Remaining Course Material

1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety systems9. Emergency response procedures

4. Standard Operating Procedures

Process Safety Management for

Biofuels

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.

29 CFR 1910.119 (f)

Operating Procedures

• Written (or electronic) instructions• List the steps• Describe the order of the steps• Describe process, hazards,

protective equipment, and controls

What are Operating Procedures?

Describe the tasks necessary to safely start up,

operate, and shut down the process.Include emergency shutdown and

special situations.

Why Operating Procedures are Important

Assures that the intended procedures and methods are used by each operator,

Helps to insure that an individual operator will consistently execute a particular task in the intended manner.

Example operating procedure

Written Procedures

Written Procedures

Employee Training on Operating Procedures

Start-up Procedures

BP Texas City Explosion;Texas City, Texas;March 23, 2005

Ineffective

http://www.csb.gov/CSB REPORT NO. 2005-04-I-TX March, 2007

Outdated startup procedure

Inadequate Shutdown Procedures

Bayer CropScience, 2008

New Equipment – Inadequate Operating

Procedures

Runaway Reaction

http://www.csb.gov/newsroom/detail.aspx?nid=268

Developing Operating Procedures

A. Identify what operating procedures are needed.B. Address all operating modes in your operating procedures.C. Establish an operating procedure control system.

Developing Operating Procedures

D. Validate your operating procedures and verify that actual practice conforms to intended practice.

E. Supplement your operating procedures with checklists.

Operating Procedures

A. Identify what operating procedures are needed.

Operating Procedures

B. Establish an operating procedure control system.

Operating Procedures

 C. Address safe operating limits and consequences of deviation from the safe operating limits.

Operating Procedure = PracticePractice = Operating Procedure

D. Validate your operating procedures and verify that actual practice conforms to intended practice.

Operating Procedures

E. Supplement your operating procedures with checklists.

Remaining Course Material

1. Overview of Process Safety2. Compliance with standards3. Process Hazard Analysis4. Standard Operating Procedures5. Safe work Procedures6. Mechanical Integrity7. Management of Change8. Auditing Process Safety systems9. Emergency response procedures