Process Safety Management

of Highly Hazardous &

Explosive Chemicals
Process Safety Management
of Highly Hazardous &
Explosive Chemicals
Application, Exclusions & Definitions
Application, Exclusions & Definitions
Application
Application
1910.119(a)(i)
A process which involves a chemical at or above the
specified threshold quantities listed in Appendix A
to this section
1910.119(a)(i)
A process which involves a chemical at or above the
specified threshold quantities listed in Appendix A
to this section
Application
Application
1910.119(a)(ii)
A process which involves a flammable liquid or gas
(as defined in 1910.1200(c) of this part) on site
in one location, in a quantity of 10,000 pounds
(4535.9 kg)
1910.119(a)(ii)
A process which involves a flammable liquid or gas
(as defined in 1910.1200(c) of this part) on site
in one location, in a quantity of 10,000 pounds
(4535.9 kg)
What Facilities are Covered
What Facilities are Covered
Those Who Use Chemicals in Appendix A: A List of highly
hazardous chemicals, toxics and reactive (Mandatory). Contains a
listing of 137 toxic and reactive highly hazardous chemicals which
present a potential for a catastrophic event at or above the
threshold quantity
Examples
Chemical Threshold Quantity (TQ)
Anhydrous Ammonia 10,000 lbs
Chlorine 1,500 lbs
Hydrogen Sulfide 1,500 lbs
Phosgene 100 lbs
Sarin 100 lbs
Those Who Use Chemicals in Appendix A: A List of highly
hazardous chemicals, toxics and reactive (Mandatory). Contains a
listing of 137 toxic and reactive highly hazardous chemicals which
present a potential for a catastrophic event at or above the
threshold quantity
Examples
Chemical Threshold Quantity (TQ)
Anhydrous Ammonia 10,000 lbs
Chlorine 1,500 lbs
Hydrogen Sulfide 1,500 lbs
Phosgene 100 lbs
Sarin 100 lbs
Important Interpretation: 2007 - 06/11/2007 - OSHA defines "on-site
in one location" for Process Safety Management of Highly
Hazardous Chemicals standard
OSHA interprets "on-site in one location" to mean that the standard
applies when a threshold quantity of a highly hazardous chemical
(HHC) exists within an area under the control of an employer or
group of affiliated employers. It also applies to any group of vessels
that are interconnected, or in separate vessels that are close
enough in proximity that the HHC could be involved in a potential
catastrophic release.
Important Interpretation: 2007 - 06/11/2007 - OSHA defines "on-site
in one location" for Process Safety Management of Highly
Hazardous Chemicals standard
OSHA interprets "on-site in one location" to mean that the standard
applies when a threshold quantity of a highly hazardous chemical
(HHC) exists within an area under the control of an employer or
group of affiliated employers. It also applies to any group of vessels
that are interconnected, or in separate vessels that are close
enough in proximity that the HHC could be involved in a potential
catastrophic release.
What Facilities are Covered
What Facilities are Covered
Important Interpretation: 02/01/2002 - PSM applicability to warehousing flammable
liquids and other HHCs
A company has a warehouse for the storage and distribution of
laboratory grade chemicals such as flammable liquids and formaldehyde.
The company storage and distribution operation does not include any
processing, dispensing, mixing, stirring, agitation, blending, filtering,
evaporating, or drying.
PSM-covered highly hazardous chemical( s) (HHC) exists in your
warehouse/process. You listed two HHCs that are covered by PSM:
formaldehyde and flammable liquids. If other HHCs exist in the
warehouse/process, they too would be a basis for establishing a PSM-
covered process
However, when an HHC is stored in one or more cans, packages,
containers, tanks, vessels, etc., the amount is aggregated if a single
event such as a fire, explosion, incompatible chemical reaction, etc.
could result in a release of HHC. For example, if a fire could consume an
entire warehouse all the HHCs would be aggregated as either flammable
liquids, flammable gasses, or by specific Appendix A chemical listing,
where applicable.
