Course Material

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Overview of Process Safety

Compliance with standards
Process Hazard Analysis
Standard Operating Procedures
Safe Work Procedures
Mechanical Integrity
Management of Change
Auditing Process Safety systems
Emergency response procedures

Process Safety
Management for
Biofuels

5. Safe Work Procedures

29 CFR 1910.119 (f)(4)
This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health
Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S.
Department of Labor, nor does mention of trade names, commercial products, or organizations imply
endorsement by the U.S. Government.

Process Safety
Management for
Biofuels

5. Safe Work Procedures

29 CFR 1910.119 (f)(4)
This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health
Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S.
Department of Labor, nor does mention of trade names, commercial products, or organizations imply
endorsement by the U.S. Government.

Piper Alpha Oil Platform

Explosion

Failure of Lock out / Tag out

Procedure

Permit-To-Work System
Safe Work Permit

Safe Work Procedures

Lock out / Tag out

Each Craft Should have

Their Own Lock

Lock out / tag out

Safe Work Permit

OSHA 29 CFR 1910.147

Try the Lock Out

OSHA 29 CFR 1910.147

Additional
Information

Additional information on Lock out / Tag out

procedures can be found in the document
referenced in the below link.

Hot Work Permit

29 CFR 1910.119 (k)

Hot Work Permit

Requirements

OSHA 29 CFR
1910.252

Hot Work Permit Failure

Closing the Permit

Joint inspection when the nonroutine work is complete
1. Valve alignment
2. Blinds removed
3. Sewer drains
reopened
4. Vents
5. Rotating equipment
6. Locks and tags
7. Utilities
8. Barricades removed

Confined Space Fatalities

CSB Bulletin

Safe Work
Procedures
Confined Space Entry Permit
Permit-Required Confined Spaces (PRCS) standard 29 CFR 1910.146
http://www.osha.gov/pls/
oshaweb/owadisp.show_
document?
p_table=STANDARDS

Opening Process
Equipment Fatalities

29 CFR 1910.119 (f)(4)

www.csb.gov

Opening Process
Equipment Fatalities

29 CFR 1910.119 (f)(4)

www.csb.gov

BP Amoco Incident; Georgia; March, 2001

www.csb.gov

CSB Video on BP Amoco Incident

Can be viewed from video time 6:45 10:20

BP Amoco Incident; Georgia; March, 2001

www.csb.gov
Fact: Three maintenance workers were fatally injured.

1. Why?
The workers were working on the Polymer Catch Tank.
The polymer catch tank was still pressurized.
The workers partially removed the cover.

BP Amoco Incident; Georgia; March, 2001

www.csb.gov
Fact: The polymer catch tank was still pressurized

2. Why?
Loss of gas venting capability by catch tank.
Decomposition generating gas in core of vessel.
Pressure gauge was inoperative.
No de-energizing procedure for vessel.

BP Amoco Incident; Georgia; March, 2001

www.csb.gov
Fact: There was no de-energizing procedure for tank.

3. Why?
Pressure gauge and drain used as indication of deenergized status.
Process had been shut down, was not operative.
Outdated vessel cleaning procedure was being used.

BP Amoco Incident; Georgia; March, 2001

www.csb.gov
Fact: Outdated vessel cleaning procedure was being
used.

4. Why?

Foaming of the polymer product was not well

understood by operations.
The plugging capacity of the foaming polymer
was not well understood by operations.

BP Amoco Incident; Georgia; March, 2001

www.csb.gov
Foaming and plugging of product was not well
understood by operations.

5. Why?
Operations had not taken advantage of opportunities to
learn from near misses on product foaming and plugging.
Operations safe work procedures had not been
modified to consider foaming of polymer material.

Applicability of
Previous Material
1.
2.
3.
4.
5.

Overview of Process Safety

Compliance with standards
Process Hazard Analysis
Standard Operating Procedures
Safe Work Procedures

Remaining Course
Material
1.
2.
3.
4.
5.
6.
7.
8.
9.

Overview of Process Safety

Compliance with standards
Process Hazard Analysis
Standard Operating Procedures
Safe Work Procedures
Mechanical Integrity
Management of Change
Auditing Process Safety systems
Emergency response procedures