Process Safety Management / Risk Management Program

(PSM/RMP)Five-Year Revalidation

HanhPhuc Nguyen

If you’d like to reach SCS Engineers, Tracer Environmental Division

please contact us at: Service@scsengineers.com

Overview

• Regulatory Review

– OSHA Process Safety Management (PSM)

– EPA Risk Management Program (RMP)

– General Duty Clause

• Five-Year Revalidation Process

– Process Hazard Analysis

– Hazard Assessment

– Risk Management e Submit (RMPeSubmit)

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Regulatory Review

Worker Safetyvs.

Neighbor Safety

There are two agencies that have chemical related safety and accident prevention regulations:

Occupational Safety and Health Administration (OSHA)

regulates PSM

Environmental Protection Agency (EPA)

enforces the RMP

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Regulatory Review

• OSHA PSM:– OSHA published the proposed standard - “Process Safety

Management of Highly Hazardous Chemicals” in the Federal Register on July 17, 1990.

– The Federal PSM standard became effective on May 24, 1992.

• EPA RMP:– 40 CFR Part 68, Chemical Accident Prevention Provisions, was

published on June 21, 1996, requires facilities to develop a Risk Management Program to manage the potential risks associated with processes that use regulated substances.

– Existing facilities were required to comply by June 21, 1999.

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Regulatory Review

Applicability: Any facility that handles, stores, uses, or produces in excess

of the threshold quantity of a listed regulated substance in any single process. A process is any group of interconnected vessels and separate vessels located such that a highly hazardous chemical could be involved in a potential release.

Regulated Substance OSHA PSM EPA RMP

Anhydrous Ammonia 10,000 lbs 10,000 lbs

Aqueous Ammonia 15,000 lbs (≥44%) 20,000lbs (≥20%)

Chlorine 1,500 lbs 2,500 lbs

Sulfur Dioxide 1,000 lbs (liquid) 5,000 lbs (anhydrous)

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Regulatory Overlap

•PSI•PHA•SOPs•Training•Mechanical Integrity•Contractors•Employee Participation

•Compliance Audit•PSSR•MOC•Incident Investigation•Hot Work•Emergency Plan

OSHA PSM

EPA’S RMP

•Management Programs•RMP*eSubmit •Hazard Assessment

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General Duty Clause

Clean Air Act Amendments of 1990, Section 112(r) - General Duty Clause:

Purpose and General Duty - It shall be the objective of the regulations and programs authorized under this subsection to prevent the accidental release and to minimize the consequences of any such release of any substances listed or any other extremely hazardous substance.

Obligations Under General Duty Clause: identify hazards which may result from such releases using appropriate

hazard assessment techniques; design and maintain a safe facility taking such steps as are necessary

to prevent releases; and minimize the consequences of accidental releases which do occur.

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General Duty Clause

Occupational Safety & Health Act - General Duty Clause Section 5 (a)(1):

“Each Employer shall furnish to each of his employees, employment and a place of employment which are free from recognized hazards

that are causing or are likely to cause death or serious physical harm to his employees.”

Suggested Minimum Strategy Conduct Hazard Review & Determine Off-Site Consequences Reference: EPA Guidance for Implementation of the General

Duty Clause (550-F-09-002, March 2009)

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Process Hazard Analysis RevalidationPurpose & Requirements

What’s the purpose?•Comply with the OSHA PSM [29 CFR 1910.119(e)(6)] and EPA RMP [40 CFR 68.67(f)] regulations.•Ensure that the PHA is consistent with the current process.

What are the requirements?•Revalidate and update at least every five years after its initial or previous completion. •Revalidation to be performed by a qualified team.

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Process Hazard Analysis RevalidationPhilosophy – To Re-do or Read Through?

How should I decide?• Thoroughness of the initial or

previous PHA• Did we re-do or read through

five years ago?• Who was present in the

previous PHA?• Changes to the process in the

last five years – significant or minor?

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Process Hazard Analysis RevalidationPHA Requirements

• OSHA Letter of Interpretation (June 28, 1998):• “Employers must establish the scope and extent of their PHA updates

and revalidations to include at least the following: evaluations of existing PHAs for accuracy and completeness using the criteria set forth in 1910.119(e)(3);

• checks to ensure that modifications to processes since the last PHAs have gone through management of change procedures or PHAs when required and that those changes are reflected in the PHAs;

• an evaluation of process safety information (PSI) to ensure that it is complete, current and accurate;

• verifications to ensure PHA specified procedures are adequate, up-to-date and are being implemented;

• determinations that existing PHA recommendations have been documented in their required respective areas such as PSI, PHAs, and procedures (operating, mechanical integrity, emergency response, etc.) and have been implemented;

• a review of all incident investigation reports required by 1910.119(m) to assure all affected PSI, procedures, training, etc., have been updated to reflect recommendations set forth in the subject reports and that appropriate information from those reports have been incorporated into the PHAs.

