Industrial Hygiene

1 Background2 Objectives of IH3 Type of HI control4 Estimation of evaporation rate ventilation rate of volatiles

Crowl amp Louvar

Chapter 3

2nd and 3rd editions

Origin of Hygiene

bull Hygeia was the Greek goddess of health

bull Rene Dubos wrote ldquoFor the worshippers of Hygeia health is hellipa positive attribute to which men are entitled if they govern their lives wiselyrdquo

bull Prevention is key

What Is Industrial Hygiene

Definition Science and art devoted to the anticipation recognition evaluation and control of those workplace environmental factors which may cause sickness impaired health and well-being or significant discomfort and inefficiency among workers or among citizens of the community

Some Occupational HazardsChemical agents

bull Gases vapors and particulate aerosols

Physical (energy) agents

bull Noise ionizing non-ionizing radiation heat and cold stress

Biological agents

bull Infectious agents allergens

Psychological stressors

Ergonomicsafety

Examples of ODOR Threshold

[Table 3-9 in 3rd Edition]

Acetic acid 0016 ppmAmmonia 575 ppm Camphor 0051 ppmChloroform 117 Ethanol 0136Hydrogen sulphide 00005Methanol 141Ozone 0051Phosgene 055

Government Regulations

1 Laws are enacted by the Government The laws do not

have details on implementation

2 The applicable government agency develops and proposes

a regulation The regulation contains the details on

implementation It is published in the Government

Register and a comment period and hearing is normally

held

3 The Final Rule is published in the Government Register

and the Code of Government Regulations

Government Regulationsbull The two regulations most applicable to

chemical plants arebull Occupational Safety and Health Administration (OSHA)

(NIOSH ndash Malaysia)

29 CFR 1910119 ldquoProcess Safety Management

of Highly Hazardous Chemicalsrdquobull Environmental Protection Agency (EPA) ndash (DoE Malaysia)

40 CFR Part 68 ldquoRisk Management Programsrdquo

bull In 2006 Chemical Facility Anti-Terrorism Standards (CFATS)

6 CFR 27

Table 3-1 Laws and RegulationsTable 3-3 Legislation to Chemical process safety 2nd amp 3rd Eds

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Origin of Hygiene

bull Hygeia was the Greek goddess of health

bull Rene Dubos wrote ldquoFor the worshippers of Hygeia health is hellipa positive attribute to which men are entitled if they govern their lives wiselyrdquo

bull Prevention is key

What Is Industrial Hygiene

Definition Science and art devoted to the anticipation recognition evaluation and control of those workplace environmental factors which may cause sickness impaired health and well-being or significant discomfort and inefficiency among workers or among citizens of the community

Some Occupational HazardsChemical agents

bull Gases vapors and particulate aerosols

Physical (energy) agents

bull Noise ionizing non-ionizing radiation heat and cold stress

Biological agents

bull Infectious agents allergens

Psychological stressors

Ergonomicsafety

Examples of ODOR Threshold

[Table 3-9 in 3rd Edition]

Acetic acid 0016 ppmAmmonia 575 ppm Camphor 0051 ppmChloroform 117 Ethanol 0136Hydrogen sulphide 00005Methanol 141Ozone 0051Phosgene 055

Government Regulations

1 Laws are enacted by the Government The laws do not

have details on implementation

2 The applicable government agency develops and proposes

a regulation The regulation contains the details on

implementation It is published in the Government

Register and a comment period and hearing is normally

held

3 The Final Rule is published in the Government Register

and the Code of Government Regulations

Government Regulationsbull The two regulations most applicable to

chemical plants arebull Occupational Safety and Health Administration (OSHA)

(NIOSH ndash Malaysia)

29 CFR 1910119 ldquoProcess Safety Management

of Highly Hazardous Chemicalsrdquobull Environmental Protection Agency (EPA) ndash (DoE Malaysia)

40 CFR Part 68 ldquoRisk Management Programsrdquo

bull In 2006 Chemical Facility Anti-Terrorism Standards (CFATS)

