Awareness Training Goals - Salinas Valley Ammonia Safety Day

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