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Process Safety Information  1910.119 (d)  
bulletWhat the regulation says:
bullet

(d) Process safety information. In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. The compilation of written process safety information is to enable the employer and the employees involved in operating the process to identify and understand the hazards posed by those processes involving highly hazardous chemicals. This process safety information shall include information pertaining to the hazards of the highly hazardous chemicals used or produced by the process, information pertaining to the technology of the process, and information pertaining to the equipment in the process.

(d)(1) Information pertaining to the hazards of the highly hazardous chemicals in the process. This information shall consist of at least the following:

(d)(1)(i) Toxicity information;

(d)(1)(ii) Permissible exposure limits;

(d)(1)(iii) Physical data;

(d)(1)(iv) Reactivity data:

(d)(1)(v) Corrosivity data;

(d)(1)(vi) Thermal and chemical stability data; and

(d)(1)(vii) Hazardous effects of inadvertent mixing of different materials that could foreseeably occur.

Note: Material Safety Data Sheets meeting the requirements of 29 CFR 1910.1200(g) may be used to comply with this requirement to the extent they contain the information required by this subparagraph.

(d)(2) Information pertaining to the technology of the process.

(d)(2)(i) Information concerning the technology of the process shall include at least the following:

(d)(2)(i)(A) A block flow diagram or simplified process flow diagram (see Appendix B to this section);

(d)(2)(i)(B) Process chemistry;

(d)(2)(i)(C) Maximum intended inventory;

(d)(2)(i)(D) Safe upper and lower limits for such items as temperatures, pressures, flows or compositions

(d)(2)(i)(E) An evaluation of the consequences of deviations, including those affecting the safety and health of employees.

(d)(2)(ii) Where the original technical information no longer exists, such information may be developed in conjunction with the process hazard analysis in sufficient detail to support the analysis.

(d)(3) Information pertaining to the equipment in the process.

(d)(3)(i) Information pertaining to the equipment in the process shall include:

(d)(3)(i)(A) Materials of construction;

(d)(3)(i)(B) Piping and instrument diagrams (P&ID's); 

(d)(3)(i)(C) Electrical classification;

(d)(3)(i)(D) Relief system design and design basis;

(d)(3)(i)(E) Ventilation system design;

(d)(3)(i)(F) Design codes and standards employed;

(d)(3)(i)(G) Material and energy balances for processes built after May 26, 1992

(d)(3)(i)(H) Safety systems (e.g. interlocks, detection or suppression systems).

(d)(3)(ii) The employer shall document that equipment complies with recognized and generally accepted good engineering practices.

(d)(3)(iii) For existing equipment designed and constructed in accordance with codes, standards, or practices that are no longer in general use, the employer shall determine and document that the equipment is designed, maintained, inspected, tested, and operating in a safe manner.

 

bulletWhat it means:
bullet Complete and accurate written information concerning process chemicals, process technology, and process equipment is essential to an effective process safety management program and development of a comprehensive process hazards analysis. The compiling of this information will provide a necessary resource to a variety of users including the team that will perform the process hazards analysis as well as those developing the training programs and the operating procedures; contractors whose employees will be working with the process; those conducting the pre-startup reviews; local emergency preparedness planners; and insurance and enforcement officials.
bulletThe information to be compiled about the chemicals needs to be comprehensive enough for an accurate assessment of the fire and explosion characteristics, reactivity hazards, safety and health hazards to workers, and the corrosion and erosion effects on the process equipment and monitoring tools. Current material safety data sheet (MSDS) information can be used to help meet this requirement.
bulletMaximum inventory levels for process chemicals must be stated and a qualitative estimate of the consequences or results of deviation that could occur if operating beyond the established process limits.
bulletAt minimum, a block flow diagram must be available to show the major process equipment and interconnecting process flow lines. Flow rates, stream composition, temperatures, and pressures should be included when necessary for clarity. The block flow diagram is a simplified diagram.
bulletProcess flow diagrams are more complex and will show all main flow streams including valves to enhance the understanding of the process, as well as pressures and temperatures on all lines within all major vessels, in and out of headers and heat exchangers, and points of pressure and temperature control.
bullet Also, materials of construction information, pump capacities and pressure heads, compressor horsepower and vessel design pressures and temperatures are shown when necessary for clarity. In addition, major components of control loops are usually shown along with key utilities on process flow diagrams.
bulletUp to date piping and instrument diagrams (P&IDís) that accurately depict the current state of the process are required prior development of the Process Hazard Analysis. P&IDís provide a comprehensive description of the relationships between equipment and instrumentation as well as other relevant information. They can also include materials of construction information, pump capacities and pressure heads, compressor horsepower and vessel design pressures and temperatures where clarity is necessary. In addition, major components of control loops are usually shown along with key utilities on process flow diagrams. Computer software programs which help to detail and identify components listed on P&IDís may be used to help meet this requirement.
bulletThe information pertaining to process equipment design must be documented. In other words, what were the codes and standards relied on to establish good engineering practice. These codes and standards are published by such organizations as the American Society of Mechanical Engineers, American Petroleum Institute, American National Standards Institute, International Institute of Ammonia Refrigeration, American Society for Testing and Materials, and the National Board of Boiler and Pressure Vessel Inspectors
bulletIn addition, various engineering societies issue technical reports which impact process design. For example, the Refrigeration Engineers and Technicians Association, has published technical reports on topics such as flow calculations for venting devices. This type of technically recognized report would constitute good engineering practice.
bulletFor existing equipment designed and constructed many years ago in accordance with the codes and standards available at that time and no longer in general use today, the employer must document which codes and standards were used and that the design and construction along with the testing, inspection and operation are still suitable for the intended use. Where the process technology requires a design which departs from the applicable codes and standards, the employer must document that the design and construction is suitable for the intended purpose.  

 




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