6 CFR 27

Table 3-1 Laws and RegulationsTable 3-3 Legislation to Chemical process safety 2nd amp 3rd Eds

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

What Is Industrial Hygiene

Definition Science and art devoted to the anticipation recognition evaluation and control of those workplace environmental factors which may cause sickness impaired health and well-being or significant discomfort and inefficiency among workers or among citizens of the community

Some Occupational HazardsChemical agents

bull Gases vapors and particulate aerosols

Physical (energy) agents

bull Noise ionizing non-ionizing radiation heat and cold stress

Biological agents

bull Infectious agents allergens

Psychological stressors

Ergonomicsafety

Examples of ODOR Threshold

[Table 3-9 in 3rd Edition]

Acetic acid 0016 ppmAmmonia 575 ppm Camphor 0051 ppmChloroform 117 Ethanol 0136Hydrogen sulphide 00005Methanol 141Ozone 0051Phosgene 055

Government Regulations

1 Laws are enacted by the Government The laws do not

have details on implementation

2 The applicable government agency develops and proposes

a regulation The regulation contains the details on

implementation It is published in the Government

Register and a comment period and hearing is normally

held

3 The Final Rule is published in the Government Register

and the Code of Government Regulations

Government Regulationsbull The two regulations most applicable to

chemical plants arebull Occupational Safety and Health Administration (OSHA)

(NIOSH ndash Malaysia)

29 CFR 1910119 ldquoProcess Safety Management

of Highly Hazardous Chemicalsrdquobull Environmental Protection Agency (EPA) ndash (DoE Malaysia)

40 CFR Part 68 ldquoRisk Management Programsrdquo

bull In 2006 Chemical Facility Anti-Terrorism Standards (CFATS)

6 CFR 27

Table 3-1 Laws and RegulationsTable 3-3 Legislation to Chemical process safety 2nd amp 3rd Eds

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Some Occupational HazardsChemical agents

bull Gases vapors and particulate aerosols

Physical (energy) agents

bull Noise ionizing non-ionizing radiation heat and cold stress

Biological agents

bull Infectious agents allergens

Psychological stressors

Ergonomicsafety

Examples of ODOR Threshold

[Table 3-9 in 3rd Edition]

Acetic acid 0016 ppmAmmonia 575 ppm Camphor 0051 ppmChloroform 117 Ethanol 0136Hydrogen sulphide 00005Methanol 141Ozone 0051Phosgene 055

Government Regulations

1 Laws are enacted by the Government The laws do not

have details on implementation

2 The applicable government agency develops and proposes

a regulation The regulation contains the details on

implementation It is published in the Government

Register and a comment period and hearing is normally

held

3 The Final Rule is published in the Government Register

and the Code of Government Regulations

Government Regulationsbull The two regulations most applicable to

chemical plants arebull Occupational Safety and Health Administration (OSHA)

(NIOSH ndash Malaysia)

29 CFR 1910119 ldquoProcess Safety Management

of Highly Hazardous Chemicalsrdquobull Environmental Protection Agency (EPA) ndash (DoE Malaysia)

40 CFR Part 68 ldquoRisk Management Programsrdquo

bull In 2006 Chemical Facility Anti-Terrorism Standards (CFATS)

6 CFR 27

Table 3-1 Laws and RegulationsTable 3-3 Legislation to Chemical process safety 2nd amp 3rd Eds

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Examples of ODOR Threshold

[Table 3-9 in 3rd Edition]

Acetic acid 0016 ppmAmmonia 575 ppm Camphor 0051 ppmChloroform 117 Ethanol 0136Hydrogen sulphide 00005Methanol 141Ozone 0051Phosgene 055

Government Regulations

1 Laws are enacted by the Government The laws do not

have details on implementation

2 The applicable government agency develops and proposes

a regulation The regulation contains the details on

implementation It is published in the Government

Register and a comment period and hearing is normally

held

3 The Final Rule is published in the Government Register

and the Code of Government Regulations

Government Regulationsbull The two regulations most applicable to

chemical plants arebull Occupational Safety and Health Administration (OSHA)

