Awareness Training Goals - Salinas Valley Ammonia Safety Day

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Ammonia Safety Day The SIMPLE Plan for Emergency Events: Date:_________ Time:________ Name(s) Technician:___________________________________________________________________ Facility Emergency Coordinator: ______________________________________________________ LANCE and SIMPLE: What happened? Who is at risk? What is anticipated? What is the plan? ____________________________________________________________________________________ What type and amount of problem (fire, overpressure, release – aerosol, dense gas, vapor, liquid)? ________________________________________________________________________ Sources of Ignition: If the release approaches 15,000 PPM, aggressively control sources of ignition. Define control of potential sources:___________________________________________________ Isolate the Release: Consult P&ID for location of valves to control a potential release; make sure liquid isn’t trapped. Upstream valve: ___________________________________________________________________ Downstream valve:_________________________________________________________________ Trapping concerns:_________________________________________________________________ Manage the Pressure: Reduce system pressure, reduce cooling demand, isolate the amount of ammonia flowing to leak site. High Side:_________________________________________________________________________ Intermediate:______________________________________________________________________ Low Side:_________________________________________________________________________ Positive Pressure Ventilation: Plan for the downwind and/or route of your ventilation release. Sources of ignition controlled? Fire spread potential? Public safety access, traffic control concerns? Inside travel of gases (Building Plan):_________________________________________________ Downwind concerns (Site Plan):______________________________________________________ LANCE Again: Continuously check in with LANCE and improve upon the plan. Recheck LANCE: _________________________________________________________________ Notify the local, state and federal environmental regulators: Date/Time/Initials Emergency Response Plan: Transition to the 30-Minute Plan; size up, notification, incident action plan, safety plan and command and control. IAP, Safety Plan, backup staffing, EMS, decontamination, rehabilitation Site Plan/Building Plans, P&IDs and Photographs 18 ©ASTI – www.ammonia-safety.com – August 2008
PSM Readiness Outline 1. Employee Participation – A team approach! Who is on the team? Engineering, Operations and Maintenance, fork lift drivers, general laborers, supervisors, managers How are you looking at your problems? Impacts – priorities – perceived vs. real threats Economics – most benefit for the investment Tracking and recording problems, challenges, needs The cost of a forgotten fix? Yearly awareness training – readiness to evaluate the facts; focus on making good fixes Keep minutes and good records of your efforts Employee access to the information (with conditions) 2. Process Safety Information Knowing the chemical and hazards – data book, MSDS Understanding your system – P&ID and valve tagging Operational SOPs Materials, electrical, certification of service relief valves Operational limits/capacities, consequences of deviation Unobstructed and accessible exits Monitoring systems – pressure and release monitoring Ventilation systems controls and valve operation Compliance to “good engineering practices” 3. Process Hazard Analysis – site specific What if/checklist methodology Every piece of equipment (unless exactly the same) documented and problems addressed ASAP Facility and human factors Updated every five years 4. Operational Procedures Clearly documented initial start up, normal operations, emergency/normal shut down, start up after turn-around SOPs – preventing slugging, trapping, overfilling Safety, health, PPE, lockout/tagout, operating limits, deviation, safeties, confined space, operator qualification Recognizing a problem and tracking its repair IIAR Bulletin 107 Maintenance, review, access, training plan 5. Training Identify who is to be trained and set competency levels Awareness, Technician, Operator – Initial and Refresher Operator training – efficiency, effectiveness, and safety Records and recognition – testing and certifying readiness Ammonia properties, refrig. cycle, mechanical integrity, normal operations and operating limits, correcting abnormal operations, power failure, responsibilities, emergency plans, basic electrical, MSDS, etc. 6. Contractors Contractor packet, sign-in, sign-off procedures – readiness and tracking; SOP – who is in charge of an emergency incident involving contractor-related work, WHAT IS THE PLAN, Process Hazard Analysis (PHA) the worst case scenario 7. Pre-Start Review Manufacture support; qualified start-ups; IIAR Bulletin 110 Ammonia Safety Day 8. Mechanical Integrity – system and components Pressure vessels, piping, valves, controls, emergency shut down systems and every refrigeration component Log book – safety valves checked – PM schedule IIAR Bulletin 109 Planned maintenance, inspection, testing, training, documentation, equipment inventory, manufacturer details Inspections: check sheets, daily inspection/log, oil samples, scans, scheduled maintenance Operators and technicians must be trained Documentation! Deficiency list addressed! Annual audit and Preventive Maintenance manuals 9. Hot Works Permit Program – training – discipline – fire and LANCE and SIMPLE readiness Welding, grinding, and cutting safety checklist Procedures: initiating, issuing, performing, and completing Hot Work Permits 10. Management of Change – technical basis for change Impact of change on safety and health; time period for change; authorization for change PHA – MOC – SOP in sync Deficiencies and concerns addressed – walk the talk Not needed for “replacement in kind” 11. Incident Investigation ALL near misses and incidents investigated – do the PMP within 48 hours of the incident; recommendations must be addressed in timely manner Records and reports – 5-year history Investigation team trained and ready to do the evaluation Notifications timely and recorded – follow up Documentation 12. Emergency Response The ERP – Strategy – PPE/SOP – connection with public safety, evacuation alarm systems, meeting places, accountability of employees Training and readiness to respond – medical, physical Training records and follow-up – PMP opportunities Spill notification – numbers and readiness forms PPE and response equipment readiness 13. Audit Credibility (trained, tested, complete) Deficiencies recorded and resolved and documented Certify that compliance has been audited at least once every three years; include an audit checklist and deficiency tracking log 14. Ammonia Calculations – Know your system! System capacities, release amount charts, delivery log RMP details/compliance ©ASTI – www.ammonia-safety.com – August 2008 19
Page 1 and 2: Ammonia Safety Day “We will not a
Page 3 and 4: Lowest Common Denominators For Safe
Page 5 and 6: Ammonia Safety Day 6. Why is SAL
Page 7 and 8: Ammonia Safety Day Initiate emergen
Page 9 and 10: The SIMPLE Plan Take a breath and t
Page 11 and 12: Ammonia Safety Day Electricity Ser
Page 13 and 14: Ammonia Safety Day FECs shall be tr
Page 15 and 16: Piping and Instrumentation Diagram
Page 17: Ammonia Safety Day Worksheet: Servi
Page 21 and 22: Glove Box Version of the One-Plan S
Page 23 and 24: Ammonia Safety Day Containment: Whe
Page 25 and 26: Ammonia Safety Day Summary Reminder
Page 27 and 28: Workbook Questions - Emergency Resp
Page 29 and 30: Ammonia Safety Day Workbook Answers
Page 31 and 32: Ammonia Safety Day 13. What is SAL
Page 33 and 34: Ammonia Safety Day ASTI Final Exam
Page 35 and 36: L__________________________________
Page 37: 2008 SAFETY DAY EVALUATION Ammonia

Awareness Training Goals - Salinas Valley Ammonia Safety Day

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