Pumping unit safety
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Rosie's answer
Published by SALUSPumping units, as process equipment, fall under OSHA's mechanical integrity requirements, which include written procedures, training, inspections, and quality assurance to ensure their ongoing integrity. Employers must establish and implement written procedures to maintain the integrity of process equipment, including pumps. [1] [2] [3]
Training is essential for employees involved in maintaining pump integrity, covering process overview, hazards, and safe job performance. Employers need to train each employee involved in maintaining the ongoing integrity of process equipment in an overview of that process and its hazards and in the procedures applicable to the employee's job tasks to assure that the employee can perform the job tasks in a safe manner. Refresher training should be provided at least every three years to ensure employees understand and adhere to current operating procedures. [1] [2] [4] [5]
Regular inspections and tests must be conducted on process equipment, following recognized engineering practices and manufacturer recommendations. The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience. Each inspection and test performed on process equipment should be documented, including the date, inspector's name, equipment identifier, description of the inspection, and results. [1] [1] [1] [1] [2] [2] [2] [2]
Deficiencies in equipment that fall outside acceptable limits must be corrected before further use, or in a safe and timely manner with necessary precautions. The employer shall correct deficiencies in equipment that are outside acceptable limits (defined by the process safety information in paragraph (d) of this section) before further use or in a safe and timely manner when necessary means are taken to assure safe operation. [1] [2]
Operating procedures must include steps for emergency shutdown, including conditions that trigger it and assigned responsibilities. The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address at least the following elements: Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner. [4] [5]
Operating procedures should address safety and health considerations, including chemical properties and hazards, exposure precautions (engineering, administrative controls, and PPE), control measures for contact or exposure, and any special hazards. Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment. [4] [5]
PPE should be used in conjunction with guards, engineering controls, and sound manufacturing practices. A hazard assessment should be conducted to identify potential hazards and the appropriate PPE. To assess the need for PPE a walk-through survey of the areas in question should be conducted to identify sources of hazards to workers and co-workers, and basic hazard categories. [6] [6]
Sources used for this answer
[1] Occupational Safety and Health Standards (OSHA 29 CFR 1910) - 1910.119 - Process safety management of highly hazardous chemicals
Page 16
Open source documentSource excerpt
# Employer responsibilities. (cont.) ## 1910.119(h)(3)(v) (cont.) Safety, operating, maintenance, and emergency procedures are in place and are adequate; 1910.119(i)(2)(iii) For new facilities, a process hazard analysis has been performed and recommendations have been resolved or implemented before startup; and modified facilities meet the requirements contained in management of change, paragraph (l). 1910.119(i)(2)(iv) Training of each employee involved in operating a process has been completed. 1910.119(j) Mechanical integrity- 1910.119(j)(1) Application. Paragraphs (j)(2) through (j)(6) of this section apply to the following process equipment: 1910.119(j)(1)(i) Pressure vessels and storage tanks; (!!)(I)({)6TT'0161 Piping systems (including piping components such as valves); 1910.119(j)(1)(iii) Relief and vent systems and devices; - 1910.119(j)(1)(iv) - Emergency shutdown systems; (^)(I)({)6TT'0161 Controls (including monitoring devices and sensors, alarms, and interlocks) and, - 1910.119(j)(1)(vi) - Pumps. Submit Feedback
[2] General Industry Safety and Health Standards (MIOSHA)
Page 9
Open source documentSource excerpt