(NIOSH ndash Malaysia)

29 CFR 1910119 ldquoProcess Safety Management

of Highly Hazardous Chemicalsrdquobull Environmental Protection Agency (EPA) ndash (DoE Malaysia)

40 CFR Part 68 ldquoRisk Management Programsrdquo

bull In 2006 Chemical Facility Anti-Terrorism Standards (CFATS)

6 CFR 27

Table 3-1 Laws and RegulationsTable 3-3 Legislation to Chemical process safety 2nd amp 3rd Eds

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Government Regulations

1 Laws are enacted by the Government The laws do not

have details on implementation

2 The applicable government agency develops and proposes

a regulation The regulation contains the details on

implementation It is published in the Government

Register and a comment period and hearing is normally

held

3 The Final Rule is published in the Government Register

and the Code of Government Regulations

Government Regulationsbull The two regulations most applicable to

chemical plants arebull Occupational Safety and Health Administration (OSHA)

(NIOSH ndash Malaysia)

29 CFR 1910119 ldquoProcess Safety Management

of Highly Hazardous Chemicalsrdquobull Environmental Protection Agency (EPA) ndash (DoE Malaysia)

40 CFR Part 68 ldquoRisk Management Programsrdquo

bull In 2006 Chemical Facility Anti-Terrorism Standards (CFATS)

6 CFR 27

Table 3-1 Laws and RegulationsTable 3-3 Legislation to Chemical process safety 2nd amp 3rd Eds

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Government Regulationsbull The two regulations most applicable to

chemical plants arebull Occupational Safety and Health Administration (OSHA)

(NIOSH ndash Malaysia)

29 CFR 1910119 ldquoProcess Safety Management

of Highly Hazardous Chemicalsrdquobull Environmental Protection Agency (EPA) ndash (DoE Malaysia)

40 CFR Part 68 ldquoRisk Management Programsrdquo

bull In 2006 Chemical Facility Anti-Terrorism Standards (CFATS)

6 CFR 27

Table 3-1 Laws and RegulationsTable 3-3 Legislation to Chemical process safety 2nd amp 3rd Eds

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

bull Word file with abbreviations of institutions relevant to chemical safety

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Table 3-4 in 2nd Ed Table 3-5 in 3rd Ed Identify the differences between PSM and RMP

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Process Safety Management(PSM) 29 CFR 1910119

On July 17 1990 OSHA published in the Federal Register (55 FR 29150) a proposed standardmdashrdquoProcess Safety Management of Highly Hazardous Chemicalsrdquomdashcontaining requirements for the

management of hazards associated with processes using highly hazardous chemicals to help assure safe and healthful workplaces After discussions the Clean Air Act Amendments (CAAA) were enacted into law (November 15 1990)Source httpswwwoshagovPublicationsosha3132pdf

Specified minimum elements that the OSHA standard must require employers to do as follows (show osha pdf file)

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Process Safety Management some terms

Catastrophic release

Major uncontrolled emission fire or explosion Involves one or more highly hazardous chemicals Presents serious danger to employees in the workplace

Highly hazardous chemical a substance possessing toxic reactive flammable or explosive properties and specified by section 1910119(a)(1)

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Process bull Any activity involving a highly hazardous

chemical including use storage manufacturing handling or the on-site movement of such chemicals or combination of these activities

bull Any group of vessels that are interconnected ampbull Separate vessels which are located such that a

highly hazardous chemical could be involved in a potential release

bull All considered a single process

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Category 1 Flammable Liquid (per 19101200) or

Flammable Liquid with flashpoint below 1000F on site at one location in a quantity of 10000 lbs or more