• Finally, OSHA intends that the PHA update and revalidation be documented.”

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Process Hazard Analysis RevalidationPreparing for the PHA - Summary

• List any changes to the process in the last five years (i.e., MOC review).

• Verify accuracy of PSI:– Piping diagrams– Normal operating conditions– Safety systems

• Ensure SOPs are current.• Review implementation status of previous PHA

recommendations.• Review five year accident history / incident

investigation records.

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Process Hazard Analysis RevalidationPreparing for the PHA –

RAGAGEP

• Define recognized and generally accepted good engineering practices (RAGAGEPs) used to design, operate, and maintain your process.• Mechanical, Fire, and Building Codes• Standards – ANSI/ASHRAE 15, ANSI/IIAR 2• Guidelines – IIAR Bulletins, Chlorine Institute Pamphlet, API• Manufacturer’s Recommendations

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• The PHA methodology must be: “appropriate to determine and evaluate the hazards of the process

being analyzed.” [40 CFR 68.67(b) & 29 CFR 1910.119(e)(2)]

What methodology did you use? What-If (IIAR Questions) Checklist What-If / Checklist HAZOP (Hazard & Operability Study) Failure Mode & Effects Analysis (FMEA) Fault-Tree Analysis “appropriate to the complexity of the process”

Process Hazard Analysis RevalidationPreparing for the PHA –

Selecting the PHA Methodology

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Process Hazard Analysis RevalidationPHA – Basic Methodology

• Identify hazards associated with the process• Determine causes and consequences of each potential hazard• Discuss any incidents (facility and/or industry)• Identify administrative and engineering safeguards• Determine risk ranking• Postulate mitigation measures to reduce consequences and/or

likelihood

ConsequencesFrequency

A: Frequent

B: Periodical

C: Occasional

D: Possible

E: Improbable

I: Catastrophic 1 1 2 4 4

II: Severe 1 2 3 4 4

III: Moderate 2 3 4 4 4

IV: Slight 4 4 4 4 4

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Process Hazard Analysis RevalidationPreparing for the PHA –

Who’s on your team?

“The PHA shall be performed by a team with expertise in engineering and process operations, with at least one employee who has experience and knowledge specific to the process being

analyzed. Also, one member of the team must be knowledgeable in the specific PHA methodology being used.” [40 CFR 68.67(d) & 29

CFR 1910.119(e)(4)]

• Design Engineers• Operations and Maintenance Personnel• Engineering/Design Contractor• Safety / Environmental Management• PHA Leader & Recorder

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Process Hazard Analysis RevalidationPerforming the PHA

• Ensure previous PHA adequately satisfied PHA requirements:

• Previous incidents

• Safeguards and the consequences of the safeguard failing.

• Engineering and administrative control relationships.

• Facility Siting

• Human Factors

• Qualitative Assessment of Frequency and Consequences

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Process Hazard Analysis RevalidationRecommendation Tracking

• Develop a written schedule for completing action items.

• Assign responsibilities.

• Review status of recommendations and ensure progress is

being made periodically.

• Document recommendation review meetings and actions

taken to implement recommendations.

• Maintain evidence that shows progress or completion of

action items.

• Review status/outcomes with operating, maintenance, and

any other persons who are affected by the recommendations.

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Process Hazard Analysis RevalidationsDocumentation

• All Process Hazard Analysis Study reports must be maintained for the life of the process.

– Including recommendation resolution.– Sign In Sheets.– Piping Diagrams from the date of the study.– Team Leader Qualifications.– Methodology.– Regulatory Invites as applicable.

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Hazard Assessment

Hazard Assessment regulatory notations: EPA: 40CFR § 68.20 – 68.42

Hazard Assessment Update Requirements: “The owner or operator shall review and update the off-site

consequence analysis at least once every five years.”

Also, if changes to the process which “might reasonably be expected to increase or decrease the distance to the endpoint by a factor of two or more”, the Hazard Assessment shall be revised with the results being submitted in a revised RMP.

