Information About Process Equipment - DOE-HDBK-1100-20040016

DOE-HDBK-1100-2004

Block flow diagrams may be used to show major process equipment and interconnecting process

flow lines, flow rates, stream composition, temperatures, and pressures. When necessary for

completeness, process flow diagrams should be used to show all main flow streams including

valves; pressures and temperatures on all feed and product lines within all major vessels; and

points of pressure and temperature control. Construction materials, pump capacities, pressure

heads, compressor horsepower, and vessel design pressures and temperatures are shown when

necessary for clarity. Major components of control loops are usually shown along with key

utilities. Piping and instrumentation diagrams (P&IDs), which are required under process

equipment information, may be more appropriate to show some of these details.

2.1.3 Information About Process Equipment

Process equipment information must include at least: (1) materials of construction; (2) 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 ; and (8)

safety systems.

Process equipment design and materials must be documented by identifying the applicable

codes and standards (e.g., ASME, ASTM, API). If the codes and standards are not current, the

DOE contractor must document that the design, construction, testing, inspection, and operation

are still suitable for the intended use. If the process technology requires a design that departs

from the applicable codes and standards, the contractor must document that the design and

construction are suitable for the intended purpose.

2.2

Process Hazard Analysis

A PrHA is an organized and systematic method to identify and analyze the significance of

potential hazards associated with processing or handling highly hazardous chemicals. A PrHA

helps employers and workers to make decisions for improving safety and reducing the

consequences of unwanted or unplanned releases of hazardous chemicals. It is used to analyze

potential causes and consequences of fires, explosions, releases of toxic or flammable

chemicals, and major spills of hazardous chemicals. It focuses on equipment, instrumentation,

utilities, routine and non-routine human actions, and external factors that might impact a

process.

The PSM Rule specifies that a PrHA be performed on every process covered under the rule. If

several processes require PrHAs, the PrHAs must be prioritized. A preliminary hazard analysis

(PHA) may be used to determine and document the priority order for conducting PrHAs. At a

minimum, the PSM Rule requires the prioritization to consider the potential severity of a

chemical release, the number of potentially affected employees, and the operating history of the

process, including the frequency of past chemical releases and the age of the process.