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Department of Chemical Engineering

CHE 617 Chemical Process Safety Loss Prevention

CHAPTER ONE
Introduction:ChemicalProcessSafetyFundamentals
withApplications

Dr.YaserDahman

What is Safety?

Figure 1-1 Headlines are indicative of the publics concern over chemical safety.

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S.A.F.E.T.Y

Figure 1-2 The ingredients of a successful safety program.

Steps to Create a Safety

Program
1st:
(1)to record what needs to be done to have an outstanding safety program,
(2)to do what needs to be done, and
(3)to record that the required tasks are done.

2nd:
The participants must have a positive attitude. This includes the willingness to do some of the thankless
work that is required for success.

3rd:
The participants must understand and use the fundamentals of chemical process safety in the design,
construction, and operation of their plants.

4th:
Everyone must learn from the experience of history or be doomed to repeat it.

5th:
Everyone should recognize that safety takes time. This includes time to study, time to do the work, time to
record results (for history), time to share experiences, and time to train or be trained.

6th:
Everyone (you) should take the responsibility to contribute to the safety program. A safety program must
have the commitment from all levels within the organization. Safety must be given importance equal to
production.

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Ethics
Fundamental principles:
Engineers shall uphold and advance the integrity, honor, and dignity of the engineering
profession by
1. using their knowledge and skill for the enhancement of human welfare;
2. being honest and impartial and serving with fidelity the public, their employers, and
clients;
3. striving to increase the competence and prestige of the engineering profession

Fundamental canons:
1. Engineers shall hold paramount the safety, health, and welfare of the public in the
performance of their professional duties.
2. Engineers shall perform services only in areas of their competence.
3. Engineers shall issue public statements only in an objective and truthful manner.
4. Engineers shall act in professional matters for each employer or client as faithful agents
or trustees, and shall avoid conflicts of interest.
5. Engineers shall build their professional reputations on the merits of their services.
6. Engineers shall act in such a manner as to uphold and enhance the honor, integrity, and
dignity of the engineering profession.
7. Engineers shall continue their professional development throughout their careers and
shall provide opportunities for the professional development of those engineers under
their supervision.

Definitions

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Accident and Loss Statistics

The 3 statistical systems used are:
OSHA incidence rate,
Fatal accident rate (FAR)
Fatality rate, or deaths per person per year

OSHA Incidence Rate

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Fatal Accident Rate (FAR)

and Fatality Rate

Example

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Example

Example

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Accidental Statistics

Figure 1-3 The accident pyramid.

Acceptable Risk

Figure 1-4 The manner in which workplace fatalities occurred in 2006. The total number of
workplace fatalities was 5840; this includes the above plus 14 for bodily reaction
and exertion, and 10 nonclassified. (Data source: Injury Facts, 2009, p. 56.)

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Public Perception

Figure 1-5 Results from a public opinion survey asking the question, Would you say chemicals
do more good than harm, more harm than good, or about the same amount of
each? (Source: The Detroit News.)

Accidental Patterns

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Hydrocarbon Chemical Plant

Accidents

Figure 1-6 Types of loss for large hydrocarbonchemical plant accidents. (Data from
The 100 Largest Losses, 19722001.)

Causes of Accidents

Human error

Figure 1-7 Causes of losses for largest hydrocarbon-chemical plant accidents. (Data from The
100 Largest Losses, 19722001.)

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Causes of Accidents

Figure 1-8 Hardware associated with the largest hydrocarbon-chemical plant accidents. (Data
from The 100 Largest Losses, 19722001.)

Accidents in the Hydrocarbon and

Chemical Industry
Larger buildings and more complex plants

Figure 1-9 Loss distribution for the largest hydrocarbon-chemical plant accidents over a
30-year period. (Data from The 100 Largest Losses, 19722001.)

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Preventing Accidents

Definitions

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Inherent Safety Techniques

Inherent Safety relies on the chemistry and physics of a process for
accident prevention rather than on control systems, interlocks,
special operation procedures, etc.

Flixborough, England

Figure 1-10 A failure of a temporary pipe section replacing reactor 5 caused the Flixborough accident.

https://www.youtube.com/watch?v=WevjRH5fX98
https://www.youtube.com/watch?v=Q77zkdvTTb0
https://www.youtube.com/watch?v=Of5AbsC8NxQ

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https://www.youtube.com/watch?v=YONbi79JD4A

Bhopal, India

Figure 1-11 The upper reaction is the methyl isocyanate route used at Bhopal. The lower
reaction suggests an alternative reaction scheme using a less hazardous
intermediate. (Adapted from Chemical and Engineering News (Feb. 11, 1985), p. 30.)

Pasadena, Texas

Figure 1-12 Polyethylene plant settling leg and product takeoff system.

https://www.youtube.com/watch?v=3l2PQEjMnnM

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