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7. Prevention Program -- Program 3
Complete the following information about each Program 3 process at your source. If the
same information applies to more than once covered process, the owner or operator may
provide the information only once, but shall indicate to which process the information
applies.
7.1 SIC code for process: The four-digit Standard Industrial Classification
(SIC) Code is the federal government category of business activity. See Standard
Industrial Classification Manual, Office of Management and Budget, U.S. Government
Printing Office, Washington, D.C. The four-digit SIC code should be applicable to the
process, not the source as a whole.
7.2 Name of substance(s) covered: The name of the regulated substance(s) in the
process.
7.3 Date on which the safety information was last reviewed or revised:
7.4 PHA: Answer the following questions about the status of your Process Hazard
Analysis (PHA). The owner or operator must perform a PHA on processes covered by the risk
management program rule.
The date of completion of the most recent PHA or update
The technique used: Indicate which of the following methodologies
were used to evaluate the hazards of the process. Check all that apply.
What If: A What If analysis considers the consequences associated
with events that occur as a result of failures involving equipment, design, or procedures.
All possible system failures may be collected in checklist form and evaluated. Compiling a
list of failures requires a basic understanding of what is intended and the ability to
combine or synthesize possible deviations and reject incredible situations.
Checklist: This system involves developing a checklist of failure
areas and reviewing each area to determine the possible effects of failure.
What If/Checklist: This methodology combines the what if and
checklist analysis methodologies to identify and evaluate process hazards.
HAZOP: Hazard and Operability Studies (HAZOPs) are conducted by
teams that brainstorm to systematically identify hazards or operability problems
throughout a source through the use of certain guidewords such as "no flow" and
"no cooling". The consequences of the deviation associated with the guidewords
are assessed and credible deviations are identified and addressed.
Failure Mode and Effects Analysis: This is a methodology of
tabulating the source's equipment, failure modes (how equipment fails), each failure
mode's effect on the source, and a ranking of each failure mode.
Fault Tree Analysis: This is a deductive technique that focuses
on one particular accident event and provides a method for determining causes of the
event. The fault tree is a graphic model that displays the various combinations of
equipment faults and failures that can result in a release.
Other (specify)
The expected date of completion of any changes resulting from the
PHA: Not all recommendations will have resulted in changes. Record the date of
expected final implementation of any changes that are made as a result of PHA
recommendations.
Major hazards: Indicate with a check mark all major
hazards that were identified for the Program 3 process at your source as a result of the
PHA. Major hazards are defined as the potential for:
Toxic Release: If an accidental release occurred a regulated
toxic substance could be released.
Fire: Process upsets, leaks, equipment failure, etc., could
result in a fire. For listed flammables, fire will always be a major hazard. Fire,
however, may also be a hazard in other processes and could lead to a toxic release.
Explosion: Confined or unconfined vapor cloud explosions, BLEVES;
explosion will be a major hazard for listed flammables. It may also be a hazard for
toxics, especially those handled at extreme conditions.
Runaway Reaction: An uncontrolled reaction that proceeds at an
increasing rate.
Polymerization: A chemical reaction that produces the bonding of
two or more monomers.
Overpressurization: Instantaneous energy release or detonation.
Corrosion: The presence of the regulated substance could lead to
destruction of equipment and a release. Corrosion may be a major hazard for substances
identified as corrosives on MSDSs unless the equipment used limits the hazard.
Overfilling: Filling a tank or vessel beyond its maximum safe
capacity.
Contamination: A release could occur if inappropriate substances
are introduced into storage or process vessels. Contamination may be a major hazard if
controlling inappropriate substances (e.g., H2O) is difficult.
Equipment Failure: Equipment failure is likely to be a major
hazard for most processes because such failure could lead to a release. Equipment failure
includes cracks, weld failures, disk failures, ruptures, pump/gauge/control system
failures, etc.
Loss of Cooling, Heating, Electricity, Instrument Air: These
losses could be major hazards if they would lead to releases. For example, loss of cooling
could lead to an increase in pressure and failure of a vessel or pipe; a loss of heating
or power could lead to unstable processes. These conditions are less likely to be major
hazards for substances handles at atmospheric temperatures and pressures.
