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Environment (CN3135)
Outline of CN3135
Importance of process safety design and
operation
Identifying safety and health hazards eg.
HAZOP, Fault Tree
Predicting consequences
Design for sustainable processes eg. reliability
engineering, sustainable engineering
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Tutorial Exercises
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Module Assessment
Mid term test (date, topics, duration) 10%
HAZOP/ Reliability Engineering project 30%
Final Examination 60%
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Author
: CROWL
LOUVAR
Publisher : Pearson
ISBN
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: 9780132782838
Expectations
IVLE/CN3135
Lecture materials - download
Tutorial problems Attempt
Register your project teams
o Form team of 4 5 members
o Register: IVLE/Workspace/Groups/Sign-up
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Lecture 1
Introduction to Loss
Prevention
Learning Outcomes
Review major process safety accident cases
Assess loss prevention in process design and
operation
Analyse incident statistics
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Video: Bhopal
http://www.youtube.com/watch?v=ELllSxnDS0g
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Shell was charged under Section 11(a) of the Workplace Safety and Health Act
(Chapter 354A) for having failed in its duty as an occupier to take reasonably
practicable measures to ensure the safety of persons at its workplace
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Source: www.wsh-institute.sg
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Source: www.wsh-institute.sg
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$10B costs
reported !
Source: Economic Cost of Work-related Injuries and Ill-health in Singapore, WSH Institute
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Definitions
Safety: Strategy of accident prevention. Main
emphasis is on worker safety
Loss Prevention: Prevention of accidents through use
of appropriate technologies to identify and eliminate
hazards before an accident occurs. Includes
protection of people, equipment, production, property
and the environment
Hazard: An inherent physical or chemical characteristic
of a material, system, process or plant that has the
potential for causing harm or damage
Risk: A measure of the likelihood of occurrence and
consequence (severity) of an accident
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Definitions
Lower Risk Level
HAZARD:
Venom
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Spitting Cobra
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Definitions
Accident: Incident which results in consequent
losses
Incident: An unplanned or undesired event that
adversely affects a companys work operations
Include work-related fatalities, major injuries, minor
injuries, first aid cases, occupational illnesses,
property damage, spills, fires, dangerous
occurrences or near miss events
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Accident Pyramid
1
100
500
10 000
Disabling Injury
Minor Injury
Property Damage
No Damage
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What is Acceptable
Risks?
Acceptable Risks
Any risk that is currently tolerated is considered
to be acceptable (US EPA)
Tolerable risk: risk which is accepted in a given
context based on the current values of society
(ISO & IEC)
Level of potential losses that a society or
community considers acceptable given existing
social, economic, political, cultural, technical
and environmental conditions (UN)
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Acceptable Risks
Cannot eliminate risks totally
At design stage, need to decide if risks are
acceptable
< Normal day-to-day risks in non-industrial
environment
Risks from multiple exposures are additive
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Acceptable Risks
Risk acceptance is a function of many factors
and varies considerably across industries
Company culture and the culture of the country
in which a facility is located influence risk
acceptability
Risk acceptability is also time dependent what is acceptable today may not be
acceptable tomorrow, next year or next decade
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Sources of Hazards
huMan
Machine
Method
Material
Physical
Environment
Organisation/
Work factors
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Severity of Hazard
Level
Score
Severity
Major
3
3
Moderate
Description
Minor
Negligible
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Likelihood of Occurrence
Level
Likelihood
Description
Rare
Remote
Occasional
Frequent
Almost Certain
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Almost
-2
-3
-4
Certain - 5
10
15
20
25
Major - 4
12
16
20
Moderate - 3
12
15
Minor -2
10
Negligible - 1
Catastrophic 5
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Risk Acceptable
Low Risk (1 3)
Acceptable
Tolerable
Not acceptable
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Source
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Path
Receiver
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Toxic
Release
Explosion
Fire
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Scenario
Outcomes
Probability
of
Occurrence
Potential
for
Fatalities
Release +
Dispersion
Toxic exposure
to employees
and
community
Low
High
Intermediate
Intermediate
High
Low to
Intermediate
Ignition in
confined space
Extensive plant
damage
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Sequence of Accidents
Initiation Event that starts the accident
Propagation Event(s) that maintain or
expand the accident
Termination Event(s) that stop the accident
or diminish it in size
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Desired Effect
Procedure
Initiation
Diminish
Process design
Inert atmosphere
Intrinsically safe equipment
Grounding, bonding
Procedures, permit to work
Risk assessment
Training
Propagation
Diminish
Construction materials
Plant layout
Reduce inventories of materials
Install check and emergency shutoff valves
Emergency material transfer
Termination
Increase
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CN3135 Introduction to Occupational Health and Safety 1
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Bhopal Accident
Methyl isocyanate used in pesticide
manufacturing
Heavier than air
Reacts exothermically with water
Substitute with less hazardous chemical that
produce a less toxic chloroformate
intermediate (Substitute)
Decrease inventory of MIC on site (Minimise)
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Taipei
Formosa
Water Park
Fire
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Performance Monitoring
Provide assurance that process safety risks are adequately
controlled
Leading Indicators - monitor proactively the effectiveness
of risk control systems and provide feedback on safety
performance before an incident or accident happens
Evaluate present state of workplace through routine and
systematic inspections
Lagging Indicators when desired safety outcome has
failed. Monitor reactively the effectiveness of risk control
systems, identify gaps and weaknesses in these systems,
and report on incidents or accidents
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Accident Statistics
Ministry of Manpower
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Accident Statistics
OSHA (Occupational Safety & Health
Administration)
# of injuries & Illness*200,000
Total hrs worked by all employees
Incidence rate per 100 worker years
40hrs 50wk
hr
WorkYear
2000
yr
wk yr
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Accident Statistics
FAR (Fatal Accident Rate): Fatalities per
1000 employees over 50 years ( = 108 working hours)
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Assessing Risks
Target FAR
For planning, design to meet national or
company requirements
Sum of risks for most exposed person on site
< 2 deaths/108 exposed-hr
Single risk < 0.4 deaths/108 exposed-hr
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Accident Statistics
FR (Fatality Rate): per person per year
Independent of hours actually worked
FR = No. of fatalities per year
Total no. of people in
applicable population
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Fatality Rate:
FR = no. of deaths x
total population
Assessing
Risks
frequency
Acceptability Criteria
10-3/yr
unacceptable
10-4/yr
public money spent to control
10-5/yr
some degree of inconvenience
10-6/yr
no great concern
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Engineering Ethics
Use knowledge and skill for enhancement of
human welfare
Be honest and impartial
Strive to increase competence and prestige of
engineering profession
Hold paramount the safety, health and welfare
of public
(Extracted from American Institute of Chemical Engineers Code of
Professional Ethics)
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VISION
ZERO
Zero Harm
Achievable?
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3rd Edition
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