29 CFR 1910119 does NOT apply to

bull Hydrocarbon fuels used solely for workplace consumption as a fuel not as part of a process containing another highly hazardous chemical

bull Flammable liquids with a flashpoint below 1000F stored in atmospheric tanks or transferred kept below their normal boiling point without benefit of chilling or refrigeration

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

A method to determine plant or process chemical hazards and develop policies procedures and safeguards against emergencies which may occur

Process Hazard Analysis (PHA) - this will be discussed in more detail under Hazard Identification topic

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

bull Shall be conducted as soon as possible but no later than (NLT)

NLT Initial Process completed by

25 May 26 199450 May 26 199575 May 26 1996

Completed by May 26 1997

bull After May 26 1997 - Acceptable if requirements of initial PHA are met

For example

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

bull Updated and revalidated by a team meeting at least every 5 years

bull Update and retain the PHA for each process for the life of the process

Operating Proceduresbull Written for safely conducting activities involved in each covered process

PHA = Process Hazard Analysis(this will be discussed in more detail under Hazard Identification topic)

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Steps to cover for each Operating Procedure- this can be helpful for your assignment

Addresses at least

bull Initial set-up

bull Normal operations

bull Temporary operations

bull Emergency shutdown

bull Emergency operations

bull Normal shutdowns

bullStartup following

turnaround or

emergency shutdown

bull Operating Limits

bull Consequences of

deviation

bull Steps required to

correct or avoid

deviation

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Methods used to determine and evaluate hazards (this will be discussed in more detail under Hazard Identification topic)

bull What Ifbull Checklistbull What IfChecklistbull HAZOP (Hazard amp Operability Study)bull FMEA (Failure Mode amp Effects Analysis)bull Fault Tree AnalysisbullEvent Tree Analysis bull An Appropriate Equivalent Methodology

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Relevance to your assignment some points

Discussion of the process in terms of PSM criteria (your assignment 1)Discussion of the process in terms of PSM criteria (your assignment 1)

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS

PLANT SAFETY1 Nuisance trips Emergency shutdowns and subsequent startups are among the

greatest threats to plant safety They divert attention from situations that could present real danger and result in unnecessary shutdowns and restarts ndash all of which pose additional risk

Sources failures due to systems wearing out spurious equipment failures and human failures caused by alarm floods

Recommendations Lifecycle equipment management asset management embedded

diagnostics and alarm management all help to eliminate nuisance trips

Source httpglobalwonderwarecomBRDocumentsDesafios20na20seguranC3A7a20de20uma20fC3A1bricapdf

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

2 Insufficient use of the full functionality of the control and safety system Process control and safety systems continue to do the lsquoheavy liftingrsquo in keeping plants operatingsafely but few companies take full advantage of their capabilities

Recommendations Alarm management loop management inhibit and bypass management and the smart integration of control systems help to ensure that you are maximising the full safety potential from your system investment

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

4 Training limitations Comprehensive hands-on safety training is difficult ndash if not impossible ndash to deliver No matter howtalented the trainers and trainees or how effective the curriculum classes and materialsconventional training can go only so far in conveying the realities of a hazardous situation

Recommendations However todayrsquos simulation and virtual-reality techniques allow operators to experience hazardous situations and consequences with a realism that has never been possible before

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

5 Lack of visibility of safety status

While safety breaches usually result from a combination of factors that have been deterioratingover time in many cases no one knows there is a problem or that an incident has occurred Mostplants are collecting the data that could provide early warning of problems but it is usually fragmented haphazard and not in a safety context

Recommendations Simulation techniques real-time monitoring sensors and operator dashboards can help provide a realistic dynamic view of safety conditions

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

6 Unnecessarily exposing people to hazardous environmentsProtecting the community environment and personnel is key to a sustainable safety programme

Recommendations Simulated training fire and gas detection systems smart instrumentation and personnel locationsystems can minimise human exposure to hazardous situations

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

7 External threats The realities of terrorism and business disruption due to plant safety incidents are critical considerations for plant managers

