SAFETY IN PROCESS PLANTS

PRESENTED BY GROUP 2.
CHE 522
Supervised by
Prof. k. OBAHIAGBON.

A
PRESENTATION ON
SAFETY IN A PROCESS PLANT
GROUP 2
CHE 522
COURSE LECTURER: PROFESSOR OBAHIAGBON KESSINGTON
DEPARTMENT OF CHEMICAL ENGINEERING
UNIVERSITY OF BENIN, BENIN CITY, NIGERIA.

INTRODUCTION
As chemical process technology becomes more complex, Chemical
Engineers will need a more detailed and fundamental understanding
of safety for a proper handling of a chemical process. The growth of an
industry is totally dependent on technological advances. This is
essentially true in the chemical industry, which is entering an Era of
more complex processes: Higher pressure, more reactive chemicals,
and Exotic chemistry. More complex processes require more complex
safety technology. Many industrialists even believe that the
development and application of safety technology is actually a
constraint on the growth of the chemical industry. Examples of Safety
technology include:

Hydrodynamic models representing two phase flow through a vessel

relief

Dispersion models representing the spread of toxic vapour through a

plant after a release

Mathematical techniques to determine the various ways that

processes can fail and the probability of failure.

Safety in a chemical process is an act of preventing fires,

explosions and accidental chemical releases in process
facilities or other facilities such as refineries, and oil and
gas (onshore and offshore) production installations. Process
safety involves the prevention of leaks, spills, equipment
malfunction, over pressures, over temperatures,
corrosion, metal fatigue and other similar conditions.
Chemical plants contain a large variety of hazards. There
are mechanical hazards that cause worker injuries from
tripping, falling, or moving equipment. There are also
chemical hazards which include fire and explosion hazards,
reactivity hazards, and toxic hazards.

THE NEED FOR SAFETY PROGRAM

IN A CHEMICAL PROCESS PLANT
As chemical technology become more complex, chemical
engineers will need more detailed and fundamental
understanding of safety program.
This is done to achieve the following

Record what needs to be done

To do what needs to be done

To record that the required task are done

Requirements for a successful safety conditions in a process

plant by employees

Positive attitude to the safety program

Understanding the use of fundamental safety in the design,

construction and operation of the plant.

Learning from history of previous accidents

Seeking advice from superiors and experts before carrying out

operations.

SAFETY STEPS TAKEN IN A

PROCESS PLANT

These steps are divided into 3 major categories which are:

1. Planning for an emergency

2. during an emergency

3. After an emergency

PLANNING FOR AN EMERGENCY

Study the surrounding for fixed and mobile sources of hazard

materials

Learn about warning sirens in the plant

Prepare and familiarize with a shelter-in-place kit that is

appropriate for the type(s) of emergency that can occur in the
plant.

Pay attentive to the Public Address System (PAS) for directive

Learn CPR First-Aid

For the shelter-in-place select a room that has few windows

Ensure all workers understand emergency situations and calls

Review your plan periodically and conduct chills

DURING EMERGENCY

Shut off heating and cooling systems and fans

that draw in air from outside

Shut and look doors and windows

Turn on radio for information

Stay off the phone-it should be used for

emergency calls only.

Be prepared to evacuate if ordered to do so by

the emergency personnel

AFTER AN EMERGENCY

Open doors and windows

Turn on your healthy/cooling system to ventilate

place

Go outside

TYPES OF SAFETY
It is important to distinguish between products that meet standards that are safe
and those that merely feel safe. The highway community uses these terms:

Normative Safety: The Normative safety is achieved when a product or design

meets applicable standards and practices for design and construction or
manufacture, regardless of the products actual safety history.

Substantive Safety: Substantive or objective safety occurs when the real

world safety history is favourable, whether or not standards are met.

Perceived Safety: Perceived or Subjective safety refers to the users level of

risk, without consideration of standards or safety history.

Security: This is also called social or public safety and it addresses the risk of
harm due to intentional criminal acts such as assault, burglary or vandalism.

OTHERS INCLUDE:

Process safety: This has to do with the prevention of dangers such fires,
explosions, and the accidental chemical releases in a chemical process facilities

Occupational and health Safety: These are commonly referred to as

occupational health and safety. It is an area concerned with the safety, health
and welfare of people engaged in work or employment.

Engineering Safety: This assures that a life critical system behaves as

needed, even when components fail. The primary goal of safety engineering is to
manage risk, eliminating or reducing it to acceptable levels.

