MANAGEMENT OF PROCESS HAZARDS.

PURPOSE:
INTENDED TO HELP PREVENT THE OCCURANCE OF OR MINIMIZE OF
CATASTROPIC RELEASES OF EXPLOSIVE MATERIAL

OBJECTIVEs & MANAGEMENT SYSTEM

• Process Safety information.

• Process Hazard ANALYSIS.

• MANAGEMENT OF CHANGEMENT OF CHANGE.

• OPERATING PROCEDURE.

• SAFE WORK PRACTICE.

• TRAINING.

• ASSURANCE OF QUALITY AND MECHANICAL INTEGRITY OF CRITICAL EQUIPMENT.

• PER START UP SAFTY REVIEW.

• EMERGENCY RESPONSE AND CONTRL

 HAZARD IDENTIFICATION & ANALYSIS
WHAT IS A HAZARD?

A HAZARD:

HAS THE POTTENTIAL TO CAUSE HARM.

CAN CAUSE DEATH,ILL HEALTH AND INJURY TO PEOPLE.

CAN DAMAGE TO PROPERTY, PLANT, PRODUCTS OR THE ENVIRONMENT

CAN LEAD to PRODUCTION LOSSES, BUSINESS HARM AND INCREASED

LIABILITIES.
 TYPES OF HAZARDS IN THE PROCESS
INDUSTRIES
 CHEMICAL HAZARDS: ACIDITY, ALKALINITY, CORROSIVITY,
EXPLOSIVENESS, FLAMEEABILITY,
REACTIVITY, TOXICITY ETC.

 THERMODYNAMIC : HIGH PRESSURE AND VACUUM, HEAT

TRANSFER AND LOW TEMPERATURE
AND FLUID JETS.

 ELECTRICAL AND ELECTROMAGNETIC HAZARDS :

HIGH VOLTAGE, RADIATION, STATIC
ELECTRICITY AND ELECTRICAL CURRENT.

 MECHANICAL HAZARDS : MECHANICAL ENERGY, STRESSES,

FORCES AND IMPACT BLOWS.

 HEALTH HAZARDS : NOISE, POLLUTANTS,CHEMICALS,

VIBRATION, RADIOACTIVITY AND TEMP.
EXTREMES.
 OTHER HAZARDS

 EXTERNAL THREATS : ACCIDENTAL IMPACT DAMAGE BY

 MISSILES, ACT OF GOD AND NATURAL
CAUSES.
 EXTERNAL INTERFERENCE LIKE ACTION
BYHUMANS AND CHEMICALS, INSTABILITY
OF STRUCTUES OR FOUNDATIONS, EXTERNAL
RELEASE OF ENERGY/ TOXINS ETC.

UNPLANNED CHANGES :LOSS OF CONTAINMENT ETC.

SO THE POSITION IS MORE COMPLICATED THAN IT FIRST SEEMS

THE ANALYST CAN NOT SIMPLY AIM AT ANY

PARTICULAR TIME TO STUDY ALL HARZARDS BUT
MUST RESTRICT THE STUDY TO THE AREA OF
INTEREST AT THAT TIME.
 WHY HAZARDS IDENTIFICATION IS
REQUIRED
 TO FIND OUT WHAT HAZARDS ARE PRESENT IN A PLANT
OR PROCESS.

METHODS OF IDENTIFYING HAZARDS

 TO BUILD THE PLANT AND SEE WHAT HAPPENS

(TRADITIONAL METHOD)
- NOT BAD WHEN THE SIZE OF AN INCIDENT IS
LIMITED

 PREPARING CHECK LISTS

 HAZOP (HAZARD AND OPERABILITY STUDY)

 WHAT IS HAZOP ?
 A HAZARD AND OPERABILITY STUDY IS A METHOD FOR
IDENTIFYING HAZARDS AND PROBLEMS WHICH PREVENT EFFICIENT
OPERATION.

 TO REDUCE THE CHANCE THAT SOMETHING IS MISSED. IT IS DONE

IN A SYSTEMATIC WAY , EACH PIPELINE AND EACH SORT OF
HAZARD IS CONSIDERED IN TURN.

 IT IS CARRIED OUT BY A TEAM SO THAT THE MEMBERS CAN

STIMULATE EACH OTHER AND BUILD UPON EACH OTHER’S IDEAS.

 A SERIES OF GUIDE WORDS ARE APPLIED.