Recommendations These can be mitigated by defence-in-depth securityprogrammes and by careful integration of safety and control systems

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Recommendations to maintain plant safety

1 Monitor equipment proactively

Proactive equipment condition monitoring can extend to all assets and processes that are critical to safe plant performance

Data from asset management systems can be integrated into an overall plant safety view This allows modification of the safety envelope model and real-time updating of plant safety dashboards providing a measure of overall integrity

of the plant This can also integrate condition management computerised maintenance management condition-based maintenance (CBM) and reliability-centred models ndash all of which contribute to operations and maintenance (RCORCM) solutions that improve plant safety

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Recommendations to maintain plant safety

2 Utilise embedded diagnostics

It is essential to have confidence in the operational effectiveness and correct functioning of the installed safety systems Embedded automatic diagnostic featuresof control systems instrumentation and control elements increase this confidence and allow plant personnel to focus on production Data derived from a testing and diagnostic framework canautomatically reveal the appropriate communication strategies and coordinate the interaction ofthe personnel communications asset management and maintenance functions

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Recommendations to maintain plant safety 3 Rationalise and prioritise alarms Alarms are often the first layer of protection and provide the first indication that there is a potential unsafe condition on the site However too many process alarms occurring at once can decrease the integrity of the alerts and the effectiveness of the operator response An effective and efficient alarm management system promotes both safety and performance Alarm rationalisation based on industry standards applies layers of protection to link the alarm priority with the time required to respond effectively to an alarm before the plant must undergo a costly shutdown This reduces nuisance trips by enabling operators to attend only to alarms associated with real dangers

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Recommendations to maintain plant safety 4 Do not bypass inhibit-and-bypass management functionality Highlighting significant deviations from the normal operational state and adjusting the online plant safety case requires a robust management system to monitor record and report the status on all inhibit events and override conditions This allows for handover shift reports and key performance indicators to detect patterns and trends as well as status reports identifying and explaining the application of a bypass It also enables automatic removal of specified bypasses after a configurable period and advises when the plant achieves a steady operational state Inhibit and bypass management functions communicate with all electronic systems facilitate the systematic recording of events from other systems and provide a formal rule-based interpretation of the overall plant inhibit condition They initiate reports and display the operational status of the plant emergency systems

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

1

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

CHEMICAL (or MATERIAL) SAFETY DATA SHEET

1 Identification - Name of the substance or preparation - Name address and telephone of the companysupplier

2 Composition and information on ingredients

3 Hazard identification

4 First-air measures

5 Fire-fighting measures

6 spillage accidental release measures

7 Handling and storage

8 Exposure controls and personal protection

9 Physical and chemical properties

10 Stability and Reactivity

11 Toxicological information

12 Ecological information

13 Disposal considerations

14 Transport information

15 National regulations and references

16 Other information

EXAMPLE (Word file)

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Example of MSDS worddoc

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

2 Anticipation

bull Anticipationrecognition of potential or actual hazards through knowledge of

bull ndashMaterials

bull ndashOperations

bull ndashProcesses

bull ndashConditions1048714

Scope of IH activities encompasses the ldquocradle-to-graverdquo concept (research through waste disposal)

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

3 Evaluation

bull Evaluation of environmental factors through

ndashMeasurement of exposure intensity

ndashDetermination of exposure frequency and duration

ndashComparison with regulatory professional and internal standards

bull Judgment weigh all factors

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

EnvironmentalOccupational Health Paradigm

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Sampling and Measurement

bull OSHA and NIOSH publish sampling and analysis procedures appropriate for particular substances

bull ASTM has standards on instrumentation sampling and analytical procedures

bull ACGIH publishes a book on Air sampling instruments

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

4 Control

bull Employ methods to eliminate or reduce exposure resulting in elimination or reduction of the occurrence of occupational disease through

ndashEngineering (including process) interventions

ndashAdministrativeprogrammatic measures

ndashPersonal protective equipment (PPE)