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Hazard AssessmentElements

• Off-Site Consequence Analysis (OCA)– Identify the worst-case release for each regulated substance;

– Identify the alternative release scenario for each regulated substance;

– Define the areas of potential off-site impacts for worst-case release and alternative release scenarios;

– Identify affected population, public receptors, and environmental receptors within worst-case and alternative release scenario impact regions.

• Five-Year Accident History

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Hazard AssessmentWorst Case Release Scenario

Determine released amount used in the modeling (Maximum capacity of Largest Vessel / Maximum intended inventory of regulated substance)

Review passive mitigation measures (vessel located in an enclosure or outside?)

Review assumptions and modeling technique (the use of EPA Guidance documents is suggested)

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Hazard AssessmentAlternative Release Scenario

Review Accident History – Have there been any releases or near releases at your facility that fit the definition of Alternate Release?

Must be more likely to occur than the worst case Must reach an endpoint offsite (unless no such scenario exists)

Review passive and active mitigation measures considered (room ventilation, water diffusion tank, automatic shut offs [safety cutouts, high level shut downs], etc.)

Review assumptions and modeling technique (the use of EPA Guidance documents is suggested)

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• Residential Population – Most Recent Census Data– References:

• Marlplot• Public Libraries• Local government offices or planning commissions

• Public– schools, hospitals, daycare centers, prisons, parks/recreational areas,

and major commercial office, and industrial buildings.– On-site facilities to which the public has routine and unrestricted access.

• Environmental– National or state parks, forests, or monuments;– Officially designated wildlife sanctuaries, preserves, refuges, or areas;– Federal wilderness areas.– Data Sources

• US Geological Survey Maps (USGS)• Data sources containing USGS data.

Hazard AssessmentOff-site Impacts

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Qualifications for Five-Year Accident History

• The EPA’s Risk Management Program (40 CFR § 68.42(a))[2] Five-Year Accident History reporting requirement:

“The owner or operator shall include in the five-year accident history all accidental released from covered processes that resulted in

deaths, injuries, or significant property damage on site, or known offsite deaths, injuries, evacuations, sheltering in place, property

damage, or environmental damage.”

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Hazard AssessmentFive-Year Accident History

• Data Required:– Date, time, and approximate duration of the release;

– Chemicals released;

– Estimated quantity released in pounds;

– Type of release event and its source (gas release, liquid spill, fire, explosion);

– Release source (storage vessel, piping, process vessel, transfer hose, valve, pump);

– Weather Conditions (if known) (temperature, wind speed/direction, stability class, precipitation);

– On-site impacts (number of deaths, injuries, property damage);

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Hazard AssessmentUpdate Tips

• No change in chemical inventory / capacity of largest vessel and no incident history meets the Alternative Release definition and existing scenario is valid

VERIFY dispersion calculations previously completed

• Update Maps & Population

• Update Sensitive Receptors lists

2010 US Census was released!!!

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Risk Management Plan

Risk Management Plan regulatory notations:

EPA: 40CFR § 68.150 – 68.190

RMP*eSubmit data elements submitted to EPA

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Risk Management Plan

EPA Risk Management Plans

Historically were submitted via 3.5” floppy diskette; now via internet (RMP*eSubmit on EPA’s CDX website).

Following your submittal, Keep the letter issued by EPA! It includes your next 5 year re-submission due date along with your unique facility ID #

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Risk Management PlanUpdate Requirements

“At least once every five years from the date of its initial submission or most recent update.”

Within 6 months of a change that requires a revised PHA or Hazard Review.

Within 6 months of a change that requires a revised off-site consequence analysis.

Within 30 days of a change in the owner or operator of the facility.

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Risk Management PlanCorrections

Within 6 months of an applicable accidental release

Within 30 days of a change to the Emergency Contact Information (see section 1.8 of the RMP*Submit)

Changes to the chemical process: revise the PSM/RMP program documentation no later than 60 days after the modifications.

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Risk Management Plan

Submitting to EPA No hard copy submittal as of January 2010. EPA’s RMP*eSubmit Software

– Online submittal on EPA’s Central Data Exchange system (https://cdx.epa.gov )

– Standard user ID and password protocols– Electronic Signature Agreement– Ability to access / update your submission on line at any

time Due every 5 years

Reference: EPA Risk Management Plan RMP*Submit Users’ Manual, EPA 555-B-09-001,

September 2009.

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Questions and Answers

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