determine live actions. 

Make sure your company s short-term objectives (e.g., updating aii P IDs) are consistent with broader PSM goais (e.g., accurate process safety information), sind communicate them in ways that clearly encourage work habits and procedures that support PSM performance. For exampie, your employees need to understand that the company will achieve its goal of reducing reportable incidents by changing its PSM procedures, not its reporting processes. 

Process Safety Information Process Hazard Analysis Management of Change Operating Procedures Safe Work Practices Training... 

Prevention Program —Management System —Process Hazards Analysis —Process Safety Information —Standard Operating Procedures —Training... 

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