Mary Kay O’Connor Process Safety Center THE RELATIONSHIP OF SAFETY AND RISK MANAGEMENT TO ENGINEERING FOR SUSTAINABLE DEVELOPMENT Dr. M. Sam Mannan, PE,

Mary Kay O’Connor

Process Safety Center

THE RELATIONSHIP OF SAFETY AND RISK MANAGEMENT TO ENGINEERING

FOR SUSTAINABLE DEVELOPMENT

Dr. M. Sam Mannan, PE, CSPRegents Professor and Director

Holder of T. Michael O’Connor Chair IMary Kay O’Connor Process Safety Center

Artie McFerrin Department of Chemical EngineeringTexas A&M University System

http://cheweb.tamu.edu/index.html




2

I am telling you we have to do Risk Assessment for an Asteroid or Comet collision! and if we don’t know the consequences we could be made extinct!

I don’t believe a word!

Don’t worry! We have ruled this planet for 160 million years! and We will always rule it!

THE FIRST SAFETY CONFERENCE




Mary Kay O’Connor Process Safety Center

Present

3

0

2

4

6

8

10

Estimated GDP growth for 2010

Estimated Population for 2010 in billion

G 20 Countries1





Future

4

Energy Demand2 World Commercial Energy Use2





Deep Water Horizon In September 2009, the rig

drilled the deepest oil well in history at a vertical depth of 35,050 ft

On 20 April 2010, while drilling at the Macondo Prospect, an explosion on the rig caused by a blowout killed 11 crewmen

After burning for approximately 36 hours, Deepwater Horizon sank on 22 April 2010

The resultant oil spill continued until July 15

5




http://upload.wikimedia.org/wikipedia/commons/9/9d/Deepwater_Horizon_offshore_drilling_unit_on_fire_2010.jpg


Fukushima Nuclear Incident, 2011

6





Did the incident happen occasionally?

Over the intervening 33 years, other catastrophic incidents have grabbed the attention of the public and media

These incidents happened all over the world threatening people’s lives and property

7




8

Location Date Killed people Damage Loss(that year)Umm Said Qatar 4/3/1977 6 76350000Abqaiq Saudi Arabia 4/15/1978 0 53700000Ekofisk Norway 3/27/1980 123Edmonton Canada 4/18/1982 21000000Remeoville Illinois US 7/23/1984 17 191000000San Juan Ixhuatepec Mexico City Mexico 11/19/1984 650 19940000Bhopal Gas Tragedy 12/3/1984 2000Las Piedras Venezuela 12/13/1984 62076000Norco Lousiana US 5/5/1988 4 254700000Piper Alpha North Sea UK 7/8/1988 167 965000000Antwerp Belgium 3/7/1989 77000000Richmond California US 4/10/1989 87170000Baton Rauge Lousiana US 12/24/1989 68900000Coatzacoalcos Mexico 3/11/1991 91300000Dhaka Bangladesh 7/20/1991 71000000North Rhine Germany 12/10/1991 50500000Guadalajara Mexico 4/22/1992 206 300000000Westlake Louisana US 7/28/1992 25000000Wilmington California US 10/8/1992 73300000Sodegaura Japan 10/16/1992 10 160500000La Mede France 11/9/1992 260000000Baton Rauge Lousiana US 8/2/1993 65200000Simponville Sacramento US 6/6/1996 27000000Rio Piedras San Juan Puerto Rico 11/21/1996 33 5000000Martinez California US 1/27/1997 80000000Yokkaichi Mie Japan 5/2/1997Visakhapatnam India 9/14/1997 50 64000000St Helena California US 12/2/1997 14000000Bintulu Serawak Malaysia 12/25/1997 12 275000000Longford Victoria Australia 9/25/1998 2 160000000Berre I'Etang France 10/6/1998 22000000Inderhe Niger Delta Nigeria 10/17/1998 100Knoxville Tennesse US 2/9/1999 8100000Martinez California US 2/23/1999 4Winchester Kentuchy US 1/27/2000 7100000Hunt Texas US 3/3/2000 40000000Prince Georges US 4/7/2000 50000000Mina Al-Ahmadi-Kuwait 6/25/2000 5 412000000Carlsbad New Mexico US 8/19/2000 12 100000000Roncador Brazil 3/15/2001 2 515000000Carson City California US 4/23/2001 120000000Rawdhatain Kuwait 1/31/2002 4 200000000Brookdale Manitoba Canada 4/14/2002 13000000Moomba Australia 1/1/2004 5000000Skikda Algeria 1/19/2004 27 30000000Humber Estuary Killingholme UK 4/16/2001 82400000Ghislenghien Belgium 7/30/2004 24Mihama Japan 8/9/2004 6Texas City Texas US 3/23/2005 15 30000000Sidoarjo Est Java Indonesia 11/22/2006 11

Major Incidents from 1977 to 2009




Safety is a key factor in sustainable developmentAfter so many disasters, more study should be

dedicated to prevent incidents- make safety the second nature

New sustainability issues requires: 1. R&D to be put at the core of chemical industry.2. Development of a longer term vision for the chemical3. Development of inherently safe design that involves

substances without risks for human health and environment





Safety Strategies

Inherent: when the safety features are built into the process, not added.