 NONE, MORE OF, LESS OR OTHER THAN, PART OF,
 MORE THAN (OR AS WELL AS).
(1) IDENTIFY – WHAT CAN GO WRONG?

The first and most important stage in any hazard

study is to identify the things that can go wrong and
produce accidents or operating problems. It is little
use studying small hazards if we have failed to
realize that bigger ones are round the corner.
(2) HOW BIG WILL THE CONSEQUENCES
BE?

We need to know the consequences to employees.,

member of the public, plant and profits, now and in
the long term. The best way of finding out is to
look at past experience but sometimes there is no
experience and we have to use synthetic methods.
(3) HOW OFTEN WILL IT OCCUR?

We need to know how often the hazard will occur.

Again, the best way is to look at past experience
but sometimes there is no experience and we
have to use synthetic tic methods.
(4) PREVENTION -1

How can we prevent the accident occurring, or

make it less probable or protect people from the
consequences?
(5) WHAT SHOULD WE DO?

We should compare the risk (that is, the

probability times the consequences) with
generally accepted codes and standards or with
the other risks around us.
(6) IS IT WORTH THE COST?

We should also compare the cost of prevention

with the cost of the accident in order to see if the
remedy is ‘reasonably practicable’ or if we should
look for a cheaper solution.
 (7) PREVENTION -2

Perhaps our method of prevention has

disadvantages. Perhaps we can think of better
methods. We should answer this question before
the table is made or the glass ordered.
 The effects of increasing expenditure on safety.
• IN THE LEFT-HAND AREA BY SPENDING MONY ON SAFETY, APART FROM PREVENTING INJURIES,
OUR PLANTS BLOW UP OR BURN DOWN LESS OFTEN AND WE MAKE PROFIT.

• IN THE NEXT AREA WE GET SOME M0NEY BACK FOR OUR SAFETY EXPENDITURE BUT NOT AS
WE WOULD GET BY INVESTING OUR MONEY IN OTHER WAYS.

• IN THE THIRD AREA MONEY IS SPENT SO THAT PEOPLE DO NOT GET HURT AND WE DO NOT
EXPECT TO GET ANY MATERIAL PROFIT BACK IN RETURN.

• FINALLY INTO THE FOURTH AREA WHERE WE ARE SPENDING SO MUCH ON SAFETY THAT WE GO
OUT OF BUSINESS. OUR PRODUCTS BECOME SO EXPENSIVE THAT NO-ONE WILL BUY THEM. OUR
COMPANY IS BANKRUPT AND WE ARE OUT OF JOB. THE PUBLIC ARE DEPRIVED OF THE
BENEFITS THEY COULD GET FROM OUR PRODUCTS.
• WE HAVE TO DECIDED WHERE TO DRAW THE LINE BETWEEN THE

LAST TWO AREAS. USUALLYTHIS IS A QUALTATIVE JUDGMENT BUT IT

IS OFTEN POSSIBLE TO MAKE IT QUANTITATIVE. THE METHODS FOR

DOING SO ARE KNOWNN AS HAZARD ANALYSIS OR HAZAN.

• WHILE HAZOP IS A TECHNIQUE THAT CAN BE APPLIED TO EVERY

NEW DESIGN AND MAJOR MODIFICATION, HAZAN IS A SELECTIVE

TECHNIQUE FOR QUANTIFICATION OF HAZRDS.

• IT IS NEITHER NECESSARY NOR POSSIBLE TO QUANTIFY EVERY

HAZARD ON EVERY PLANT.

 CONCLUSION

ALL HUMAN ACTIVITIES INVOLVE SOME RISK. IT CAN BE REDUCED

BUT NOT ELIMINATED COMPLETELY.

HAZDARS AND OPERABILITY STUDY (HAZOP) IS NOW A MATURE

TECHNIQUE FOR IDENTIFYINGHAZARDS WIHTOUT WAITING FOR AN
ACCIDENT TO OCCUR.

HAZARD ANALYSIS (HAZAN) IS NOW A MATURE TECHNIQUE FOR

ESTIMATING THE PROBABILITY AND CONSEQUENCES OF A HAZARD.

