osha 自愿保护纲要申请.docx
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osha 自愿保护纲要申请.docx
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osha自愿保护纲要申请
VPPApplicationSupplement
forthe
SitesSubjecttotheProcessSafetyManagement(PSM)Standard
Publicburdenreporting,forthiscollectionofinformationisestimatedtotakeapproximately40hoursperresponseincludingtimeforreviewinginstructions,searchingexistingdatasources,gatheringandmaintainingthedataneeded,andcompletingandreviewingthecollectionofinformation.
Standardmustprovideresponsestoeachquestionthatisapplicabletotheiroperations.ResponsesmustcoverallPSM-relatedoperations.Pleaseindicatethataquestionis"NotApplicable"ifitaddressesfunctionalityoutsidethescopeoftheoperations,andbrieflyexplainwhy.
I.ManagementofChange.
A.Hasthethroughputchangedfromitsoriginaldesignrate?
Hasthesiteconductedamanagementofchange(MOC)procedureforeachthroughputchangesinceMay26,1992?
B.FortheMOCproceduresconductedfortheunit(s),hastheprocedurelistedthetechnicalbasisforthechangeandALLpotentialsafetyandhealthimpactsofthechangepriortoitsimplementation?
C.Fromthesite'slistofMOCs,identifytheoldestMOCprocedurewhichmightaffecttheintegrityofoneormorepressurevesselsintheunit(s).DotheseMOCproceduresmeetall1910.119(l)requirements?
D.DoestheMOCprocessaddresstemporarychangesaswellaspermanentchanges?
E.HaveMOCsbeenconductedonallchangestoprocesschemicals,technology,equipmentandprocedures,andchangestofacilitiesthataffectacoveredprocess?
II.ReliefDesign.
A.ForeachthroughputMOCprocedureconducted,hastheprocedureaddressedareview/analysisofthereliefsystem(includesreliefdevices,reliefdischargelines,reliefdisposalequipmentandflaresystem)todetermineiftheremaybeanysafetyandhealthimpactsduetoincreasedflowasaresultofthroughputchangeswhichmightimpacttheexistingreliefsystem?
Guidance:
AnMOCprocedureisrequiredanytimeachangepertherequirementsof1910.119(l)isconsidered.AnMOCprocedureisaproactivemanagementsystemtoolusedinparttodetermineifachangemightresultinsafetyandhealthimpacts.OSHA'sMOCrequirementisprospective.ThestandardrequiresthatanMOCprocedurebecompleted,regardlessofwhetheranysafetyandhealthimpactswillactuallyberealizedbythechange.
B.Afterachangeinthethroughputintheunit(s),didtheprocesshazardanalysis(PHA)teamconsidertheadequacyoftheexistingreliefsystemdesignwithrespecttotheincreasedthroughputduringthenextPHA?
Guidance:
Typically,thePHAteamdoesnotdoareliefsystemengineeringanalysis.However,thePHAteamshoulddetermine,throughproperevaluationandconsultationwiththeengineering/technicalstaff,iftheexisting/currentengineeringanalysisofthereliefsystemisadequateforthecurrent/actualunitthroughput.
IfthethroughputchangewasimplementedbetweenthetimethePSMstandardbecameeffective(May26,1992)andthetimetheoriginalPHAwasrequiredbasedonthePHAphase-inschedule,theoriginalPHAwouldneedtoaddressthethroughputchange.However,iftherewasathroughputchangeaftertheoriginalPHA,thenextPHAupdate/"redo"orPHArevalidationwouldneedtoaddressthethroughputchange.Ineitherevent,anMOCprocedureonthethroughputchangewouldneedtohavebeenconductedandincorporatedintothenextscheduledPHA.
C.Doesthesite'sprocesssafetyinformation(PSI)includethecodesandstandardsusedinthedesignofreliefsystems?
D.Doesthesite'sPSIincludethereliefsystemdesignanddesignbasis?
Guidance:
Thisincludestheoriginaldesignanddesignchanges.ExamplesofPSIrelatedtoreliefdevices,theirdesignanddesignbasisinclude,butarenotlimitedtosuchitemsas:
1.Identification/descriptorofeachreliefdevice;
2.Alistingofallequipmentwhichwillberelievedthroughthedevice;
3.Designpressure;
4.Setpressure;
5.Listingofallsourcesofoverpressureconsidered;
6.Identificationoftheworstcaseoverpressurescenarioorreliefdesign;
7.Stateofmaterialbeingrelieved(i.e.,,liquid,vapor,liquid-vapor,liquid-vapor-solid,alongwithanidentificationofthematerialwhichwasthebasisforthereliefdeviceselection);
8.Physicalpropertiesoftherelievedmaterials,vaporrate,molecularweight,maximumrelievingpressure,heatofvaporization,specificgravityandviscosity;and
9.Designcalculations.
SimilardesignanddesignbasesPSIarerequiredfortherestofthereliefsystemequipmentdownstreamfromthereliefdevices,i.e.,reliefventlines,manifolds,headers,otherreliefdisposalequipment,andflarestack.
E.Arethereinterveningvalvesontheupstreamordownstreamlinesto/fromreliefdevices?
Ifso,doesthePHAconsiderthepossibilitythatthesevalvescouldbeclosedduringoperation,renderingthereliefdevicesnon-functional?
