Safety & Training

PSM Operating Procedures for Fertilizer Plant

Blackshare was contracted to develop PSM operating procedures for ammonia and nitric acid plants at a fertilizer manufacturing facility. A team of Blackshare personnel developed a template compliant with all required elements including all operating scenarios (normal, temporary, emergency shutdown, startup following turnaround, etc.), safety & health considerations, properties of chemicals used in the process, operating limits, and consequences of deviation. Following development of the template, Blackshare learned the operation of equipment and processes in the plants. Including utility systems, the project resulted in a total of over 60 detailed, step-by-step procedures specific to equipment, valves, gauges, controls, etc. Training was conducted with operators and the procedures are frequently reviewed and updated as necessary.

Job Safety Analysis for Pipe Manufacturer

Blackshare completed job safety analysis (JSAs) for an oilfield pipe manufacturer who was having injuries too frequently due to handling and working around the heavy pipe and rolling hazards. Blackshare observed approximately 40 tasks performed by employees, documented their actions step-by-step, evaluated movements and location, and developed JSAs with recommendations on how to reduce employee injuries. Since implementation and training of the JSAs, related injuries have dropped by more than 50%.

Industrial Hygiene Sampling at Galvanizing Facilities

Blackshare conducted industrial hygiene sampling on employees at three galvanizing facilities. Pumps were calibrated and placed on employees to evaluate exposure levels. The parameters analyzed for were zinc oxide, zinc chloride, ammonia chloride, lead/nickel/zinc, soluble and insoluble lead/nickel/zinc, and PM 10. Levels were compared to applicable OSHA standards to determine if additional personal protective equipment (PPE) and/or engineering controls were necessary.

Development of OSHA Plans and Programs for Glass Manufacturing Plant

Blackshare has completed the development and training of many OSHA-required plans and programs such as lockout/tagout, confined space entry, hot work permit, and personal protective equipment (PPE) programs. At a glass manufacturing plant, Blackshare has developed site-specific plans and programs for entry of furnaces, de-energizing mechanized equipment, and monitoring space for hazards prior to entry. At an asphalt roof felt manufacturing facility, Blackshare has developed and provided training on equipment-specific lockout/tagout procedures for the entire facility and also developed parameters for issuing hot work permits. Blackshare also wrote the PPE program for a chemical plant.

Process Hazard Analysis (PHA) for Refinery

Blackshare has participated in many process hazard analysis (PHAs) using various methodologies such as What if, Hazop, fault tree, and failure mode analysis. Blackshare served as facilitator for a Hazop to add a NOx abatement unit at a refinery. Blackshare also routinely leads Pre-startup safety reviews (PSSRs) and management of change (MOCs) for PSM-regulated facilities.

Intergrated Contingency Plan for Refined Product Terminals

Blackshare prepared an integrated contingency plan for over 80 pipeline terminals which combined components from the SPCC plan, RCRA contingency plan, SWPPP, OSHA emergency action plan, and other required regulatory emergency plans into one comprehensive document. Common information can then be automatically updated when facility or process modifications are made that affect a myriad of regulatory required plans.

Industrial Hygiene Monitoring at Manufacturing Plant

Due to exposure concerns at the plant, the Blackshare conducted both personal and area air monitoring of several operations for lead, oil-mist, silica, VOCs and noise exposure. Area and personal air pumps were calibrated, set and monitored for several 8-hour work shifts. Dosimeter readings were also taken and recorded. Data logged results were then compared against OSHA standards to determine necessary controls. Exposure levels above OSHA standards would result in the need for modification of process controls or PPE for workers. In this instance, results were below OSHA standards and modifications were not required.

Stormwater Training Video & Manual

Airports are required to comply with Storm Water Regulations. Under a grant from the Oklahoma Aeronautics Commission, Blackshare was contracted to produce a training video and accompanying workbook to assist airport staff and facility users in complying with the Storm Water regulations. The video and workbook provided examples of various storm water permitting tasks such as filling out an NOI, developing a storm water site map, preparing a site-specific Storm Water Pollution Prevention Plan (SWPPP), conducting inspections, assembling a polluting preservation team and having meeting to evaluate plan and BMP effectives and preparing annual reports for solutions to the state regulatory agency. The package was distributed free of charge to every airport in the state.

Process Safety Management Audit for Gas Plant

Blackshare conducted a required three-year audit of a gas plant for the 29 CFR 1910.119 Process Safety Management Standard. The audit included a review of the 14 elements of the standard, including Hazop Reviews / Process Hazard Analysis (PHA), Mechanical Integrity and Management of Change. The findings were reported to the client and we assisted with implementing corrective actions.

Training for Certification Exam

Blackshare instructs exam preparation courses for certified hazardous materials manager certification on both on ongoing and in-house basis. Topics covered include regulation overview and introduction, chemistry, RCRA, DOT, EPCRA (Sara Title III), CWA and permitting, CAA and permitting, auditing, assessments, USTs, sampling, IH. The review courses instructed by our professionals have the highest pass rate in the country for CHMM and REM certifications. Blackshare has been involved with these courses since their inception. Blackshare also teaches a graduated level engineering course in environmental and hazardous materials management.

DOT Training Courses

Blackshare normally conducts four DOT training courses per year for Hazmat Employees. Employees who affect the transportation of hazardous materials (packaging, labeling, loading, preparing paperwork, etc.) are required to have training every three years on general awareness, safety, security, and function-specific tasks. Blackshare has well-developed materials, completes this training, and provides certification to individuals that are good for the next three years.