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American Society of Safety Engineers.
National Safety Council.
What do they do?
These professional organization consider the
safety, health and welfare of workers and the
public.
Whenever safety, health and welfare are in
question.
They have an obligation to advise employers
or appropriate authorities
Center for Chemical Process
Safety (CCPS)
By the American Institute of Chemical
Engineers
Established in 1985
Develop and disseminate technical
information.
Prevention of major chemical accidents.
Chemical safety management
FYI: Chemical industry has fairly low accident
rate compared to other industry.
Risk can be further reduce to protect
employees and general public.
Requires integrated approach.
Table 10-1 An integrated
approach…
Goals and Objectives of the safety program
Risk Analysis and Management
Industrial process design and operation
Mechanical integrity of process equipment
Safety Regulations, Codes and Standards
Project Safety and Health Review
Hazard Evaluation of process design and operation
Personnel Motivation and Training
Process and Plant Modification and Change
Incident Investigation and Safety audits
Goals and Objectives of the
Safety Program.
Most Important Goal of Process and Plant
Design
Safe Development
Design
Construction
Start-up
Operation of the plant
Examples of Major Industrial
Accidents
Occurred with Union Carbide in Bhopal, India
December 3, 1984 , methyl isocyanate (MIC) gas leaked.
Philips Petroleum Company in Houston, Texas
On Oct. 23, 1989, about 40 tons of flammable vapor were
accidentally released and ignited.
ARCO in Channelview, Texas
A deadly blast ripped through the Channelview, Texas
ARCO Chemical Co. plant on July 5, 1990, killing 17 non-
unionized workers and transforming a 564 acre
Hazard evaluation of process and plant
design.
Reassessment of all process and plant
modifications, future changes in design and
operation of the facility.
Management of projects
Any incident involving the process or plant
should cause immediate concern and result
in thorough, objective critique and
investigation to determine the cause of the
incident.
Near miss accident should also be
investigated to determine cause.
Periodical safety audit by experienced,
qualified team.
Management of projects
Dedicate sufficient resources to reduce risk of
hazards.
Personnel
Equipment
Time
Money
Benefits of Safety
Adds to capital expenditures required and the
operating costs BUT in the long term return
on this short-term investment.
Improved on-stream factors and Product
Quality
Better Product Availability for the marketplace
Benefits of Safety
Lower insurance costs
Higher Morale of personnel
More objective project evaluation
Improved public and personnel relations.
Reminder
Identify first the risk
Delphi Method
- ranks the hazards according to their
probable occurrence and severity.
Risk analysis and
Management
1. All practical steps should be made to
reduce both the probability and severity of
the risk
By integrating risk management in the
process and plant design, risk can be
managed in a practical and effective
manner
Industrial process design and
operation
A desirable process and plant safety program
starts with a well conceived process and
plant design
Material datasheets should be reviewed to
identify hazards each chemical represents
and the methods to control it
Data and Informationassessment
for chemical hazard
Name and chemical composition
Regulatory requirements
Reactivity data
Health information
Debottlenecking opportunities
Significant deviation from the normal operation
would result to an upset condition
Safety equipment and systems for process and
plant
Fire design
protection
A smooth shutdown greatly assist a successful start-
up.
Mechanical Integrity of Process
Equipment
Design, fabrication, installation, and
maintenance affect safety
Specified construction materials should be
used in fabrication and maintenance
All equipment used in the operating facility
should be fabricated in accordance with
design specifications
Mechanical Integrity of Process
Equipment
When design specifications are
compromised, probability of accident is
increased
Inspect, verify and test to confirm reliability
Perform testing prior to start-up and
periodically thereafter
Place procedures where hazardous materials
are involved
Mechanical Integrity of Process
Equipment
During maintenance operations, facility is
vulnerable to the creation of a hazardous
conditions
Design considerations should be given for
different kinds of work during operation
Safety relief devices
Process Hazard Analysis
Hazard analysis is a study to identify,
analyze, and evaluate the risk of hazards
associated with a process or operating facility
Used to identify limitations in siting, design,
layout, and operation of facilities
Improve the safety and management of risk
at operating facilities
Process Hazard Analysis
OSHA
US Environmental Protection Agency
US Department of Transportation
Have promulgated regulations concerning
safety and health hazards
These regulations addresses the probability,
severity, and consequences
Process Hazard Analysis
Severity – What can go wrong? How bad can
it get?
Probability – How likely is it to occur?
Consequences – What are the impact?
Consequences of Hazard
Identification
Material Safety Data Sheets
Laboratory experiments
Research and Development
HAZARD ANALYSIS
TECHNIQUES
Hazard analysis are used to determine
the potential for deviations from or
weaknesses in the system design that
could pose a hazard to personnel
and/or equipment.
Hazard Analysis
Hazard Analysis should identify risks,
methods to reduce risk, and any actions
needed to ensure that the equipment
can be operated and maintained safely.
Hazard Analysis Techniques
What-if
Check list
What-if/Check list
Hazard and operability study (HAZOP)
Failure mode and effects analysis (FMEA)
Fault tree analysis
Appropriate equivalent methodology
What-if
Safety Guidelines for Semiconductor
Manufacturing Equipment
defines minimum performance-based safety
requirements that address a number of
hazards, including chemical, electrical, fire
safety, sound, radiation, mechanical, and
seismic.
What-if
It is used for step of the process.
Time consuming in development
Can be apply also to complex processes with
similar hazards.
Also like what-if in development
Example of checklist
(FMEA)
Begins of all listing the Equipments and
process components of the system under
study
More applicable to projects that are well into
design phase.
Contains failure mode, consequences,
safeguards, recommended action
Fault Tree Analysis
Begins with graphical diagrams of all
sequence of events that could result on
incidents, accidents, or exposure.
Uses logic symbols and event symbols
Fault tree analysis symbols
TOP
EVENT Transfer IN-OUT OR GATE AND GATE
BASIC UNDEVELOPED
EVENT
EVENT
Fault Tree Analysis Example
SYSTEM
FAILS
C D
A B
Personnel Motivation and
Training
Operations and Maintenance Personnel
needs training
Highly trained and skilled personnel are
excellent resource for improving safety and
productivity.
Outside contractors are also to be considered
Well-conceived process control system
should reflect a balance between:
Human Control
Reflects human capability at a particular time when the
response is required
Hardware Control
Reflects
integrity atupon the hardware
a particular design and mechanical
point of demand
Human Errors
Errors of Omission
Employee forgot to execute a required task
Errors of Commission
Employee Performed the task but did it incorrectly
Errors of Sequence
Employee did the task out of order with the required
sequence
Errors of Timing
Employee did the task either too fast or slow
Operator-Induced Error
Employee has the knowledge to make the correct
decision but acts incorrectly
System-Induced Error
Created by integration of incompatible
components into a total system
Design-Induced Error
Results from faulty equipment design, fabrication
or installation
Input Errors
Caused by typographical errors associated with
data or information
Low Stress Errors
Cause by a lapse of memory during a normal
environmental condition
High Stress Errors
When employees make wrong decisions in
life-threatening situations
Process and Plant Modification
Change
It should not result in errors that could lead to
accidents
Safety program at the operating facility
should have procedures to manage
modifications
Hazard Analysis should be performed
Incident Investigation and Safety
Audits
Near-miss Incidents should be studied
Safety Audits are used to verify compliance
with regulatory standards
Used to protect the safety and health of the
employees, surrounding communities and
environment
Safety Audits
Review of Relevant Documentation
Review of Process Safety Information
Inspection of Operating Facilities
Interviews with selected plant personnel