Collection and Integration of Hazards Information

DOE-HDBK-1163-2003

4.2

Collection and Integration of Hazards Information

The OSHA PSM Rule requires that up-to-date chemical process safety information be collected

and maintained before conducting a PrHA. Likewise, nuclear safety information and process

knowledge is required to support safety analysis activities. The approach used to collect hazards

information should be inclusive of all hazard types to support a balanced evaluation of hazards

and necessary controls.

An integrated approach to information collection is a requirement for commercial nuclear

operations subject to 10 CFR 70. This requires that process safety information be collected to

support an integrated safety analysis and should be inclusive of information pertaining to the

hazards of the materials used or produced in the process, information pertaining to the technology

of the process, and information pertaining to the equipment in the process. Although not a

requirement for DOE operations, this approach provides a good model that is also consistent with

OSHA PSM requirements and DOE nuclear safety requirements.

Hazardous Material Data

Information about hazardous substances used in a process must be comprehensive enough for an

accurate assessment of fire and explosion characteristics, reactivity hazards, criticality hazards,

corrosion or other adverse effects on process equipment and various safety and health hazards.

Information should include, as appropriate: (1) toxicity information; (2) permissible exposure

limits; (3) physical data such as boiling point, freezing point, liquid/vapor densities, vapor

pressure, flash point, auto ignition temperature, flammability limits (LFL and UFL), solubility,

appearance, and odor; (4) reactivity data, including potential for ignition or explosion; (5)

corrosivity data, including effects on metals, building materials, and organic tissues; (6) identified

incompatibilities and dangerous contaminants; (7) thermal data (heat of reaction, heat of

combustion); and (8) quantities, locations and forms of both hazardous and radioactive materials.

Where applicable, process chemistry information should also be included about potential runaway

reactions, overpressure hazards, and hazards arising from the inadvertent mixing of incompatible

chemicals. Sources of these data should be indicated (e.g., MSDS)

Process Technology Data

Where facility processing of radiological or hazardous chemicals is conducted, process

information should be collected and should include at least: (1) block flow diagrams; (2) process

chemistry (including mixtures and intermediates); (3) established criteria for maximum inventory

levels for process chemicals or radioactive materials; (4) process limits that, when exceeded, are

considered an upset condition; and (5) qualitative estimates of the consequences of deviations that

could occur if established process limits are exceeded.

Facility Process Equipment Information

Facility and process equipment information should include at least: (1) materials of construction;

(2) piping and instrumentation diagrams (P&IDs); (3) electrical classification; (4) relief system

design and design basis; (5) ventilation system design; (6) design codes and standards; (7)

material and energy balances for processes; (8) safety systems; (9) major energy sources; and (10)

interfaces with other facilities.