POLLUTION

CONTROL AND
SAFET Y
MANAGEMENT
P R O F. J I G N E S H R A J E N D R A K U M A R J O S H I
WEEK:1
SAFETY , HAZARD, RISK

• Safety or loss prevention is the prevention of accidents by the use of appropriate technology
to identify the hazard of a chemical plant and to eliminate them before an accident occur
• A hazard is anything with the potential for producing an accident
• Risk is the probability of a hazard resulting in an accident
HAZARD

• An inherent physical or chemical characteristic that has the potential for causing harm to
people, the environment , or property
• Hazard are intrinsic to a material, or its conditions of use
• Examples
• Hydrogen sulphide : toxic by inhalation
• Moving machinery: (1) kinetic energy (2) pinch points
• Gasoline: flammable
FOR ANY INDUSTRIAL PROCESS PLANT,
FOLLOWING QUESTIONS MUST BE ASKED
AND ANSWER
• What are the hazards ?
• What can go wrong and how?
• What are the chances?
• What are the consequences ?
ANALYSIS

• Experienced personnel brainstorming a series of question that begin , “what if”

• Each question represents a potential failure in the facility or misoperation of the facility
• The response of the process and or operators is evaluated to determine if a potential hazards
can occur
• Equipment failures ( what if ….Valves leaks)
• Human error ( what if … operators fails to restart pumps)
ANALYSIS

• What if the raw material contains impurities ?

• What if cooling water is lost ?
• What if the vessel agitation stops?
• What if power supply fails ?
• What if temp/ pressure sensor fails ?
• What if the pumps stops?? Etc
STEPS

• 1. divide the system up into smaller, logical subsystem

• 2. identify a list of questions for a subsystem
• 3. select question
• 4. identify hazards, consequences, severity, likelihood, and recommandations
• Repeat steps 2 through 4 until complet
HAZOP

• Hazard and operability analysis

• Identify hazards (safety, health, environmental) , and
• Problems which prevent efficient operation
SAFETY PROGRAM

• Safety regulation requires five ingredients

• Safety knowledge
• Safety experience
• Technical competence
• Safety management support
• Commitment
SCOPE (ELEMENTS OF PROCESS
SAFETY MANAGEMENT)
1. Accountability
2. Process knowledge and documentation
3. Capital project review and design procedure
4. Process risk management
5. Management of chage
6. Process and equipment integrity
7. Human factors
8. Training and performance
9. Incident investigation
10. Company standard, codes and regulations
11. Audits and corrective actions
12. Enhancement of the process safety knowledge
SAFETY PROGRAM
THEY THOUGHT THEY WERE SAFE
• Good companies can be lulled into false sense of
security by their performance in personal safety and
health
• They may not realise how vulnerable they are to a
major accident until it happens
• Subsequent investigation typically shows that there
were multiple causes, and many of them were known
long before the event
WHY AND HOW DEFENCE FAIL

• People often assume system work as intended, despite warning signs

• Examples of good performance are cited as representing the whole, while poor once are
overlooked or soon forgotten
• Analysis of failure modes and effects should included human and organizational aspects as well
as equipment, physical and IT systems
 PROCESS SAFETY MANAGEMENT
• Recognition of seriousness of consequences and mechanism of
causation leads to focus on the process rather than the individual
worker
• Many of the key decision influencing safety may be beyond the
control of the worker or even the site- they may be made by people
at another site, country or organisation
• Cause differ from those for personnel safety
• Need to look at the whole- materials , equipment and systems – and
consider individual and procedure as part of the system
• Management system approach for control
SAFETY ASPECT

• The most effective means of implementing a safety aspect is to make it everyone’s

responsibility in a process plant
• The older concept of identifying a few employees to be responsible for safety is inadequate by
today’s standards
• All employees have the responsibility to be knowledgeable about safety and to practice safety
• It is important to recognize the distinction between a good and an outstanding safety process.
 SAFETY ASPECTS
• A good safety process identifies and eliminates existing safety hazards

• An outstanding safety process has management systems which prevents the existence of safety
hazards
PROCESS SAFETY

• Inherent safety
• Hazard safety
• Risk assessment
INHERENTLY SAFER PROCESSES

• Reduction or elimination of the hazards associated with a process and this reduction or
elimination is permanent and inseparable from the process
• Example : use a less toxic
• Raw material to produce A product
INHERENT SAFER PROCESS METHODS

• Minimize: reduce quantity in process

• Substitute : use less hazardous raw material
• Moderate: use lower temperature and pressure
• Simplify : reduce unnecessary complexity in the design and operations
 HAZARD IDENT/RISK ASSESS.
PROCEDURE
• Hazard identification methods
(1) Process hazard checklist (2) hazard survey (3)
HAZOP hazard & operability study (4) safety
review
Risk assessment
(1) What can go wrong & how ?
(2) What are the chances
(3) Consequences
Extremes
(1) Low probability
(2) Minimal consequence
 HAZARD IDENTIFICATION
• Why ? To identify hazards so that they can be eliminated or controlled
• How ? Using number of available procedure