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Opportunities for Control

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Types of Controls 1 Engineering controls

bull Substitution ndash replacing a hazardous materials with a non-hazardous one

bull Isolation ndash use a barrier between a source of contaminants and workers

bull Ventilation ndash general or dilution ventilation and local exhaust ventilation

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

2 Work practices and Administrative controls

bull Housekeeping ndash regular cleaningbull Materials handling or Transfer procedures ndash to

remove generation of hazards during process of transferring (eg loadingunloading generates dust transferring liquids generates vaporsspills)

bull Leak detection programs ndash visual inspections auto sensors systems

bull Training ndash staffbull Modifying the work ndash limiting exposure periods

share activities between workersbull Personal hygiene ndash cleaning skins eyes change

cloths ete

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

OPERATIONAL CONTROL PROGRAMMES bull In the workplace workers are exposed to chemical

hazards in various activities such as transfer storage handling and use in the workstation and waste disposal

bull For the safe handling of chemicals it is necessary to take several preventive measures

bull Technical measures can be instituted to eliminate or reduced the worker exposure

bull The priority is to eliminate whenever possible very hazardous chemical form the workplace by substitute with less hazardous chemical or process

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

If substitution is not possible prevent exposure to the chemicals by implementing engineering control Measures that should be considered in engineering controls ( but not limited to ) are

1 enclosure or isolation

2 wet methods

3 use of industrial ventilation system

4 change of process

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

bull It must be remembered that personal protective equipment should always be the last to be considered

bull In some situations where substitution and engineering controls is not reasonably practicable and reliance has to be placed with personal protective equipment

bull For technical measure to be effective safe work practices and procedures should be developed and implemented hand in hand with the technical measures

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Technical measures are but not limited tobull isolation of ignition sourcesbull development of procedures to cover handling use

operating procedures during manufacture transport storage use and disposal of chemicals

bull development and implementation of safe system of work such as permit to work system modification procedure maintenance and repair procedure inspection and testing

bull housekeeping bull hygiene facilitiesbull emergency procedure and facilitiesbull posting of warning sign

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

47

3 Personal Protective Equipment (PPE) for Hazardous Chemicals

bull Dust masks and respirators

bull Glasses goggles and face shields

bull Hearing protectionbull Glovesbull Foot protectionbull Head protectionbull Aprons or full-body suits

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

48

Personal Protective Equipment (PPE) for Hazardous Chemicals

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

49

Personal Protective Equipment (PPE) for Hazardous Chemicals

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

50

Hazardous Materials First Aid

bull Eyes Flush with water for 15 minutes

bull Skin Wash with soap and water

bull Inhalation Move to fresh air

bull Swallowing Get emergency medical assistance

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

51

Spills and Leaks

bull Evacuate the areabull Notify a supervisor or

the emergency response team

bull Remove ignition sources (if safe to do so)

bull Stay awaybull Call 9-9-9

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

2 Evaluation of chemical hazards

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Qm=Mass rate of volatile material

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Accumulation rate is lsquo0rsquo

Applying ideal gas law m=mass ρ=density v=volatile species b=bulk speciesRg=ideal gas constantT and P absolute temp and pressureM=molecular weight of volatile speciesmvVb=C=QmkQv

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Vapor Pressure

Given two substances of the same volume which one has more potential hazard

ndashExample Motor oil vs ether

Ether has more potential hazard than motor oil due to its high vapor pressure and volatility

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Examples of Health Effects

Asphyxiants Carbon dioxide carbon monoxide

Irritants Chlorine formaldehyde

Anesthetics Toluene benzene

Hepatotoxins Carbon tetrachloride chlorobenzene

Nephrotoxins Toluene xylene

Neurotoxins Carbon disulfide

Hematopoietictoxins Benzene carbon monoxide

Pulmonarytoxins Nitrogen dioxide phosgene

Carcinogens Benzene vinyl chloride monomer

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Ideal Gas Law

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Conversion of Units

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

VP and Concentration

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Selection of methods to control identified hazard