Earthquake: Report these only if they are frequent enough or
likely enough to occur at your site so that you design and plan for them.
Floods (Flood Plain): Report these only if they are frequent
enough or likely enough to occur at your site so that you design and plan for them.
Tornado: Report these only if they are frequent enough or likely
enough to occur at your site so that you design and plan for them.
Hurricanes: Report these only if they are frequent enough or
likely enough to occur at your site so that you design and plan for them.
Other (specify)
Process controls: Indicate all of the process controls used on
this Program 3 process. Process controls are equipment and associated procedures used to
prevent or limit releases. Check all that apply.
Vents: An opening provided for the discharge of pressure or
release of pressure form tanks, vessels, processing equipment, etc.
Relief Valves: A relief valve is a valve that relieves pressure
beyond a specified limit and recloses upon return to normal operating conditions.
Check Valves: A device for automatically limiting flow in a
piping system to a single direction,
Scrubbers: A pre-release protection measure that uses water or
aqueous mixtures containing scrubbing reagents to remove discharging liquids and possibly
also treating the discharging chemical.
Flares: A pre-release protection measure used for flammable gases
and vapors to remove and possibly treat discharged liquids.
Manual Shutoffs: Controls the shutoff flow to a pipe or vessel
and that must be operated manually.
Automatic Shutoffs: Controls the shutoff flow to a pipe or vessel
and that are triggered automatically when process conditions are exceeded.
Interlocks: A switch or other device that prevents activation of
a piece of equipment when a protective door is open or some other hazard exists.
Alarms and Procedures: Systems that operate a warning device
after the occurrence of a hazardous condition and procedures to activate the alarm system.
Keyed Bypass: A bypass system that is activated by a control
signal.
Emergency Air Supply: A backup system to provide air to a process
when the regular air supply fails.
Emergency Power: Backup power systems.
Backup Pump: A secondary pump intended to serve the same function
as the primary pump if the primary pump fails.
Grounding Equipment: Devices that ground electrical equipment to
avoid explosions.
Inhibitor Addition: A substance that is added to a reaction that
is capable of stopping or retarding a chemical reaction.
Rupture Disks: A rupture disk is a device that relieves pressure
beyond a specified limit and recloses upon return to normal operating conditions.
Excess Flow Device: Flow-limiting equipment that protects
downstream equipment from surges.
Quench System: A system that cools by removing excess heat or
immersing liquid into a cooling medium.
Purge System: A system that replaces the atmosphere in a
container with an inert substance to prevent the formation of an explosive mixture.
Other (specify)
Mitigation systems: Indicate with a check mark all of the
mitigation systems in place to control a release should one occur from the process.
Sprinkler System: A system for protecting a building against fire
by means of overhead pipes which convey an extinguishing fluid through heat activated
outlets.
Dikes: A low wall that acts as a barrier to prevent a spill from
spreading.
Fire Walls: A wall constructed to prevent the spread of fire.
Blast Walls: A heavy wall used to isolate buildings or areas that
contain highly combustible or explosive materials.
Deluge System: A system to overflow an area of a release with
water or other extinguishing fluid.
Water Curtain: A spray of water from a horizontal pipe through
nozzles, the curtain may be activated manually or automatically.
Enclosure: Physical containment of the release within a structure
(e.g., a building).
Neutralization: Controlling a release by neutralizing the
released chemical.
Other (specify)
Monitoring/detection systems: Indicate with a check mark the
monitoring and detection systems installed to detect a release of a regulated substance
from the process.
Process Area Detectors: Detection systems located on or close to
process equipment. Detection systems include indicator tubes, and chromatographic,
spectrometric, electrochemical, and colorimetric gas analysis.
Perimeter Monitors: Integrated detection networks at the source
boundary. Detection systems can include fluorescent SO2 analyzers,
photoelectric tape sensors, or electrolytic chlorine detectors.
