Introduction - DOE-HDBK-1100-20040013

DOE-HDBK-1100-2004

1.0 INTRODUCTION

On February 24, 1992, the Occupational Safety and Health Administration (OSHA) released a

revised 29 CFR Part 1910 that added Section 1910.119, "Process Safety Management of Highly

Hazardous Chemicals; Explosives and Blasting Agents," to protect employees by preventing or

minimizing the consequences of chemical accidents. This regulation, hereafter referred to as the

PSM Rule, prescribes a total safety management program with 14 defined elements. DOE O

440.1, WORKER PROTECTION MANAGEMENT FOR DOE FEDERAL AND

CONTRACTOR EMPLOYEES, requires that covered chemical processes within DOE comply

with the PSM Rule. In June 2004 the DOE sent the Office of Management and Budget, DRAFT

10 CFR 851 "Worker Safety and Health" for subsequent publication in the Federal Register as

the new DOE Worker Safety and Health Rule. This new Rule will require contractors to follow

all applicable portions of 29 CFR 1910. Guidance for implementing the PSM Rule is provided

in "Process Safety Management for Highly Hazardous Chemicals" (DOE-HDBK-1101-2004).

One of the most important elements of the PSM Rule is the process hazard analysis (PrHA)1. It

requires the systematic identification of hazards and related accident scenarios. The PSM Rule

allows the use of different analysis methods, but the selected method must be based on the

process being analyzed. The PrHA and the other PSM elements must be in place prior to process

startup. PrHAs must be reviewed and updated at least every 5 years.

This handbook should be considered basic information for the required PrHA element, not a

complete resource on PrHA methods. Summary descriptions and basic step-by-step instructions

are provided. However, existing references, which are identified in each section, provide

additional insight and should be used. The primary reference should be Guidelines for Hazard

Evaluation Procedures (CCPS, 1992). IN addition, resources from relevant professional

organizations should be used on a continuing basis to maintain competence in PrHA. These

resources include books and publications, technical meetings, and continuing education. Each

DOE facility that stores or uses hazardous chemicals in above-threshold quantities is required to

have staff knowledgeable in PrHA. At least one member of the PrHA team must be

knowledgeable in the specific process methodology being used.

1. To those already familiar with hazard/risk analysis methods, a "PHA" designates a

Preliminary Hazard Analysis. Unfortunately, the PSM Rule uses these same letters to

designate Process Hazard Analysis. In this document, PrHA will designate Process

Hazard Analysis to avoid confusion with Preliminary Hazard Analysis. Note that other

literature may be confusing on this issue.