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Table 3-9 Chemical Plant Control Techniques

Generalized form

In many cases Psat raquo ρ

Eq3-12

Generalized form

In many cases Psat raquo ρ

Eq3-12

KA is often very small compared to displacement and can be neglected

Control of identified hazard

Purposes of Industrial Ventilation

bull Control of toxic air contaminants to

acceptable levels

bull Control of noxious odors

bull Control of heat and humidity for comfort

and health

bull Prevention of fire and explosions

Types of Industrial Ventilation1 General ventilationndashControl of temperature humidity and odors

2 Dilution ventilationndashMaintain control of low toxicity gases and vapors below acceptable levels through dilution of concentration

3 Local exhaust ventilationndashCapturing and removing contaminants at or near their sources of emissionndashPrevents the transmission of contaminant to workerndashGiven priority in ldquoHierarchy of Controlsrdquo

Ventilation Terminology

Air velocity at the hood or slot opening n important design parameter

Air velocity through the cross-section of the duct

Basic Ventilation Equation

WhereQ = air flow rate (ft3min)A = cross-sectional area of duct or opening (ft2)V = average air velocity (ftmin)

Example

ndashIf fan is unchanged and number of hoods is

doubled then the resulting hood face velocities

will be 12 original velocity (possibly reducing air

velocity to less-than-needed capture velocity)

Hood Proximity and Exhaust Volume

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Control of identified hazard

Purposes of Industrial Ventilation

bull Control of toxic air contaminants to

acceptable levels

bull Control of noxious odors

bull Control of heat and humidity for comfort

and health

bull Prevention of fire and explosions

Types of Industrial Ventilation1 General ventilationndashControl of temperature humidity and odors

2 Dilution ventilationndashMaintain control of low toxicity gases and vapors below acceptable levels through dilution of concentration

3 Local exhaust ventilationndashCapturing and removing contaminants at or near their sources of emissionndashPrevents the transmission of contaminant to workerndashGiven priority in ldquoHierarchy of Controlsrdquo

Ventilation Terminology

Air velocity at the hood or slot opening n important design parameter

Air velocity through the cross-section of the duct

Basic Ventilation Equation

WhereQ = air flow rate (ft3min)A = cross-sectional area of duct or opening (ft2)V = average air velocity (ftmin)

Example

ndashIf fan is unchanged and number of hoods is

doubled then the resulting hood face velocities

will be 12 original velocity (possibly reducing air

velocity to less-than-needed capture velocity)

Hood Proximity and Exhaust Volume

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Purposes of Industrial Ventilation

bull Control of toxic air contaminants to

acceptable levels

bull Control of noxious odors

bull Control of heat and humidity for comfort

and health

bull Prevention of fire and explosions

Types of Industrial Ventilation1 General ventilationndashControl of temperature humidity and odors

2 Dilution ventilationndashMaintain control of low toxicity gases and vapors below acceptable levels through dilution of concentration

3 Local exhaust ventilationndashCapturing and removing contaminants at or near their sources of emissionndashPrevents the transmission of contaminant to workerndashGiven priority in ldquoHierarchy of Controlsrdquo

Ventilation Terminology

Air velocity at the hood or slot opening n important design parameter

Air velocity through the cross-section of the duct

Basic Ventilation Equation

WhereQ = air flow rate (ft3min)A = cross-sectional area of duct or opening (ft2)V = average air velocity (ftmin)

Example

ndashIf fan is unchanged and number of hoods is

doubled then the resulting hood face velocities

will be 12 original velocity (possibly reducing air

velocity to less-than-needed capture velocity)

Hood Proximity and Exhaust Volume

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Types of Industrial Ventilation1 General ventilationndashControl of temperature humidity and odors

2 Dilution ventilationndashMaintain control of low toxicity gases and vapors below acceptable levels through dilution of concentration

3 Local exhaust ventilationndashCapturing and removing contaminants at or near their sources of emissionndashPrevents the transmission of contaminant to workerndashGiven priority in ldquoHierarchy of Controlsrdquo

