pipemarking for psm...anhydrous ammonia is a common chemical used for refrigeration. facilities that...

Pipe Marking for Process Safety Management (PSM)Learn how to clearly communicate about highly hazardous chemicals using ANSI and IIAR-compliant pipe markers

Contents

1 What Is Process Safety Management

2 Who Uses Process Safety Management

3 PSM and Visual Communication

4 General Pipe Marking Requirements

5 Ammonia Pipe Marking Requirements

6 Creating Pipe Marking Labels

7 Additional Resources

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Creative Safety Supply is the leader in visual safety. We aim to help you create a safer, more efficient and compliant workplace using visual tools such as floor marking tapes, signs, labels, 5S & Lean products, and safety merchandise.

Chapter 1

What Is Process Safety Management?

Process Safety Management (PSM) is an analytical tool used to prevent the release of highly hazardous chemicals (HHCs). According to OSHA, HHCs are chemicals that can pose physical or health hazards to workers or the surrounding community. These chemicals are usually toxic, reactive, flammable, and/or explosive.

OSHA standard CFR 1910.119, Process Safety Management of Highly Hazardous Chemicals, covers the requirements for handling PSM in the workplace. This standard was published in 1992. Businesses that use, store, or transport HHCs must comply with this standard, which includes 14 parts:

• Employee Participation

• Process Safety Information

• Process Hazard Analysis

• Operating Procedures

• Training

• Contractors

• Pre-startup Review

• Mechanical Integrity

• Hot Work Permit

• Management of Change

• Incident Investigation

• Emergency Planning & Response

• Compliance Audits

• Trade Secrets

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Chapter 1

Process safety management programs take a close look at processes that use HHCs, taking into consideration:

• The design of the process

• The technology used

• Maintenance activities

• Procedures for emergencies, etc.

By using such a comprehensive approach, PSM helps businesses foresee problems and feel confident they can address problems if they arise.


Chapter 2

Who uses Process Safety Management?

Many facilities need to use PSM, and OSHA has focused its efforts on this standard in recent years. A 2013 Executive Order (EO 13650 “Improving Chemical Facility Safety and Security”) also asked government agencies such as OSHA and the EPA to make PSM (and other related chemical safety standards) a priority and examine how chemical accidents could better be prevented. This Order was prompted by recent chemical accidents such as the explosion that killed 15 people at a fertilizer facility in West, Texas, in 2013.

Industries that commonly use PSM include:

• Chemicals

• Gas/electricity/sanitation

• Fabricated metals

• Paint, adhesives, and sealants

• Pharmaceuticals

• Petrochemicals

• Pyrotechnics/explosives

• Paper mills

• Food processing

Whether a business needs to comply with the PSM standard in some cases also depends on the quantity of a chemical present in the workplace. For example, if a food processing facility uses anhydrous ammonia for ammonia refrigeration and it has more than 10,000 pounds of ammonia on site, the facility would need to follow PSM.


PSM and Visual Communication

An important part of process safety management is assessing processes and making sure the people involved in those processes understand the equipment they’re working with. They need to know how equipment works, what daily operations and maintenance look like, and how to respond when irregularities occur.

To facilitate this, effective PSM programs use visual communication so it’s easy to understand what’s happening where. These visuals could be warning signs, instructions, gauge markers, pipe marking labels, and more. Posting clear visual cues also tends to increase efficiency, since people can quickly get the information they need to perform their jobs.

Posting visuals also improves a PSM program by translating your documented program to the physical workplace. Training can be forgotten over time, but visuals can reinforce procedures.

The signs and labels you post should be easy to understand and follow standard formats. Consistency is key in a visual communication system.

In particular, pipe marking labels should use specific formats. This consistency will help your facility stay compliant and help workers do their work. For example, if someone needs to trace a pipe in a system, clear labels will make that process much faster.

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Chapter 4

General Pipe Marking Requirements

The ANSI/ASME A13.1 Standard provides guidelines for marking pipes in the workplace, and OSHA has accepted this standard as a best practice. This standard includes guidelines for label size, text size, color, and placement of labels on pipes.

COLOR GUIDELINES

FLAMMABLEFluids which are a vapor or produce vapors that can ignite and continue to burn in air.

Black on Yellow

COMBUSTIBLE Fluids that may burn but are not flammable. White on Brown

TOXIC/CORROSIVEFluids which are corrosive or toxic or will produce corrosive or toxic substances.

Black on Orange

FIRE QUENCHINGWater and other substances used in sprinkler fire fighting piping systems.

White on Red

OTHER WATERAny other water except for water used in sprinkler & fire fighting piping systems.

