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Eberz Bayer AG Prof. Pettelkau Federal Ministry for the Environment Dr. For example, Brethericks Handbook Urben Obviously, the more information andknowledge that is available, the more thorough and valuable the risk studycan be.

Essential Practices for Managing Chemical Reactivity Hazards

This chapter assumes chemical reactivity hazards exist at your facility. Amount and rate of gas evolution. However, they cannot be relied upon to give complete infor-mation, particularly with regard to chemical incompatibilities andchemical reactivity at actual process conditions.

Temperatures are closely monitored, andstack emissions are routinely sampled. Determination of these limits is outside the scope of this publication; refer-ences such as Barton and RogersCCPS a and HSE canbe consulted for further information.

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Somemajor companies have their own testing facilities, but there are a number oftesting houses and consultancies available that you could use. Over the years, many things happen in a plant that are not written down,but the ability to relate new questions or problems to past experience is crit-ical to effective problem solving. A truly inherently safer process will reduceor eliminate the hazard Kletzrather than simply reducing itsimpact.

Group compatibility data indicates no reaction between propylenedichloride and aluminum oxide which would form an outside layer on thealuminum 591. Procedures and job descriptions may specify some of theseresponsibilities for an existing facility. Implied in line responsibility is a clear understanding of facility owner-ship, including who owns the facilitys chemical reactivity hazards. Training and communication must address: The process definition should be documented in a single document orset of documents, bringing all process-related information together.

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Sources such as CCPS b trts consulted when designing emergency relief protection in physical andchemical processing systems involving chemical reactivity hazards.

In many cases, the pressure data canalso yield valuable information. YES Organic feed materials; concen-trated hydrochloric acid; oxygen5.

It is documented with worked examples inCCPS b. YES Propylene dichloride is a flammableliquid5. Measures taken to control an exothermic process, which are based onsuch functionality will therefore be futile. This is one reason why broadthinking should be encouraged when developing mixing scenarios to beevaluated. The cooling capacity has therefore been chosen in such away that the heat of reaction that is released at the intended metering rate can be removed atthe required process temperature.

Case histories of chemical reactivity incidents, such as those in Appen-dix A-1, are useful in getting needed attention and priority for a chemicalreactivity hazard management system.

Someone, often the seniorengineering and senior research and development officers, should indicateacceptance of the technology as it evolves during the design process.

CCPS addresses content and format issues foreffective written procedures. Adding a material out of sequence Adding the wrong material Delayed discharge of material from vessel.

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Procedural ControlsProcedural controls sometimes called administrative controls use operat-ing procedures, emergency response and other management approachesto prevent incidents or to minimize their effects. Ideally, all components of interest including such entities as commoncleaning materials, air, water, heat, materials of construction, additives, cat-alysts, other utility services, etc.

Examples includedikes, anlagw, orifice plates or narrow bore piping to control flow, and the4 Essential Management Practices 97use of equipment rated for higher pressure. It has over 20, entries; however, thereactivity and incompatibility information tends to be relatively brief.

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Forfacilities with chemical reactivity hazards, this requires a thorough under-standing of possible chemical reaction scenarios with the actual equip-ment, controls and environment of the facility.

While it may be easy during the research stage to keepall relevant information coordinated, as a process moves further into its lifecycle the information coordination process becomes more complex.

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These parameters need to be considered for reactions that go towards the intended completionas well as for possible upsets see section C. The authority having jurisdiction, which initiated the preparation of this guideline, andauthor s assume no liabilities with respect to the multiplication or reproduction of this guideline. Issues of importance, which should be addressed by themanagement system, include specifying who will keep the records, whereand how they will be maintained, and how they can be retrieved and usedat both the facility and company-wide levels.

Test results and reports, including plots, graphs andcharts, are scanned into the database. Methods used todetermine chemical reaction risks are varied, as are their objectives anddata requirements. However, merelymaintaining factual design information is not sufficient. Ineither case, your management system mustalso include a means of detecting and check-ing any new or variant chemicals brought on-site for the first time.

Document Chemical Reactivity Risksand Management DecisionsCapturing process knowledge and safety information is fundamental tomany aspects of managing chemical reactivity hazards. MSDS data are likely to pertain only to ambient and fire-exposureconditions.