FAILURE IN A PROCESS
PLANT
The failure of industrial plant and equipment can have serious
consequences. This excellent guide investigates common causes of
industrial plant failure. This technical guide, originally developed by
the UKs Health and Safety Directorate covers the various causes of
industrial plant failure.
1. CORROSION: Corrosion is caused by electrochemical process in
which a metal reacts with its environment to form an oxide or
compound by the formation of cells comprising an anode (the
deterioration metal), a cathode (adjacent metal) and a conducting
solution (acid/salts). It can occur both internally and externally to
pipelines, vessels, plants, machinery, structures and supports.
2. MATERIAL SELECTION
The materials selection philosophy aspect of the design phase of all
plant and structures should take into consideration the anticipated
conditions (pressures, temperature and atmosphere) and the content
of the system in order to either minimize corrosion or to make
adequate allowances for it in the form of additional material
thicknesses.

3. HUMAN ERROR: One in five errors caused by

equipment failures in the chemical process industries
are the result of human and organizational errors
research project.
The study also identified the equipment most likely to fail
and cause accidents. Piping systems (25%), reactor
(14%), storage tanks (14%), process vessels (10%) and
heat transfer equipment (8%) accounted for two thirds
of accidents caused by equipment failures.
Others causes of industrial plant failure include;

Erosion

External loading

Impact

Pressure

Temperature

Vibration

Wrong equipment

Defective equipment

CAUSES OF PROCESS PLANT ACCIDENTS

An accident is an unplanned, unexpected and undesigned event which
occurs suddenly and causes

Injury or loss

A decrease in value of the resources, or

An increase in liabilities
There are 4 main causes of accidents in a chemical plant: human error,
improper training, manufacturing defects, and improper maintenance.

Human Error
A majority of the industrial accidents that occur every year are a result of
human error. Many of these accidents are a result of the worker failing to
follow the safety procedures that have been put into place by the
company where he or she works.
When the proper equipment is not used by personnel, accidents can
occur. Many injuries happen when personnel attempt to use improper
tools to work on equipment.

Improper Training
When personnel are not trained properly or adequately, industrial
accidents are more likely to occur. Workers should be taught how to
operate the equipment in the way it was designed to be used. They
should also learn to employ correct safety procedures when they are
operating the equipment.

Manufacturing Defects
Accidents that occur in a chemical plant can also be the result of a manufacturing
defect. These defects can be present in a piece of equipment or in the materials used.
Although companies employ several quality-control measures during the
manufacturing process, some of these may fail. This is because many of these control
measures are handled by employees. An inspector may miss a defect that occurred
during manufacturing. The problem may not be recognized until after an accident has
occurred.

Improper Maintenance
A common reason that industrial accidents occur in chemical plants is the improper
maintenance of equipment. Regular maintenance at scheduled intervals following the
manufacturers recommendations is important for ensuring that the equipment runs
smoothly and safely. When a piece of equipment is not properly maintained, it can
malfunction and ultimately fail. This can result in dire consequences to the personnel
who are operating and working around the machine.

The causes of accidents can also be broken down into unsafe conditions and unsafe
acts
Unsafe acts
Unsafe conditions
Unsafe
conditions
are
hazardous
conditions
or circumstances
Operating
equipment
or
machinery Lack of guarding
of machinery
directly
to
an
accident.
without permission

that could lead

Using
defective
Crowdingor
workers
one area
Unsafe
acts equipment
occurs when a worker ignores
is notinto
aware
of a standard operating
Using the wrong tool for the job
Inadequate alarm systems
procedure or safe work practice designed to protect the worker and prevent accidents.
Not using personal protective equipment
Fires and explosion
Working while intoxicated
Hazardous atmospheres
Horseplay

Inadequate lighting

Some examples of related process accidents investigated by

EPA/OSHA include,

Explosion in shell olefins production unit

Shell chemical company, Deer Park, TX, June 22 1997, a large
explosion and fire occurred in an olefins production unit. Shaft blow
out of a pneumatically assisted check valve resulted in the release of
large quantities of flammable hydrocarbon gas into a congested area.
A vapour cloud explosion resulted, which was felt 10miles away. Major
plant damage occurred. One employee was hospitalized, and several
others received minor injuries. Nearby resident areas suffered minor
blast damage. Highways west and south of the plant were closed for
three hours

Hydrochloric acid spill

Surpass chemical company, Albany, NY, April 8, 1997; a storage tank

failed causing a large spill of hydrochloric acid (HCL). The tank was
over pressurized during a filling operation. A hydrochloric acid cloud
drifted offsite, and spilled liquid entered the city storm sewer. 43
persons, including employees, were treated at hospitals, of these, 4
were hospitalized. One square block around the facility was evacuated.

INHERENT SAFETY

In the chemical and process industries, a process

has inherent safety if it has a low level of danger
even if things go wrong. In reality no design can be
inherently safe. However, you can have an
inherently safer design

An inherently safer design is one that avoids

hazards instead of controlling them, particularly by
reducing the amount of hazardous material and
the number of hazardous operations in the plant.

