ABSTRACT
The aim of a plant safety program is to address all the main areas of safety ensuring that the following are covered, as a minimum:
1. Description and coverage of safety program
2. Process safety management program (OSHA 1910.119 etc.) 3. How data on potential hazards will be communicated throughout the company,
e.g., MSDS
4. Emergency communication protocols
5. Emergency response plan that relates to both the on-site and surrounding community
6. Safety related to electrical systems and devices (isolation etc.) 7. Occupational Hygiene program (work exposure limits etc.) 8. Procedures for entering Confined Spaces
9. Lockout/Tagout program
10. Procedures for performing Hot Work
11. Procedures and equipment required for Hot Taps
12. Noise levels and hearing protection
13. Procedures and training in use of Self Contained Breathing Apparatus
14. Fire detection and protection
15. Procedures and standards for on-site construction
16. Procedures and standards for on-site maintenance
17. Plant isolation (blinds, spades) 18. Winterization procedures as it affects safety
19. Housekeeping and plant safety
20. Procedures for temporarily disabling/bypassing safety features
21. Procedures for using plant utilities (compressed air etc.) 22. Illness/Injury procedure
23. Accident & Incident investigation procedures
24. Personal protective equipment
25. Use of outside contractors
26. Testing plant emergency systems and alarms
27. Fire and emergency drills
28. Security system, monitoring, guard duties and responsibilities
Hazards are normally identified by identifying potential loss of containment situations, together with their causes and consequences. Potential safeguards, including those that can prevent loss of containment and/or mitigate the consequences (such as fire, explosion or toxic releases) should also be evaluated. The following are widely used methodologies to identify hazards:
• Preliminary Hazards Analysis (PrHA). • Hazard and Operability Analysis (HAZOP)
• Failure Mode and Effects Analysis (FMEA)
• What If Analysis
• Checklist
• What If+ Checklist
Reviewing these in tum:
Preliminary Hazards Analysis (PrHA) PrHA is normally used on new or existing facilities to get an overall but not a detailed view of where the major areas with concerns for hazards exist. The methodology can be used for new designs at the conceptual stage in order to assist with layouts, etc. and for existing facilities where some level of prioritization is needed, prior to more detailed hazards analyses, such as HAZOP.