White on Green

COMPRESSED AIR Any vapor or gas under pressure that does not fit a category above. White on Blue

OTHER Definable by user. White on Purple

OTHER Definable by user. White on Black

OTHER Definable by user. Black on White

OTHER Definable by user. White on Gray

HYDROGEN

ACETIC ACID

NITRIC ACID

HALON

BOILER WATER

COMPRESSED AIR

OTHER

OTHER

OTHER

OTHER

Content Type Description Required Colors Example


Chapter 4

PLACEMENT GUIDELINES

SIZE GUIDELINES

A. Every 25’ to 50’ along straight runsB. At all changes in direction (on both sides of the turn)C. At both sides of entry points through floors and wallsD. Next to all flanges and valves

A

C

B

D

0.75” to 1.25”(19 - 32 mm)

1” x 8”(25 x 203 mm)

0.5”(13 mm)

1.25” to 2.5”(38 - 51 mm)

1” x 8”(25 x 203 mm)

0.75”(19 mm)

2.5” to 8”(64 - 203 mm)

2” x 12”(51 x 305 mm)

1.25”(32 mm)

8” to 10”(203 - 254 mm)

3” x 24”(102 x 610 mm)

2.5”(64 mm)

10”+(Over 254 mm)

4” x 32”(153 x 813 mm)

3.5”(89 mm)

Pipe Diameter Min. Label Size Min. Text Height


Chapter 5

Ammonia Pipe Marking Requirements

Anhydrous ammonia is a common chemical used for refrigeration. Facilities that use it often need to comply with process safety management requirements for ammonia refrigeration, including requirements for pipe marking.

Ammonia pipe markers are more detailed than regular pipe marking labels. These labels must meet the requirements of the International Institute of Ammonia Refrigeration (IIAR) Standards Bulletin 114. These requirements state that an ammonia pipe marker should have five parts:

• Abbreviations for ammonia system components

• Physical state(s) (liquid, vapor, or both)

• Marker body (“AMMONIA”)

• Pressure level (high or low)

• Arrow indicating flow direction

These labels must also use specific colors, as seen in the sample label on the next page. The majority of the label is orange with black text. The smaller label components are yellow, blue, or green.


Chapter 5

1 2 3 4 5

1

5

2 3 4ABBREVIATIONS

FLOW DIRECTION

PHYSICAL STATE(S) MARKER BODY PRESSURE LEVEL

PIPE MARKER SIZE SPECIFICATIONS

• Abbreviations for Ammonia System Components• Printed in black on orange

• Indicates the direction of flow of the system contents• Place arrows at one or both ends of the Pipe Marker

• LIQ = Liquid (black printed on yellow)• VAP = Vapor (black or white printed on blue)• LIQ/VAP - If both states exist, use both

• Always “AMMONIA”• Printed in black on orange

Commonly used arrow types

• HIGH (printed on red)• LOW (printed on green)

Black or white text

VAP LOWLIQ HIGHLIQ HIGHVAP LOWVAP HIGHLIQ HIGHVAP HIGHVAP LOWLIQ AMMONIA LOW

LIQ/VAP LOWLIQ HIGHVAP LOWLIQ LOW

LIQ/VAP LOWVAP HIGH

LIQ/VAP HIGHLIQ HIGH

= Booster Discharge= Condenser= Defrost Condensate= Economizer Suction= Hot Gas Defrost= High Pressure Liquid= High Stage Discharge= High Stage Suction= High Temp Recirculated Liquid= High Temp Recirculated Suction= Liquid Injection Cooling= Low Stage Suction= Low Temp Recirculated Liquid= Low Temp Recirculated Suction= Relief Vent= Thermosyphon Return= Thermosyphon Supply

BDCDDCES

HGDHPLHSDHSS

HTRLHTRS

LICLSS

LTRLLTRS

RVTSRTSS

Full Arrow Chevron Arrowhead

Outside Pipe Diameter

Min. Length of Label

Min. Height of Letters

.75” - 1.25”(19mm - 32mm)

8” (203mm) 0.5” (13mm)

1.5” - 2”(38mm - 51mm)

8” (203mm) 0.75” (19mm)

2.5" - 6”(64mm - 152mm)

12” (305mm) 1.25” (32mm)

8” - 10”(203mm - 254mm)

24” (610mm) 2.5” (64mm)

over 10”(over 254mm)

32” (813mm) 3.5” (89mm)

AMMONIA LABEL GUIDELINES


Chapter 6

Create Pipe Marking Labels

If you need pipe labels, you can either order them from a supplier or print them yourself using an industrial label printer. For facilities that need lots of labels, creating them in-house is often the most economical option.

For most pipes, labels made from vinyl work well and hold up to industrial conditions. However, it’s important to note that standard vinyl has a high halide content, which can damage stainless steel or nickel pipes (typically found in food production), leading to corrosion. Make sure to select labels made from low halide vinyl for this application.

Once labels are applied to pipes, they will help people identify pipe contents for a long time. This enhances your process safety management plan by assisting people during both normal operations and emergencies.

If any changes to processes occur, make sure to evaluate the new process to determine whether any changes need to be made to your pipe marking labels. Whenever you routinely evaluate your PSM processes for PSM compliance*, it’s also a good practice to assess your pipe marking labels at that time.

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*OSHA states that a process hazard analysis must be evaluated and updated at least every five years.


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Chapter 7

Additional Resources

Related Products

LabelTac® Pipe Marking Printerswww.creativesafetysupply.com/labeltac

LabelTac® 4 Pro Pipe Marking Bundlewww.labeltac.com/labeltac-4-pro-pipe-marking-package/

Related Guides

• Pipe Marking Guide • Pipe Marking Pocket Guide • Ammonia Pipe Marking Quick Guide • Facility Marking Workbook

Available at: www.creativesafetysupply.com/guides

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