Important Interpretation: 02/01/2002 - PSM applicability to warehousing flammable
liquids and other HHCs
A company has a warehouse for the storage and distribution of
laboratory grade chemicals such as flammable liquids and formaldehyde.
The company storage and distribution operation does not include any
processing, dispensing, mixing, stirring, agitation, blending, filtering,
evaporating, or drying.
PSM-covered highly hazardous chemical( s) (HHC) exists in your
warehouse/process. You listed two HHCs that are covered by PSM:
formaldehyde and flammable liquids. If other HHCs exist in the
warehouse/process, they too would be a basis for establishing a PSM-
covered process
However, when an HHC is stored in one or more cans, packages,
containers, tanks, vessels, etc., the amount is aggregated if a single
event such as a fire, explosion, incompatible chemical reaction, etc.
could result in a release of HHC. For example, if a fire could consume an
entire warehouse all the HHCs would be aggregated as either flammable
liquids, flammable gasses, or by specific Appendix A chemical listing,
where applicable.
What Facilities are Covered
What Facilities are Covered
What Types of Industries?
What Types of Industries?
Industries that Process Chemicals Such As:
Industrial Organics & Inorganics
Paints
Pharmaceuticals
Adhesives
Sealants and Fibers
Petrochemical facilities
Paper Mills (typically four covered processes)
Food Processing with Anhydrous Ammonia over the
TQ (10,000 lbs)
Industries that Process Chemicals Such As:
Industrial Organics & Inorganics
Paints
Pharmaceuticals
Adhesives
Sealants and Fibers
Petrochemical facilities
Paper Mills (typically four covered processes)
Food Processing with Anhydrous Ammonia over the
TQ (10,000 lbs)
Exclusions
Exclusions
1910.119(a)(1)(ii)(A)
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
1910.119(a)(1)(ii)(A)
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
Retail facilities;
Oil or gas well drilling or
servicing operations; or,
Normally unoccupied
remote facilities
Retail facilities;
Oil or gas well drilling or
servicing operations; or,
Normally unoccupied
remote facilities
Exclusions
1910.119(a)(2)(ii)
Exclusions
1910.119(a)(2)(ii)
Affect of the MeerDecision:
MEER ruling and the MEER Memorandum addressed in the
Secretary's letter, OSHA's enforcement policy that the Agency
would not cite employers for violations of 1910.119 where stored
flammable liquids in atmospheric tanks were connected to a
process, unless the process outside of the amount in storage
contained more than 10,000 pounds of the substance
Affect of the
Affect of the

Meer
Meer

Decision:
Decision:
MEER MEER ruling and the ruling and the MEER MEER Memorandum addressed in the Memorandum addressed in the
Secretary's letter, Secretary's letter, OSHA's OSHA's enforcement policy that the Agency enforcement policy that the Agency
would not cite employers for would not cite employers for violations of 1910.119 where stored violations of 1910.119 where stored
flammable liquids in atmospheric tanks were connected to a flammable liquids in atmospheric tanks were connected to a
process, unless the process outside of process, unless the process outside of the amount in storage the amount in storage
contained more than 10,000 pounds of the substance contained more than 10,000 pounds of the substance
What Facilities are Covered
What Facilities are Covered
Definitions
Definitions
1910.119(b)
1910.119(b)
Definitions
Definitions
Atmospheric tank means a storage tank which has been
designed to operate at pressures from atmospheric
through 0.5 p.s.i.g. (pounds per square inch gauge, 3.45
Kpa).
Boiling point means the boiling point of a liquid at a
pressure of 14.7 pounds per square inch absolute
(p.s.i.a.) (760 mm.).
Catastrophic release means a major uncontrolled
emission, fire, or explosion, involving one or more highly
hazardous chemicals, that presents serious danger to
employees in the workplace.