Principles

Minimize: Reducing the amount of hazardous material present at any

time. Use smaller quantities of hazardous materials when the use of
such materials cannot be avoided -also called intensification. Perform a
hazardous procedure as few times as possible when the procedure is
unavoidable

Substitute: Replace a substance with a less hazardous material or

processing route with one that does not involve hazardous material. e.g.
cleaning with water and detergent rather than a flammable solvent

Moderate: Reducing the strength of an effect, e.g. using material in a

dilute rather than concentrated form. Use hazardous materials in their
least hazardous forms or identify processing options that involve less
severe processing conditions -also called attenuation or limitation of
effects

Simplify: Designing out problems rather than adding additional

equipment or features to deal with them. Design processes, processing
equipment and procedures to eliminate opportunities for errors. Less
equipment of any kind means that there is less to go wrong.

Two further principles are used by some:

Error Tolerance: Equipment and processes can be designed to be

capable of withstanding possible faults. A very simple example is making
piping and joints capable of withstanding the maximum possible
pressure if outlets are closed.

Limit Effects: Designing and locating equipment so that the worst

possible condition gives less danger.

In terms of making plants more user-friendly Kletz also

added the following

Making Incorrect Assembly Impossible;

Ease of Control.

SAFETY MEASURES AND SAFETY

STEPS IN PROCESS PLANTS

When working in Industries the employees and

workers are subjected to different types of
hazards.

An industrial hazard can be defined as a

situation which arises in industries either
naturally or man-made which may cause injury,
loss of property or product or even death.

Safety refers to freedom from any risk, loss or

injury.

The safety in process plants will consider with regards

to the three major types of hazards namely;

Chemical Hazards

Physical Hazards

Biological Hazards

Chemical hazards may be caused when chemical

reactions get out of control. This can be attributed due
to several reasons.

Over exposure to harsh chemicals

Dust explosion caused due to a rapid combustion of

a dust cloud.

Safety Measures to control

Chemical Hazards

Removal from over exposure: Removal of

persons from the overexposure site and the
provision of mandatory first aid treatment
includes provision of air respirators and other
lifelines.

Decontamination: Prompt removal of the

garments and shoes of a victim whose skin or
clothing has been contaminated.

Control of dust explosion: Avoiding any

development of explosive mixture and
controlling it can be done by using equipment
like filter, cyclone separators and electrostatic
precipitators.

Physical Hazards

While working in an industry the workers can also

face hazards which can cause physical injury.
These hazards can include occurrence of
accidents like slipping, falling, falling of materials
(especially in construction industries),
electrocution etc.

Biological Hazards

In chemical industries the employees face the risk

of biological hazards. These hazards include gas
leakage and inhalation of poisonous gases during
any disaster.

Safety Measures to protect

employees from Physical Hazards
and Biological Hazards
It is very important to implement certain safety measures by
the employer to ensure a comfortable and safe work area.
Special safety equipment needs to be provided in the case of
workers who work in mines, construction sites, metallurgy, oil
and drilling industries, chemical industries, dairy products
manufacturing industries, etc. The safety measures include
provision of special safety protection equipment like:

Providing quality goggles, helmets, masks, hooks for

protection of head and eyes.

Providing rubber gloves, aprons, rubber boots, shoes and

other clothing equipment for protection of hand, arms,
legs and feet.

Providing respiration protective devices for prevention of

breathing of poisonous gases while working in a chemical
industry.

Safety Measures to
control Fire Hazards
The safety measures to be taken by employers to control Fire Hazards in
industries include:

Proper and careful planning of the industrial plan layout and selecting
authentic and genuine constructional materials which can reduce explosion
and fire.

Any operation which is considered to be hazardous should be conducted

under isolation in separate buildings.

Elimination of unnecessary sources of ignition which will cause fire and any
sort of explosion.

Installation of sufficient fire alarms and temperature alarms and also a

good sprinkler system.

Using fire resistance brick-walls which can limit the effects of any
explosion.

While constructing the building, provision of an exit point should also be

done. A separate staircase has to be built at the exit point.

Providing proper fire safety equipment like sprinklers, fire extinguishers,

fire alarms, notifiers, etc.

Implementation of a
comprehensive safety program
The safety measures to be taken in industries should also
include an implementation of a comprehensive safety
program. The basic principles of this safety program are:

Identification of potential hazards and provision of

proper and effective safety equipment and facilities.

Developing safety policies keeping in mind the welfare

of the employees and the safety of the building.

Providing proper training to the employees with

regards to safe method of working. It is also necessary
to provide continuing education and guidance aimed
at the elimination and prevention of accidents.

Providing proper training in the optimal use of safety

equipment like fire alarms, etc.

THANK YOU