Other (specify)
Changes since last PHA update: Indicate with a check mark all of
the changes made to the process since the last PHA. Check all that apply.
Reduction in Chemical Inventory: Decrease in the quantity of
regulated substances stored on site.
Increase in Chemical Inventory: Increase in the quantity of
regulated substances stored on site.
Change in Process Parameters: Increase or decrease in
temperature, pressure, flow rates, etc.
Installation of Process Controls: Addition of controls such as
those listed in question 5 above.
Installation of Process Detection Systems: Addition of systems
such as those listed in question 7 above.
Installation of Perimeter Monitoring Systems: Addition of systems
such as those listed in question 7 above.
Installation of Mitigation Systems: Addition of systems such as
those listed in question 6 above.
Other (specify)
None Required/Recommended: PHA team recommended no change.
7.5 The date of the most recent review or revision of operating procedures: You
should have developed and implemented written operating procedures as defined in
§ 68.69 that provide clear instructions for safely conducting activities involved in
each covered process that are consistent with the process safety information. Operating
procedures shall be reviewed as often as necessary to assure that they reflect current
operating practice, including changes that result from changes in process chemicals,
technology, and equipment, and changes to stationary sources. Indicate the date of the
most recent review or revision.
7.6 Training: The training program, as specified in § 68.71, should cover
initial training for each employee involved in operating a process that emphasizes
specific safety and health hazards, emergency operations including shutdown, and safe work
practices. You should also offer refresher training at least every three years and
training documentation to show that each employee involved in operating a process has
received and understood the required training.
The date of the most recent review or revision of training programs
The type of training provided: Indicate whether the training was
held in a classroom, was a combination of classroom and on the job, on the job, or other.
The type of competency testing used: Indicate with a check mark
how employees were tested to determine and evaluate comprehension of the training
materials.
7.7 Maintenance: The maintenance program, defined in § 68.73, ensures the
mechanical integrity of process equipment. The maintenance program procedures should be
written, training should be provided for employees involved in maintenance activities,
inspection and testing should be performed in process equipment, equipment deficiencies
should be corrected before further use or in a safe and timely manner, and the owner or
operator should ensure that the equipment is installed properly and consistent with design
specifications.
The date of the most recent review or revision of maintenance
procedures
The date of the most recent equipment inspection or test
The equipment inspected or tested
7.8 Management of Change: The owner or operator shall establish and implement
written procedures to manage changes (except for "replacements in kind") to
process chemicals, technology, equipment, and procedures; and, changes to stationary
sources that affect a covered process as specified in § 68.75.
The date of the most recent change that triggered management of
change procedures
The date of the most recent review or revision of management of
change procedures
7.8 The date of the most recent pre-startup review: Pre-start up review, as
specified in § 68.77, shall be performed for new stationary sources and for modified
stationary sources when the modification is significant enough to require a change in the
process safety information.
7.9 Compliance audits: Compliance audits, as specified in § 68.79,
evaluate whether the source is in compliance with the risk management program provisions
and should be conducted at least every three years by a person knowledgeable in the
process.
The date of the most recent compliance audit
The expected date of completion of any changes resulting from the
compliance audit
7.10 Incident investigation: The owner or operator should have procedures, as
specified in § 68.81, to investigate each incident that resulted in, or could
reasonably have resulted in a catastrophic release of a regulated substance.
The date of the most recent incident investigation
The expected date of completion of any changes resulting from the
investigation
7.11 The date of the most recent review or revision of employee participation plans:
Employee participation is described in § 68.83.
7.12 The date of the most recent review or revision of hot work permit procedures:
Hot work permits are described in § 68.85.
7.13 The date of the most recent review or revision of contractor safety procedures:
Contractor safety procedures, as described in § 68.87, describe procedures to
oversee contractors performing maintenance or repair work, turnaround, major renovation,
or specialty work on or adjacent to a covered process. This section does not apply to
contractors providing incidental services that do not influence process safety (e.g.,
trash removal, groundkeeping).
7.14 The date of the most recent evaluation of contractor safety performance:
Contractor safety procedures are described in § 68.87.
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