Ventilation Terminology

Air velocity at the hood or slot opening n important design parameter

Air velocity through the cross-section of the duct

Basic Ventilation Equation

WhereQ = air flow rate (ft3min)A = cross-sectional area of duct or opening (ft2)V = average air velocity (ftmin)

Example

ndashIf fan is unchanged and number of hoods is

doubled then the resulting hood face velocities

will be 12 original velocity (possibly reducing air

velocity to less-than-needed capture velocity)

Hood Proximity and Exhaust Volume

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Ventilation Terminology

Air velocity at the hood or slot opening n important design parameter

Air velocity through the cross-section of the duct

Basic Ventilation Equation

WhereQ = air flow rate (ft3min)A = cross-sectional area of duct or opening (ft2)V = average air velocity (ftmin)

Example

ndashIf fan is unchanged and number of hoods is

doubled then the resulting hood face velocities

will be 12 original velocity (possibly reducing air

velocity to less-than-needed capture velocity)

Hood Proximity and Exhaust Volume

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Basic Ventilation Equation

WhereQ = air flow rate (ft3min)A = cross-sectional area of duct or opening (ft2)V = average air velocity (ftmin)

Example

ndashIf fan is unchanged and number of hoods is

doubled then the resulting hood face velocities

will be 12 original velocity (possibly reducing air

velocity to less-than-needed capture velocity)

Hood Proximity and Exhaust Volume

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Hood Proximity and Exhaust Volume

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Use of Enclosures

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
• Slide 67
• Slide 68
• Slide 69
• Slide 70
• Slide 71
• Slide 72
• Slide 73
• Slide 74
• Slide 75
• Slide 76
• Slide 77
• Slide 78
• Slide 79
• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Direction of Air Movement

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
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• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Direction of Air Movement

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
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• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

Eq 3-3

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
• Slide 63
• Slide 64
• Slide 65
• Slide 66
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• Slide 80
• Slide 81
• Slide 82
• Slide 83
• Slide 84
• Slide 85
• Slide 86
• Slide 87
• Slide 88
• Slide 89

• Industrial Hygiene 1 Background 2 Objectives of IH 3 Type of HI control 4 Estimation of evaporation rate ventilation rate of volatiles
• Origin of Hygiene
• What Is Industrial Hygiene
• Some Occupational Hazards
• Slide 5
• Government Regulations
• Government Regulations
• Slide 8
• Slide 9
• Slide 10
• Slide 11
• Slide 12
• Slide 13
• Slide 14
• Slide 15
• Slide 16
• Slide 17
• Slide 18
• Slide 19
• Additional points on chemical plant safety THE SEVEN GREATEST THREATS TO PROCESS PLANT SAFETY
• Slide 21
• Slide 22
• Slide 23
• Slide 24
• Slide 25
• Recommendations to maintain plant safety
• Slide 27
• Slide 28
• Slide 29
• Slide 30
• Slide 31
• CHEMICAL (or MATERIAL) SAFETY DATA SHEET
• Example of MSDS worddoc
• 2 Anticipation
• 3 Evaluation
• EnvironmentalOccupational Health Paradigm
• Slide 37
• Sampling and Measurement
• 4 Control
• Opportunities for Control
• Types of Controls 1 Engineering controls
• 2 Work practices and Administrative controls
• OPERATIONAL CONTROL PROGRAMMES
• Slide 44
• Slide 45
• Technical measures are but not limited to
• 3 Personal Protective Equipment (PPE) for Hazardous Chemicals
• Personal Protective Equipment (PPE) for Hazardous Chemicals
• Slide 49
• Hazardous Materials First Aid
• Spills and Leaks
• Slide 52
• Slide 53
• Slide 54
• Slide 55
• Slide 56
• Slide 57
• Slide 58
• Slide 59
• Slide 60
• Slide 61
• Slide 62
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• Slide 89