Intent - hdbk11010038

DOE-HDBK-1101-96

(ii)

The employer shall document that equipment complies with recognized and generally accepted good

engineering practices.

(iii)

For existing equipment designed and constructed in accordance with codes, standards, or practices that are

no longer in general use, the employer shall determine and document that the equipment is designed,

maintained, inspected, tested, and operating in a safe manner.

Intent

The objective of the PSI element is to collect complete and accurate process information sufficient to

conduct PrHAs, to support hazard communication requirements, and to document the design

configuration of each process [Q42].

PSI must be sufficient to allow assessment of fire, explosion, and toxic hazards; the corrosive or

erosive effects of process chemicals on equipment and instrumentation; the potential for

overpressures or runaway reactions; and the existence of incompatibilities between materials com-

monly found around covered processes [Q43].

Information on process technology must describe the process chemistry, maximum inventories of

process chemicals, and limits for process parameters. Information is also needed to support a

qualitative estimate of the consequences of deviations or upsets outside established process limits. A

description of process technology should include block or process flow diagrams. Process flow

diagrams may include equipment sizes and ratings, process parameters for each mode of operation in

each piping segment, limits on chemical levels in all process vessels, pressure and flow data for

pumps, and process temperature and pressure limits for all equipment. Such diagramss may include

set points for pressure relief valves and alarms, monitoring and surveillance equipment, and batch

size information. Thus, detailed process flow diagrams may contain all required process technology

information except process chemistry. However, a simple block flow diagram is adequate if the

other necessary information is captured on the P&IDs or in a written process description. For exist-

ing processes for which the original process technology information no longer exists, it may be

developed in conjunction with the PrHA.

Process equipment information should describe all hardware used in a process and provide the actual

or reconstructed design, including all codes, standards, or other good engineering practices that were

followed. It must describe materials of construction; electrical classification; and design of pressure

relief, ventilation, monitoring and surveillance equipment, and other safety systems. PSI should

contain a functional description of the safety systems in a covered process to convey the protective

features that exist for emergencies [Q43]. P&IDs, which generally contain more detailed informa-

tion than process flow diagrams, must be provided to show the relationship between equipment and

instrumentation. Information on new processes must also include material and energy balances. For

older processes where the design basis is unknown or the standards, codes, and practices are not in

general use, documentation must be developed to show that the equipment is still safe to use.

Corresponding DOE Programs and Requirements

Most DOE contractors have hazard communication programs that use information from Materials

Safety Data Sheets (MSDSs) to comply with 29 CFR 1910.1200. Information about the hazards

posed by most process chemicals may also be obtained from MSDSs. Additional information may