Atmospheric tank means a storage tank which has been
designed to operate at pressures from atmospheric
through 0.5 p.s.i.g. (pounds per square inch gauge, 3.45
Kpa).
Boiling point means the boiling point of a liquid at a
pressure of 14.7 pounds per square inch absolute
(p.s.i.a.) (760 mm.).
Catastrophic release means a major uncontrolled
emission, fire, or explosion, involving one or more highly
hazardous chemicals, that presents serious danger to
employees in the workplace.
Definitions
Definitions
Facility means the buildings, containers or equipment
which contain a process.
Highly hazardous chemical means a substance
possessing toxic, reactive, flammable, or explosive
properties and specified by paragraph (a)(1) of this
section.
Hot work means work involving electric or gas
welding, cutting, brazing, or similar flame or spark-
producing operations.
Normally unoccupied remote facility means a facility
which is operated, maintained or serviced by
employees who visit the facility only periodically to
check its operation and to perform necessary
operating or maintenance tasks. No employees are
permanently stationed at the facility.
Facility means the buildings, containers or equipment
which contain a process.
Highly hazardous chemical means a substance
possessing toxic, reactive, flammable, or explosive
properties and specified by paragraph (a)(1) of this
section.
Hot work means work involving electric or gas
welding, cutting, brazing, or similar flame or spark-
producing operations.
Normally unoccupied remote facility means a facility
which is operated, maintained or serviced by
employees who visit the facility only periodically to
check its operation and to perform necessary
operating or maintenance tasks. No employees are
permanently stationed at the facility.
Definitions
Definitions
Process means any activity involving a highly
hazardous chemical including any use, storage,
manufacturing, handling, or the on-site movement of
such chemicals, or combination of these activities.
For purposes of this definition, any group of vessels
which are interconnected and separate vessels which
are located such that a highly hazardous chemical
could be involved in a potential release shall be
considered a single process.
Replacement in kind" means a replacement which
satisfies the design specification.
"Trade secret" means any confidential formula,
pattern, process, device, information or compilation of
information that is used in an employer's business
Process means any activity involving a highly
hazardous chemical including any use, storage,
manufacturing, handling, or the on-site movement of
such chemicals, or combination of these activities.
For purposes of this definition, any group of vessels
which are interconnected and separate vessels which
are located such that a highly hazardous chemical
could be involved in a potential release shall be
considered a single process.
Replacement in kind" means a replacement which
satisfies the design specification.
"Trade secret" means any confidential formula,
pattern, process, device, information or compilation of
information that is used in an employer's business
Determining Application
Determining Application
Determine:
Chemicals in Your Process
Process Chemistry
Quantity of Chemicals in lbs
Compare to Appendix A List with
Threshold Quantities (TQs)
Determine:
Chemicals in Your Process
Process Chemistry
Quantity of Chemicals in lbs
Compare to Appendix A List with
Threshold Quantities (TQs)
Determining Application
Determining Application
How to Calculate from Gallons to lbs?
Multiply the gallons of Liquid
x 8.33 (How much a gallon of water weighs) x
Specific Gravity of Liquid = lbs of Liquid
Example: Wt of 10,000 gallons of gasoline
10,000 x 8.33 x 0.739 = 61,559 lbs
How to Calculate from Gallons to lbs?
Multiply the gallons of Liquid
x 8.33 (How much a gallon of water weighs) x
Specific Gravity of Liquid = lbs of Liquid
Example: Wt of 10,000 gallons of gasoline
10,000 x 8.33 x 0.739 = 61,559 lbs
NASA High Pressure Gas
Plant - Hydrogen Plant
NASA High Pressure Gas
Plant - Hydrogen Plant
Application & Exclusions
Case Study
Team Exercise
Application & Exclusions
Case Study
Team Exercise
Hydrogen Facts
Hydrogen Facts
A colorless, highly flammable gaseous element, the lightest
of all gases and the most abundant element in the
universe, used in the production of synthetic ammonia and
methanol, in petroleum refining, in the hydrogenation of
organic materials, as a reducing atmosphere, in
oxyhydrogen torches, and in rocket fuels.