# 1910.119(f) OPERATING PROCEDURES. 1910.119(f)(1) The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address at least the following elements. 1910.119(f)(1)(i) Steps for each operating phase: 1910.119(f)(1)(i)(A) Initial startup; 1910.119(f)(1)(i)(B) Normal operations; 1910.119(f)(1)(i)(C) Temporary operations; 1910.119(f)(1)(i)(D) Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner. 1910.119(f)(1)(i)(E) Emergency Operations; 1910.119(f)(1)(i)(F) Normal shutdown; and, 1910.119(f)(1)(i)(G) Startup following a turnaround, or after an emergency shutdown. 1910.119(f)(1)(ii) Operating limits: 1910.119(f)(1)(ii)(A) Consequences of deviation; and 1910.119(f)(1)(ii)(B) Steps required to correct or avoid deviation. 1910.119(f)(1)(iii) Safety and health considerations: 1910.119(f)(1)(iii)(A) Properties of, and hazards presented by, the chemicals used in the process; 1910.119(f)(1)(iii)(B) Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment; 1910.119(f)(1)(iii)(C) Control measures to be taken if physical contact or airborne exposure occurs; 1910.119(f)(1)(iii)(D) Quality control for raw materials and control of hazardous chemical inventory levels; and, 1910.119(f)(1)(iii)(E) Any special or unique hazards. 1910.119(f)(1)(iv) Safety systems and their functions. 1910.119(f)(2) Operating procedures shall be readily accessible to employees who work in or maintain a process. 1910.119(f)(3) The operating procedures shall be reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in…
[3] General Industry Safety and Health Standards (MIOSHA)
Page 30
Open source documentSource excerpt
APPENDIX B GUIDELINES FOR HAZARD ASSESSMENT AND PERSONAL PROTECTIVE EQUIPMENT SELECTION (NON-MANDATORY) This Appendix is intended to provide compliance assistance for employers and employees in implementing requirements for a hazard assessment and the selection of personal protective equipment. 1. CONTROLLING HAZARDS. PPE devices alone should not be relied on to provide protection against hazards, but should be used in conjunction with guards, engineering controls, and sound manufacturing practices. 2. ASSESSMENT AND SELECTION. It is necessary to consider certain general guidelines for assessing the eyes, face, head, hands, feet, and body hazard situations that exist in an occupational or educational operation or process, and to match the protective devices to the particular hazard. It should be the responsibility of the safety officer to exercise common sense and appropriate expertise to accomplish these tasks. 3. ASSESSMENT GUIDELINES. In order to assess the need for PPE the following steps should be taken: a. Survey. Conduct a walk-through survey of the areas in question. The purpose of the survey is to identify sources of hazards to workers and co-workers. Consideration should be given to the basic hazard categories: (a) Impact. (b) Penetration. (c) Compression (roll-over). (d) Chemical. (e) Heat. (f) Harmful dust. (g) Light (optical) radiation. b. Sources. During the walk-through survey the safety officer should observe: (a) Sources of motion; i.e., machinery or processes where any movement of tools, machine elements or particles could exist, or movement of personnel that could result in collision with stationary objects. (b) Sources of high temperatures that could result in burns, eye injury or ignition of protective equipment, etc. (c) Types of chemical exposures. (d) Sources of harmful dust. (e) Sources of light radiation, i.e., welding, brazing, cutting, furnaces, heat t…
[4] General Industry Safety and Health Standards (MIOSHA)
Page 9
Open source documentSource excerpt
# 1910.119(f) OPERATING PROCEDURES. 1910.119(f)(1) The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address at least the following elements. 1910.119(f)(1)(i) Steps for each operating phase: 1910.119(f)(1)(i)(A) Initial startup; 1910.119(f)(1)(i)(B) Normal operations; 1910.119(f)(1)(i)(C) Temporary operations; 1910.119(f)(1)(i)(D) Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner. 1910.119(f)(1)(i)(E) Emergency Operations; 1910.119(f)(1)(i)(F) Normal shutdown; and, 1910.119(f)(1)(i)(G) Startup following a turnaround, or after an emergency shutdown. 1910.119(f)(1)(ii) Operating limits: 1910.119(f)(1)(ii)(A) Consequences of deviation; and 1910.119(f)(1)(ii)(B) Steps required to correct or avoid deviation. 