F.Ifthereareinterveningvalvesontheupstreamordownstreamlinesto/fromreliefdevices,doesthesitehaveeffectivecontrolsinplacetoensuretheseinterveningvalvesremainopenduringoperations?
G.Ifthereareinterveningvalvesontheupstreamordownstreamlinesto/fromreliefdevices,isthereanadministrativeprocedure(e.g.,car-sealprocedure)toassurethesevalvesareintheopenpositionduringoperations?
Ifso,hasthisprocedurebeensubsequentlyaudited?
H.Arethereopenventswhichdischargetoatmospherefromreliefdevices?
Ifso,hasthePHAconsideredwhetherthesereliefdevicesdischargetoasafelocation?
Guidance:
PHAteamsmustaddressbasicquestionsregardingwhathappenstothehazardousmaterialsaftertheyarerelievedtoatmosphere,including:
1.Aretherenegativeeffectsonemployeesorotherequipmentthatcouldcauseanotherrelease("dominoeffects")ofhazardousmaterials/HHC?
2.Whatpresumptionsorassessmentsexisttosupportthattherewillbenonegativeeffectsofanatmosphericreleaseofhazardousmaterials/HHC?
3.Areemployeesnearwherereliefdevicesdischarge,includingdownwindlocations(e.g.,ontheground,onplatformsonpressurevesselsinthevicinityofelevatedreliefdevices,etc.)?
4.Couldareleasefromareliefdevicecauseareleasefromotherequipment,orcouldothernearbyequipmentaffectthereleasedmaterial(e.g.,afurnacestackcouldbeanignitionsourceifitislocatedproximatetoanelevatedreliefdevicethatisdesignedtorelieveflammablematerials)?
Partofthesite'sPHAteam'sevaluation,afteritidentifiesthelocationsofopenvents,istodetermineifemployeesmightbeexposedwhenhazardousmaterialsarerelieved.IfthePHAteamconcludesthatacurrentandappropriateevaluation(suchastheuseofdispersionmodeling)hasbeenconducted,theevaluationcouldfindthatthevessels/ventsrelievetoasafelocation.IfthePHAteamdeterminesthatthishazardhasnotbeenappropriatelyevaluated,thePHAteammustrequestthatsuchanevaluationbeconducted,ormakesomeotherappropriaterecommendationtoensurethattheidentifiedhazard/deviationisadequatelyaddressed.
I.Doesthesitehaveamechanicalintegrity(MI)procedureforinspecting,testing,maintaining,andrepairingreliefdeviceswhichmaintainstheongoingintegrityofprocessequipment?
J.Doestheprocessuseflares?
Ifso,verifythattheflareshavebeenin-service/operationalwhentheprocesshasbeenrunning.Iftheflareshavenotbeenin-service,hasthesiteusedothereffectivemeasurestorelieveequipmentintheeventofanupset?
HasanMOCprocedurebeenusedtoevaluatethesechanges?
III.Vessels.
A.Dopressurevesselswhichhaveintegrallybondedliners,suchasstripliningorplatelining,haveanMIprocedurewhichrequiresthatthenextscheduledinspectionafteranon-streaminspectionbeaninternalinspection?
B.DoesthesitehaveanMIprocedureforestablishingthicknessmeasurementlocations(TML)inpressurevessels,anddoesthesiteimplementthatprocedurewhenestablishingtheTML?
C.DoesthesitehaveanMIprocedureforinspectingpressurevesselsforcorrosion-under-insulation(CUI),anddoesthesiteinspectpressurevesselsforCUI?
D.Doesthesite'sMIprocedureaddresstesting(e.g.leaktesting)andrepairofpressurevessels?
Forexample,doestheMIprocedureindicatehowthetestingandrepairwillbeconductedandwhichpersonnelareauthorizedtodothetestingandrepair,includingwhatcredentialsthoseconductingthetestingandrepairmusthave?
Guidance:
API510requiresin-servicepressurevesseltestswhentheAPIauthorizedpressurevesselinspectorbelievestheyarenecessary.
Guidance:
RecognizedandGenerallyAcceptedGoodEngineeringPractices(RAGAGEP)thatrequirecredentialsinclude,butarenotlimitedto:
1.Credentialsforpressurevesselinspectors,seeAPI510,Section4.2.
2.RAGAGEPforpressurevesselexaminerscredentials/experienceandtrainingrequirements,seeAPI510,Section3.18.
3.RAGAGEPforcontractorsperformingNDEarethetrainingandcertificationrequirementsASNT-TC-1A,seeCCPS,Section10.3.2.1,(In-serviceInspectionandTesting)NondestructiveExamination.
4.RAGAGEPforqualificationsforpersonnelwhoconductpressurevesselrepairs,alterationandreratingincludingqualificationsforwelders,seeAPI510,Section7.2.1andtheBPVC,SectionIX.
5.RAGAGEPforcertificationsatCCPS,Section5.4Certifications,Table5-3,WidelyAcceptedMICertifications,andTable9-13,MechanicalIntegrityActivitiesforPressureVessels.
E.Wereanydeficienciesfoundduringpressurevesselinspections?
Ifso,howweretheyresolved?
Guidance:
Adeficiency(asper1910.119(j)(5))meansaconditioninequipmentorsystemsthatisoutsideofacceptablePSIlimits.Inthecaseofapressurevessel,thiscould
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