Atomic number: 1
atomic weight: 1.00794
melting point 259.14C
boiling point 252.8C
density at 0C 0.08987 gram per liter
valence 1
A colorless, highly flammable gaseous element, the lightest
of all gases and the most abundant element in the
universe, used in the production of synthetic ammonia and
methanol, in petroleum refining, in the hydrogenation of
organic materials, as a reducing atmosphere, in
oxyhydrogen torches, and in rocket fuels.
Atomic number: 1
atomic weight: 1.00794
melting point 259.14C
boiling point 252.8C
density at 0C 0.08987 gram per liter
valence 1
Hydrogen Facts
Hydrogen Facts
How much does a gallon of liquid
hydrogen weigh?
1 liter of liquid hydrogen weighs only 0.07 kg. That is
a density of 70.8 kg/m (at 20 K) There are 3.7854
liters per gallon, so 1 gallon of liquid H
2
weighs
0.268 kg. There are 2.2046 lbs per kilogram, so 1
gallon of liquid H
2
weighs 0.5908 lbs. Compare that
with the weight of 1 gallon of water: 8.3454 lbs (more
than 14 times heavier!)
How much does a gallon of liquid
hydrogen weigh?
1 liter of liquid hydrogen weighs only 0.07 kg. That is
a density of 70.8 kg/m (at 20 K) There are 3.7854
liters per gallon, so 1 gallon of liquid H
2
weighs
0.268 kg. There are 2.2046 lbs per kilogram, so 1
gallon of liquid H
2
weighs 0.5908 lbs. Compare that
with the weight of 1 gallon of water: 8.3454 lbs (more
than 14 times heavier!)
Nitrogen & Helium Plant
NASA High Pressure Gas Plant
Hydrogen Piping to Engine Test Stands
Team Exercise
Team Exercise
With the Information to Follow in The
NASA Case Study Video, Presentation &
Notebook
With Your Team Members, Answer the
Following Questions:
With the Information to Follow in The
NASA Case Study Video, Presentation &
Notebook
With Your Team Members, Answer the
Following Questions:
Case Study Facts
Case Study Facts
The High Pressure Gas Plant Uses
Helium
Nitrogen
Hydrogen
The Nitrogen & Helium Plant is one Section of the Plant
The Hydrogen Plant is remotely located from the
Nitrogen & Helium Plant
The Hydrogen is Piped from the Hydrogen Plant to the
Engine Test Stands through a valved system
There are approximately 100 miles of pipe at the NASA
Stennis Space Center
The High Pressure Gas Plant Uses
Helium
Nitrogen
Hydrogen
The Nitrogen & Helium Plant is one Section of the Plant
The Hydrogen Plant is remotely located from the
Nitrogen & Helium Plant
The Hydrogen is Piped from the Hydrogen Plant to the
Engine Test Stands through a valved system
There are approximately 100 miles of pipe at the NASA
Stennis Space Center
Case Study Exploration
Case Study Exploration
1. Are the Nitrogen & Helium sections of the plant
a covered process? Yes or No & Why
2. Is the Hydrogen Plant a covered process?
Why?
3. How Much Hydrogen is in the Hydrogen Plant
- Find in the PSM Documentation?
4. How is the amount of Hydrogen Calculated?
5. Is that All the Hydrogen in the covered
process?
We will discuss the Team Findings
1. Are the Nitrogen & Helium sections of the plant
a covered process? Yes or No & Why
2. Is the Hydrogen Plant a covered process?
Why?
3. How Much Hydrogen is in the Hydrogen Plant
- Find in the PSM Documentation?
4. How is the amount of Hydrogen Calculated?
5. Is that All the Hydrogen in the covered
process?
We will discuss the Team Findings
Whats Next
Whats Next
Process Information &
Toxicity
Process Information &
Toxicity