Safety Consulting Engineers, Inc. (SCE) provides impartial consulting services and guidance to the industry in process safety.

PSM – Process Safety Management (29 CFR 1910.119)

Process Safety Management (PSM) was promulgated by OSHA in the 1990’s to incorporate into general chemical industry practice many of the self-imposed concepts and rules that the leaders of the explosives industry were using to be among the safest of all industrial workplaces. Key to the entire concept of PSM is a clear and accurate understanding of the process materials. Process materials include ingredients, key intermediaries and final products.

Process Hazards Analysis (PHA)
Periodic safety audits, safety reviews, and on-going, effective management of change will keep the operation safe and efficient. At least every 5 years, each procedure for a covered process must be reviewed for continuing PSM compliance. This review should build upon the original PHA. It must also include a review of incidents or accidents that have occurred in the process. Lessons learned should be formally captured and incorporated into the PHA and related procedures as appropriate. Other PSM Elements such as mechanical integrity, management of change, training, etc, should be reviewed as they relate to the process.

Process hazards analysis has been described as “the accident investigation before the accident”. It is in the development of a PHA that appropriate data needs are often identified and all the pieces of data come together. By evaluating the energetic material’s sensitivity, reactivity, in-process potentials, workstation protection, engineered controls, procedural controls, and other process parameters, as one whole system, the what-ifs, failure modes and effects, flow diagrams and fault trees, as appropriate, bring into focus the hazards and effects when the process does not function as planned. A simple process normally requires only a correspondingly simple PHA. A very complex process may require all the tools a team of qualified Hazards Analysts have to offer. In either case, a valid final PHA is a data-based, real world, as-built, as-used analysis.

Process Safety Data
There are several sets of basic safety data a company must have to establish and maintain safe and efficient operations. These include 1) sensitivity data, 2) reactivity data and 3) thermal stability data. Specific tests to provide some of this data may be prescribed, such as the UN Tests for the Transport of Dangerous Goods. Similarly, the Military, ATF and other regulatory or contractual entities may prescribe particular data using standard test methods. Process Safety Data is also vital to proper site planning, storage, determination of manufacturing parameters and in-process classification.

Without accurate and adequate understanding of the process materials, assumptions and rules-of-thumb, replace engineering analysis and informed decisions. These substitutes may appear to work for a while, but sooner or later, they fail. In today’s market place, products change, processes are updated, faster, less expensive options are implemented, and without a sound understanding of the hazardous or energetic material characteristics, risk management will be lost in the shuffle. Lost product, lost facilities, lost contracts, injuries or loss of life may result.

Examples of Common Explosives Testing

Sensitivity Tests	Reactivity Tests	Thermal / Stability Tests
Impact Sensitivity (TIL, Screen, PROBIT)	Time-Pressure	Differential Scanning Calorimeter (DSC)
Friction (TIL, Screen, PROBIT)	Deflagration to Detonation Transition	Accelerated Rate Calorimetry (ARC)
ESD (TIL, Screen, PROBIT)	Internal Ignition	Simulated Bulk Acceleration Temperature
Critical Height (to explosion or detonation)	Koenen	Thermal Stability
Critical Diameter (detonation propagation)	Vented Pipe	Heat of Combustion
Card Gap	Single Package	Self Accelerating Decomposition Temperature, SADT
Dust Explosibility (minimum energy, minimum concentration)	Stack (Propagation)	Self Heating Substances
Dielectric Strength	Bullet Impact	Vacuum Stability
Thin Layer Propagation	Slow Cook-Off	Compatibility
Cap Sensitivity	TNT Equivalency	Henkin Time-to-Explosion

Safety Consulting Engineers, Inc. (SCE) is an approved test agency, recognized by the United States Department of Transportation (DOT) to test and examine explosives or potentially explosive substances and recommend the proper shipping classification. We have the skills and credentials to assist you in all your test and analysis needs for hazardous or energetic materials or processes.

For more information regarding process hazards analysis, system safety, material characterization, DOT and other regulatory compliance, and any associated testing, please contact us at 847-925-8100 or email us at sceinc@sceinc.com.

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