1910.119(f)(1)(iii) Safety and health considerations: 1910.119(f)(1)(iii)(A) Properties of, and hazards presented by, the chemicals used in the process; 1910.119(f)(1)(iii)(B) Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment; 1910.119(f)(1)(iii)(C) Control measures to be taken if physical contact or airborne exposure occurs; 1910.119(f)(1)(iii)(D) Quality control for raw materials and control of hazardous chemical inventory levels; and, 1910.119(f)(1)(iii)(E) Any special or unique hazards. 1910.119(f)(1)(iv) Safety systems and their functions. 1910.119(f)(2) Operating procedures shall be readily accessible to employees who work in or maintain a process. 1910.119(f)(3) The operating procedures shall be reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in…
[5] General Industry Safety and Health Standards (MIOSHA)
Page 11
Open source documentSource excerpt
# 1910.119(f) OPERATING PROCEDURES. (cont.) ## 1910.119(h) CONTRACTORS. (cont.) - 1910.119(j) MECHANICAL INTEGRITY. 1910.119(j)(1) Application. Paragraphs (j)(2) through (j)(6) of this section apply to the following process equipment: 1910.119(j)(1)(i) Pressure vessels and storage tanks; 1910.119(j)(1)(ii) Piping systems (including piping components such as valves); 1910.119(j)(1)(iii) Relief and vent systems and devices; 1910.119(j)(1)(iv) Emergency shutdown systems; 1910.119(j)(1)(v) Controls (including monitoring devices and sensors, alarms, and interlocks) and, 1910.119(j)(1)(vi) Pumps. - 1910.119(j)(2) Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment. - 1910.119(j)(3) Training for process maintenance activities. The employer shall train each employee involved in maintaining the on-going integrity of process equipment in an overview of that process and its hazards and in the procedures applicable to the employee's job tasks to assure that the employee can perform the job tasks in a safe manner. - 1910.119(j)(4) Inspection and testing. - 1910.119(j)(4)(i) Inspections and tests shall be performed on process equipment. - 1910.119(j)(4)(ii) Inspection and testing procedures shall follow recognized and generally accepted good engineering practices. - 1910.119(j)(4)(iii) The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience. - 1910.119(j)(4)(iv) The employer shall document each inspection and test that has been performed on process equipment. The documentation shall identify the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a descriptio…
[6] General Industry Safety and Health Standards (MIOSHA)
Page 11
Open source documentSource excerpt
# 1910.119(f) OPERATING PROCEDURES. (cont.) ## 1910.119(h) CONTRACTORS. (cont.) - 1910.119(j) MECHANICAL INTEGRITY. 1910.119(j)(1) Application. Paragraphs (j)(2) through (j)(6) of this section apply to the following process equipment: 1910.119(j)(1)(i) Pressure vessels and storage tanks; 1910.119(j)(1)(ii) Piping systems (including piping components such as valves); 1910.119(j)(1)(iii) Relief and vent systems and devices; 1910.119(j)(1)(iv) Emergency shutdown systems; 1910.119(j)(1)(v) Controls (including monitoring devices and sensors, alarms, and interlocks) and, 1910.119(j)(1)(vi) Pumps. - 1910.119(j)(2) Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment. - 1910.119(j)(3) Training for process maintenance activities. The employer shall train each employee involved in maintaining the on-going integrity of process equipment in an overview of that process and its hazards and in the procedures applicable to the employee's job tasks to assure that the employee can perform the job tasks in a safe manner. - 1910.119(j)(4) Inspection and testing. - 1910.119(j)(4)(i) Inspections and tests shall be performed on process equipment. - 1910.119(j)(4)(ii) Inspection and testing procedures shall follow recognized and generally accepted good engineering practices. - 1910.119(j)(4)(iii) The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience. - 1910.119(j)(4)(iv) The employer shall document each inspection and test that has been performed on process equipment. The documentation shall identify the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a descriptio…
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