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8/2/2019 Safety in Chemical Process Industries
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Safety In Chemical Process
Industries
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Why does it matter? Safe working protects:
You
Other lab workers Cleaners
Visitors
Your work
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Control Measures (in order of preference)
1. Use a less risky
substance2. Use a safer form of that
substance (eg solutioninstead of powder)
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Control Measures (in order of preference)
3. Totally enclose theprocess (eg a glove-box)
4. Partially enclose theprocess (eg with afume cupboard)
5. Ensure good general ventilation
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Control Measures (in order of preference)
6. Safe systems of work
7. Reduce exposure
times, increasedistance, reduce volumes
8. Personal protective
equipment (as a last resortfor primary protection)
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What are the general hazards in a
laboratory? Fire Breakage of glassware Sharps
Spillages Pressure equipment & gas
cylinders Extremes of heat & cold Chemical hazards Biological hazards Radiation
And many more!
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First Aid All laboratory workers should
undergo simple first aidtraining For ALL chemical splashes, wash
with plenty of water for 10minutes
Control bleeding with directpressure, avoiding any foreignbodies such as glass
Report all accidents to yoursupervisor or departmentalsafety officer
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Abhinav Jain
Conc. HCL
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Safety Programs System
Attitude
Fundamentals Experience
Time
You
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Five Major Disasters: Bhopal Gas Tragedy
Flixborough accident
The Seveso disaster The Texas Tragedy
IOC Depot Fire(Jaipur)
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Bhopal Gas Tragedy
Amongst the worst Industrial Disasters of its time.Occurrence: 3rd December 1984.
Place of occurrence: Bhopal, Madhya Pradesh, India.
Company: Union Carbide Corporation.
Chemical: Methyl Isocyanate (27 tons)
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Toxic Materials in Soil and Water
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25 Years after the Bhopal Gas
Disaster Changes Made in India
Changes made in USA
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Flixborough Explosion
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The Flixborough disaster was an explosion at a chemical plant
close to the village of Flixborough England on 1 st June 1974.
28 workers were killed and 36 injured on the site.53 people were injured off-site.1821 houses were damaged.
LessonsThe accident occurred due to: Poor Process DesignLack of Understanding of Mechanical Loading of Process Equipment
18
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Simplified flow diagram of cyclohexane oxidation plant
after March 1974 (Whittingham, 2005)
(Whitti h )
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(Whittingham, 2005)
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The Seveso accidentOccurrence: July 10,1976Place of Occurrence: Seveso,Milan,Italy Company: Icmesa Chemical Company Chemical:TCDD (2,3,7,8-tetrachlorodibenzoparadioxin)
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Suffering
10 square miles were contaminated
250 cases of chloracne were reported
Over600 people were evacuated 2000 people were given blood tests
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Causes
Trichlorophenol reactor went out of control
Heavy Rain
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Preventive Measures
Proper containment systems
Fundamental engineering safety principles
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The Texas Tragedy
Occurrence: October 23,1989Place of Occurrence: Pasadena,Texas,USHigh Density Polythene Plant
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Casualty 23 Deaths
314 injuries
Capital losses of over $715 million
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Causes Product taken off valve was
removed
DEMCO was open
Lockout device wasremoved
No permanentcombustible gas detection
and alarm system waslocated in the region of thereactors. Polyethylene plant settling leg and produc
takeoff system
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Preventive Measures A double-block-and-bleed valving arrangement should
have been used
Provision was made for the development,implementation, and enforcement of effective permitsystems
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IOC Depo Fire (Jaipur)
Occurred:Oct 29th
PlaceofOccurrence:Sitapura
Copmany: IOCL
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Casualty 12 people died
Over 200 people get injured
Half million people were evacuted
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Causes Leakage in Valve
Negligence
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RISK ANALYSIS
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What Risk Analysis Can Do?Helps In
Forecasting any unwanted situation
Estimating damage potential of suchsituation
Decision making to control such situation
Evaluating effectiveness of controlmeasures
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Risk Analysis Definition of Risk Analysis : “Risk analysis is the process of gathering
data and synthesizing information to develop an understanding of therisk of a particular enterprise.”
Definition of QRA : “QRA is the art and science of developing andunderstanding numerical estimates of the risk (i.e., combinations of the expected frequency and consequences of potential accidents)associated with a facility or operation.”
Risk analysis usually involves several of the five risk managementactivities shown in next slide.
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Elements of Risk Management
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Process of Risk Analysis
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Why perform QRA ? There may be either of the two reasons to perform QRA:
First, you choose to use QRA because you believe you will gain abetter understanding of risk that will aid decision making.
A second possibility is that, in some cases, QRA may be required by law, so you choose to do one.
If you are performing QRA because you want to, then there may meseveral reasons:
Underlying Motivation (It is simply a perception that a problemexists)
Concerns (You concerns the safety & economic issue) Need (need for greater risk understanding)
Information Requirement (You want to get the information by the means of QRA)
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Information Available From QRA The results of the QRA can be formulated and used on two bases:
An absolute basis
A relative basis
QRA
An absolute basis:•To determine whether the level of safety at a facility meets risktolerance criteria•If not, then change the faculty until
it meets the tolerance criteria
A relative basis:•Shows difference between the levelsof safety of one or more cases of interest•It can be used to determine the
most efficient way to improve safety
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Classical Limitations of QRA
Completeness
Accuracy/Uncertainty Reproducibility
Inscrutability
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