Perform an audit of the process safety information (PSI) at several of the storage terminals to assess the level of compliance of these sites with the PSI requirements of OSHA’s PSM regulation, 29 CFR 1910.119, and the accident prevention Program Level 3 requirements of EPA’s RMP regulation, 40 CFR 68. Subsequently provide process safety management (PSM) compliance support to address deficiencies found in the process safety information for the various sites.
AMMONIA TERMINALS PROCESS SAFETY MANAGEMENT (PSM) COMPLIANCE SUPPORT
The client owns and operates both hot and cold (cryogenic) anhydrous ammonia (NH3) storage terminals. Process Engineering Associates, LLC (PROCESS) was contracted by the client to perform an audit of the process safety information (PSI) at several of the storage terminals to assess the level of compliance of these sites with the PSI requirements of OSHA’s PSM regulation, 29 CFR 1910.119, and the accident prevention Program Level 3 requirements of EPA’s RMP regulation, 40 CFR 68. As a result of the audits, PROCESS was further contracted to provide process safety management compliance support to address deficiencies found in the process safety information for the various sites. PROCESS‘ specific tasks included:
- Calculating maximum intended inventories of process materials
- Developing safe upper and lower operating limits documentation
- Developing plot plans of safety systems
- Developing electrical classification drawings
- Developing process flow diagrams (PFDs).
The PROCESS project manager visited each hot and cold storage terminal for the purpose of performing the PSI audits and collecting the information required for developing the required PSI. Maximum intended inventories were generated via in-house computer technology that uses unit operation design and materials physical property data to calculate and summarize liquid inventories for the ammonia storage terminals. The safe upper and lower operating limit documentation summarizes the normal operating ranges, safe operating limits, consequences of deviations, detection capabilities, automatic corrective actions, and manual corrective actions for pertinent process parameters (e.g., level, temperature, pressure). The safety system plot plans depict the locations of fire extinguishers, emergency shutdown systems, ammonia sensors, safety showers, breathing apparatuses, first aid stations, wind socks, and emergency exits/evacuation routes. The electrical classification drawings depict the electrical classification boundaries throughout the facilities as outlined in API Recommended Practice 500. Finally, the process flow diagrams depict the major unit operations at the facilities and how they interconnect with each other.
PROCESS‘ execution of this project helped bring the hot and cold ammonia storage terminals into regulatory compliance and also provided site personnel with several training tools relative to plant operations.
- Storage Terminals
- Process engineering
- Process safety management