COST BENEFIT ANALYSIS IS LESS WELL- ESTABLISHED SO FAR AS

SAFETY IS CONCERNED BUT NEVERTHELESS HAS A PART TO PLAY.
 TOXICOLOGY

 PROVIDE A RELATIVE RATING (HIGH MODERATE, LOW) OF

TOXICITY OF PRODUCT BY ROUTE (CONTACT, INHALATION,
INGESTION)

TLV (THRESH HOLD LIMIT VALUE)

 GUIDE AS MAXIMUM AVERAGE, EXPOSURE TO A CHEMICAL

FOR EIGHT HOURS A DAY AND FIVE DAYS PER WEEK.

PEL (PERMISSIBLE EXPOSURE LIMITS)

 IN USAM, OSHAHAS DEFINEDTHEIR OWN THRESHOLD DOES

CALLED PEL.
UNIT OF PEORTING FOR TLV & PEL ARE

 PPM BY VOLUM, MG/CU.M (M OF VAPOUR PER CU.M OF AIR) OR

FOR DUST mppef (MILLION OF PARTICLES PER CUBIC FOOT OF AIR).

STEL :- SHORT TERM INHALATION LIMIT, SIMILAR TO TLV EXCEPT

 MAXIMUM CONCENTRATION TO WHICH WORKER CAN BE

CONTINUOUSLY EXPOSED FOR A PERIOD UPTO 15 MINUTES
WITHOUT SUFFERING IRRITATION OR CHRONIC AND IRREVERSIBLE
EFFECT PROVIDED THAT NOT MORE THAN 4 EXPOSURES.
MODE OF EXPOSURE:
• INHALATION
• INGESTION
• EXTERNAL CONTACT

EFFECTS OF EXPOSURE:
• TEMPORARY OF PERMANENT DAMAGE TO ORGANS. I.E. POISONING.
• ACUTE OR CHRONIC

ACUTE: RESULT FROM A SINGLE EXPOSURE TO A HIGH

CONCENTRATION OF THE CHEMICAL.

CHRONIC: RESULT FROM EXPOSURE LOW CONCENTRATIONS

OVER A LARGE PART OF A WORKING LIFE TIME.
RESULTS MAY SHOW AFTER MANY YEARS.
GRADED SMPTOMS SHOWN BY AN INDIVIDUAL
RESPONSE: PROGRESSIVELY MORE SERVER EXAMPLE CABON DIOXIDE
 EFFECTS OF ACUTE EXPOSURE TO TOXIC
CHEMICAL INCLUDE:

1] IRRITATION

A] RESPIRATORY B] SKIN C] EYES

2] NARCOSIS

RESPONSES ARE AFFECTED

3] ASPHYXIATION

A] SIMPLE B] CHEMICAL
4] SYSTEMETIC DAMAGE

 INHILATION OF SOME SUBSTANCES CAN SERVE AS A WARNING.

EXAMPLE: CHLORING

 SOME SUBSTANCE HAVE NARCOTIC EFFECTS

EXAMPLE: HYDROCARBON VAPORS

 PERSONS RESPONSES ARE AFFECTED AND MAY BECOME

EXPOSED TO AN ACCIDENT.
LC50: LETHAL CONCENTRATION FIFTY

 CALCULATED CONCENTRATION OF A SUBSTANCE IN AIR,

EXPOSURE TO WHICH CAUSED THE DEATH OF 50% TEST
POPULATION AT A SPECIFIED TIME.

TLCO: TOXIC CONCENTRATION LOW

 LOW CONCENTRATION OF A SUBSTANCE IN AIR FOR A

SPECIFIED PERIOD OF TIME THAT HAS PRODUCED ANY
TOXIC EFFECT ON TEST POPULATION FOR ANY GIVEN
PERIOD OF TIME

LCLO: LETHAL CONCENTRATION LOW

 LOWEST CONCENTRATION OF A SUBSTANCE IS AIR FOR A
SPECIFIC PERIOD OF TIME THAT HAS PRODUCED DEATH
IN TEST POPULATION
LD50: LETHAL DOSE FIFTY

 CALCULATED DOSE (GRAMS OF SUBSTANCE PER

KILOGRAM OF BODY WEIGHT) THAT CAUSED THE DEATH
OF 50% OF TEST POPULATION.

LDLO: LETHAL DOSE LOW

 LOWEST DOSE (G/KG) OF A SUBSTANCE. REPORTED TO

HAVE PRODUCED ANY TOXIC EFFECT IN A TEST
POPULATION.

LDLO: TOXIC DISE LOW

 LOWES DOSE OF A SUBSTANCE REPORTED TO HAVE

PRODUCED AN TOXIC EFFECT IN A TEST POPULATION.