Passive: for example, safety features that do not require action by any device – they perform their intended function simply because they exist.

Active: for example, safety shutdown systems to prevent accidents (e.g., a high level alarm in a tank shuts automatic feed valves) or to mitigate the effects of accidents (e.g., a sprinkler system to extinguish a fire in a building).

Procedural: or operating procedures, for example, operator response to alarms. Emergency response procedures, safety rules and standard procedures, training.

10





Framework to Reduce Risk and Consequences of Incidents

Academic Research – improve the science and technology to prevent incidents

Industry Research - improve the regulations and management

Academic and industrial education

11





Academic Research-Reactive Chemicals Reactivity of Ethylene Oxide in Contact with

Contaminants

Self-reacting Chemical Safe Storage Modeling

Study of N-oxidation of Alkylpyridines with Hydrogen Peroxide using Molecular Simulations

Computational Research on Mechanism of Thermal Decomposition of Cumene Hydroperoxide in Cumene & Evaluation of its Reactivity Hazard

Molecular Modeling for Runaway Reactions in Chemical Process

APTAC





Academic Research-LNG Safety

To support formulating guidelines for LNG fire mitigation and flammable cloud suppression. ◦Vapor dispersion CFD modeling◦Water curtain modeling and design◦Foam application optimization





Property

Pmax

(dp/dt)max

KSt

LOC

Study influence of particle size distribution in

explosive characteristics

METHODOLOGY: EXPERIMENTAL MEASUREMENT OF DUST EXPLOSIVE

CHARACTERISTICS

OBJECTIVES

Analyze influence of humidity content in

Explosive characteristics

Correlations between particle size distribution and dust explosive characteristics are required to predict explosion behavior.

Humidity content on dust can significantly affect the explosion hazard.

Academic Research-Dust Explosion





Inherent safety designMinimize

Significantly reduce the quantity of

hazardous material o energy in the

system, or eliminate the hazard entirely if

possible.

Substitute

Replace a hazardous material with a less

hazardous substance, or

hazardous chemistry with less hazardous

reactions.

Moderate

Reduce the hazards of a process by

handling materials in a less hazardous form, or under less

hazardous condition, for

examples at lower temperatures and

pressures

SimplifyEliminating

unnecessary complexity to

make plants more “user friendly” and

less prone to human error and

incorrect operation





Industrial Research-Process Safety ManagementPSM is the application of management principles and systems to the identification, understanding, and control of process hazards to protect employees, facility assets and the environment.

16

Application Employee Participation Process Safety

Information Process Hazard Analysis Operating Procedures Employee Training Contractors

Pre-Start up Safety Review Mechanical Integrity Hot Work (Non-routine

Work Authorizations) Management of Change Incident Investigation Emergency Planning and

Response Compliance Audits

Elements of PSM





Industrial Research- Safety Culture

• Leadership and commitment of the Chief Executive and senior management.

• The acceptance by line management that they have an executive role to play

• The acceptance by all employees that safety must be incorporated into all the organisations activities. It is not just something that is added on at the end.

• Good communication and a willingness to communicate.• The understanding of the importance of training and

competence assurance.• The understanding that every accident, every incident is an

unnecessary drain on the organisations resources.

17





Academic and Industrial Education

Educate a new generation of engineers to whom the principles of process safety are second nature

Graduate students programs Courses for undergraduate students as

core curriculumSafety Engineering CertificateLong-distance learningTraining for company engineers





Concluding Remarks

Safety should be included along with environment, economics and social components of sustainable development

Companies cannot be sustainable without successful safety and risk management programs. And thus by extension, it is impossible for society to reach the goals for “engineering for sustainable development” without successful safety and risk management programs.

Our inability to adapt to the demands of a changing world and eco-system has the potential to take us down the same path as “dinosaurs.”

19





Thank you

References 1. CIA: The World Fact Book 2. BP Energy Outlook 2030

20




Documents

Mary Kay O’Connor Process Safety Center THE RELATIONSHIP OF SAFETY AND RISK MANAGEMENT TO ENGINEERING FOR SUSTAINABLE DEVELOPMENT Dr. M. Sam Mannan, PE,