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HIGH HAZARD INDUSTRIES HIGH HAZARD INDUSTRIES
VIS-A-VIS VIS-A-VIS
MAJOR EMERGENCIESMAJOR EMERGENCIESBy
V. C.BhattCM (Fire & Safety)
GNFC LTD.
DEVASTATION BY FIRE
HIGH HAZARD INDUSTIRES:HIGH HAZARD INDUSTIRES:Hazards in chemical industry has potential for Fire, Explosion, Toxic release.
• Can cause injury, ill health, damage to property.• Damage to environment.• Serious disruption to people Onsite, Offsite, premises and services.• Short term effects and long term effects.
Potential Hazard In Chemical Industries Is High Due To:• Hazardous Materials / Chemicals / Inventories of
Materials• Rigorous Operating Conditions/High Pressure/High
Temperature / Corrosive Combination• Exothermic Reaction• Incompatibility• Varying Environmental Condition• Human Factors• Natural Disasters.
SOME POTENTIAL HAZARDS
A. ENERGY SOURCE• Process Chemicals, Fuels, Nuclear Reactors,
Generators, Batteries Source of Ignition, Radio Frequency Energy Sources, Activators, Radiation Sources
• Rotating Machinery, Prime Movers, Pulverizes, Grinders, Conveyors, Belts, Cranes
• Pressure Containers, Moving Objects, Falling Objects.
B. RELEASE OF MATERIAL• Spillage, Leakage, Vented Material• Exposure Effects, Toxicity, Burns, Bruises,
Biological Effects• Flammability, Reactivity, Explosiveness,
Corrosively and Fire Promoting Properties of Chemicals
• Wetted Surfaces, Reduced Visibility, Falls, Noise, Damage
• Dust Formation, Mist Formation, Spray.
SOME POTENTIAL HAZARDS
C. FIRE HAZARD• Fire, Fire Spread, Fireballs, Radiation• Explosion, Secondary Explosion, Domino Effects• Noise, Smoke, Toxic Fumes, Exposure, Effects• Collapse, Falling Objects, Fragmentation.
D.PROCESS STATE• High/Low/Changing Temperature And Pressure• Stress Concentrations, Stress Reversals, Vibration,
Noise
SOME POTENTIAL HAZARDS
• Structural Damage or Failure, Falling Objects, Collapse.
• Electrical Shock and Thermal Effects, Inadvertent Activation, Power Source, Failure.
• Radiation, Internal Fire, Overheated Vessel.• Failure of Equipment / Utility Supply / Flame /
Instrument / Component.• Start-up and Shutdown Condition.• Maintenance, Construction And Inspection
Condition.
SOME POTENTIAL HAZARDS
E. ENVIRONMENTAL EFFECTS
• Effect Of Plant On Surroundings, Drainage, Pollution, Transport, Wind and Light Change, Source Of Ignition / Vibration / Noise / Radiation Interference / Fire Spread/Explosion
• Effect Of Surroundings, On Plant(as Above)
• Climate, Sun, Wind, Rain, Snow, Ice, Grit, Contaminants, Humidity, Ambient Conditions.
• Acts Of God, Earthquake, Arson, Flood, Typhoon, Force Majeure.
• Site Layout Factors, Groups Of People, Transport Features, Space Limitations, Geology, Geography
• Security
SOME POTENTIAL HAZARDS
HIGH HAZARD INDUSTRIES CATEGARIZATION
• Scale Of Operation / Inventory / Process, Integrations Obvious
• Legal Requirements – Legal Criteria to Classify / Categorized Industries
• Hazardous Materials Inventories / Hazardous Processes
• Risk Levels With Respect To Location, Surrounding Neighborhood, Population Density, Environment Sensitivity
• Acceptability Criteria For Risk
Acceptability Criteria for Risk • Risk levels, risk to individuals, societal risk,
voluntary risk and involuntary risk, perception of risk.
• Profound questions of Ethics and philosophy of life.
• What risk is acceptable?• Risk can be minimized at a cost even if can not
be completely eliminated. • How far should one go along this road?
Acceptability Criteria for Risk • If we express risk as a Fatal Accident
Frequency Rate (FAFR) – calculated as the number of deaths per hours of exposure to risk multiplied by 108.
• FAFR represents the number of deaths from industrial injury in a group of people during their working lives.
• Some recommended criteria of acceptable risk in plant design. (always subjective and debatable as it is a emotive area)
Acceptability Criteria for Risk I. The value of life should not be coasted.II. FAFR below 0.4 or 0.3 for any single risk.III. For risk to general public such values are subject
to speculation and debate however the following may be considered acceptable.
a. If it occurs less frequently then once in 100 years.b. If it has a FAFR below about 0.001 or less.c. If the risk of death caused by the plant is under 10-5
per year for an offsite individual with this value determined at a higher statistical confidence limit.
d. If several people can be killed, it should be 10-7 per year per person or 10-8 per year per person.
Acceptability Criteria for Risk e. Action should be taken regardless of the criteria to
minimize the number of deaths from any single events.
• Consider the question – whether an accident that can kill 1000 people should be required to occur 1000 times less frequently than one that can kill a single person?
• Hence acceptability is highly subjective.• Limitation of number of deaths from any
incidents. It must be the goal. • Loss prevention and loss control can help to
achieve this.
Loss Prevention And Total Loss Control A major hazard materializes due to loss of containmentLoss prevention is characterized by 1.A concern with depth of technology and associated hazards.2.An emphasis on Management.3.A system rather than trial and error approach.4.A concern to avoid loss of containment resulting in major fire, Explosion, Toxic release.
5. The development of techniques for identification of hazards.
6. The principle of risk criteria and quantification of hazards.
7. The development of techniques for the quantification of hazards.
8. The use of the techniques of reliability engineering.
9. The principle of independence in critical assessments and inspections.
10. The planning for emergencies.11. Strengthening of practices, codes, standards,
statutory regulation with technological change.
Total Loss Control areas are :1.Injuries health hygiene.2.Business interruption3.Property damage4.Fire / Explosion / Toxic Release5.Environmental pollution6.Security7.Product liability
This can be avoided by:• Identification of loss producing situations.• Measurement of such loses.• Selection of methods to minimize such loses.• Implementation of methods.
In spite of all these you can have incidentsturning into emergency as : • Human behaviour is unpredictable.• Chance, complacency, false sense of security,
lullness• Low probability events• Low predictability events• High probability but consequences mis calculated• Wrong priorities
Preparedness for Emergency and Response :Preparedness for emergency starts from drawing board stage itself. It is integral part of design, construction, operation, Maintenance.(As per the chart shown)
Safe Place of Work Assessment
Safe Place of Work Assessment
Residual Accident Event
Residual Accident Event
ConsequencesConsequencesConsequence Reducing Measures
Consequence Reducing Measures
Probability of Success Acceptable
Probability of Success Acceptable
Probability of Success Acceptable
Probability of Success Acceptable
Consequences of FailureAcceptable
Consequences of FailureAcceptable
Review Based on Safe Place of Work
Review Based on Safe Place of Work
Contingency Plan
Contingency Plan
Change ConceptChange Concept
Yes
No
Yes No
No
Definitions:Incident : An unplanned event causes or could cause under different circumstances injury, ill-health or damage to property or the environment.
Emergency : A dynamic incident in which there is a continuing potential for major injury, ill-health or damage to property, the process or environment.
Evacuation : the planned and controlled removal of personnel from an emergency area.
Escape : The uncontrolled departure of personnel from an emergency area.
Rescue : The recovery of personnel from an area of danger to safe location.
At any time emergency develops due to; Change in process parametersFailure of a piece of equipment or instrument.Failure of control system.Error by human being.Natural Disaster like Flood, Wind, lightening, Earthquake.Civil disorderMalicious damage - sabotage
Sequence of Events in an Emergency:
Phase Status Activity
Prevention
Normal Operation
Correct Upset
Abnormal Operation
Controlled Plant S/D
Containment
State of Alert
Emergency S/D, Venting, Dumping, Inventory
Emergency
Fire Prevention, Fighting, Emergency
Containment Activities
Evacuation
Mitigation
Evacuation
Orderly Evacuation Under Direction of supervisor
EscapeEscape groups and
IndividualsRescue
Recuperation
Emergency Teams in Action
Safety
Medical and Trauma Treatment of Personnel,
Recovery
Rehabilitation of Facilities
Normal Operation
Sequence of Events in an Emergency:
Elements of Emergency Preparedness
1. Identification of the FACTORY.2. Map of the AREA3. Factory Lay - Out.4. Storage Hazards & Controls.5. Material Safety Data Sheets (MSDS).6. Process Vessel Hazards & Control.7. Other Hazards & Controls.8. Trade-Waste Disposal.9. Records of Past Accidents/Incidents.10.Gas Dispersion Concentration.11.Evacuation Table.12.Environmental Impact Assessment.13.Weather Conditions.14.Incident Controllers (Ics).15.Deputy Incident Controllers (Dy.Ics).16.Site Main Controllers (SMCs).
Elements of Emergency Preparedness17.Key Personnel.18.Essential Workers.19.Assembly Points.20.Emergency Control Center (ECC).21.Fire & Toxicity Control Arrangements.22.Medical Arrangements.23.Transport & Evacuation Arrangements.24.Pollution Control Arrangements.25.Other Arrangements.26.Alarms & Sirens.27.Internal Phones.28.External Phones.29.Nominated Persons to declare Major Emergency.30.A Form to record emergency telephone calls.31.Statutory Communication.32.Separation Distances.33.Emergency Instruction Booklets.
Thank YouThank You