CAUSES OF MAJOR ACCIDENTS

ENGINEERING FACTORS HUMAN FACTORS SYSTEM / PROCEDURE FAILURE

EVALUATION OF CHEMICAL RISK

INVENTORY . TYPE . MODE OF EXPOSURE FREQUENCY . LOSS OF CONTAINMENT . SEVERITY

TECHNIQUES OF EVALUATION & ANALYSIS OF RISK

- FAILURE MODE ANALYSIS - HAZOP STUDY

RATE OF ACCIDENTS
INDIA: 60 PER 1000 WORKERS USA : 25 PER 1000 WORKERS U.K. : 35 PER 1000 WORKERS

REASONS FOR BAD SAFETY PERFORMANCE MORE MANUAL OPERATIONS INSUFFICIENT VOLUNTARY EFFORTS (MANAGEMENT, TRADE UNIONS, OTHERS) LOWER ECONOMICAL & EDUCATIONAL STANDARDS MISCONCEPTS ( ACCIDENTS ARE INEVITABLE) MANAGEMENT NOT ENOUGH CONSCIOUS (CASUAL, ADHOC, COMPASSIONATE, INDIFFERENT ATTITUDE) ONLY 10% LABOUR ARE IN ORGANISED SECTOR 17 MILLION CHILD/ 10 MILLION HANDLOOM/ 18 MILLION

BRINGING SAFETY IN WORK

AVOID
WORKIND WITHOUT AUTHORITY SUDDEN ACTIVITY MAKESHIFTS TAMPERING WITH SAFETY DEVICES AND APPLIANCES HORSEPLAY OR FOOLING UNSAFE LOADING, SPILLAGE, DISORDER OVERLOAD, OVERSPEED, OVERCONFIDENCE EMOTIONS( PANIC/ EXCITEMENT) DAY DREAMING WRONG POSTURES SHORT CUTS, CHANCES

ENSURE
CLEARANCE, PERMIT WARNINGS AND INSTRUCTIONS RIGHT MEANS, TOOLS, TACKLE, PROPER SELECTION REGULAR MAINT. & CARE, PROPER STORING RIGHT METHOD OF WORK ORDER AND HOUSEKEEPING NORMS, SPECIFICATIONS, PROCEDURES PATIENCE AND CONCENTRATION ON WORK RIGHT POSTURE LAID DOWN PRACTICE

AXIOMS OF INDUSTRIAL SAFETY 1. ACCIDENTS OCCURSN DUE TO COMPLETED SEQUENCE OF FACTORS 2. UNSAFE ACTS OF PEOPLE ARE RESPONSIBLE FOR MAJORITY OF ACCIDENTS ( 73% TO 88 %) 3. PERSONS REPEAT THE UNSAFE ACTS TAKES SEVERAL CHANCES IGNORING NARROW ESCAPES, BEFORE FALLING INTO A DISABLING INJURY 4. SEVERITY OF INJURY IS A MATTER OF CHANCE BUT OCCURRENCE IS LARGELY PREVENTABLE 5. UNSAFE ACTIONS HAVE FOUR BASIC MOTIVES WHICH ARE THE AREAS OF CORRECTION . IMPROPER ATTITUDE . LACK OF KNOWLEDGE OR SKILL . PHYSICAL UNSTABILITY . IMPROPER PHYSICAL OR MECHANICAL ENVIORNMENT . FOUR BASIC METHODS ARE AVAILABLE FOR PREVENTING ACCIDENTS

HAZARDS IN STORAGE & HANDLING OF CHEMICALS EXPOSURE TO CHEMICALS : LEAK, FAILURE, OVER FILLING, FALLS FIRES: LEAK, STATIC ELECTRICITY, POOR/ DEFECTIVE ELECTRIC CONNECTION, POOR LAY OUT. INCOMPATIBILITY: RESULTING INTO SEVERE CHEMICAL REACTION. OVER PRESSURISING: PHYSICAL/ CHEMICAL REACTION WITH FOREIGHN MATERIAL, DEFECTIVE VENTS/ RELIEFS, REFRIGERATION SYSTEM FAILURE. VACCUM CREATION: VENT, FLASH BACK ARRESTER CHOKED, BREATHER CHOKED. FREEZING OF VALVES IN CRITICAL LINES.

THINGS TO BE REMEMBERED ABOUT UTILITIES

NITROGEN:- INERT BUT HEALTH HAZARD( SIMPLE ASPHYXIANT ). ENSURE NITROGEN PURITY BY SAFE PRACTICE. [ DISCONECT N2 HOSE BEFORE STAR-UP] STEAM:- SIMPLE ASPHYXIANT. CAUSE BURNS. COOLING WATER:- - NOT SAFE FOR DRINKING. - SAFE HANDLING OF COOLING TOWER CHEMICALS. SAFE HANDLING OF CHLORINE. NOT SAFE FOR EYE WASH. AIR:- - COMPRESSED AIR NOT FOR CLEANING BODY OR CLOTHES. - DRAIN WATER / OIL FROM SEPERATOR. - ENSURE PROPER TEMPERATURE CONTROL ( COMPRESSOR )

INCOMPATIBLE CHEMICALS
CHEMICALS DO NOT MIX WITH
AMMONIA - MERCURY, HALOGENS, HF AMMONIUM NITRATE - ACIDS, METAL POWDERS, ORGANIC POWDERS, S, FLAMMABLE LIQUIDS, CHLORATES METHANOL - OXIDISERS, HALOGENS FLUORINE - ISOLATE FROM EVERYTHING NITRIC ACID - ACETIC, CHROMIC, HYDROCYNIC ACIDS, ANILINE, H2S, FLAMMABLE LIQUIDS & GASES ACETYLENE - SILVER, COPPER, MERCURY, HALOGENS SULPHURIC ACID - CHLORATES, PERCHLORATE

SITUATIONS INVITING RISK

VALVES & FLANGES- GASKETS, GLAND PACKING,GLAND NUTS etc. FAILURE. REMEDY - INSPECTION, USE OF STD. MATERIAL, PREVENTIVE MAINTAINANCE. - BOX OR HOOD GUARDS FOR VALVES. DRIP TRAYS FOR FLANGES WITH DRAIN HOSES. OPERATION FAILURE - WRONG OPERATION REMEDY - TAGGING, COLOUR CODE IDENTIFICATION. FAILURE TO HAND OVER FOR MAINTAINANCE. REMEDY - DEPRESSURISE, DRAIN, PURGE, ISOLATE BLEVE UNTRAINED/ INEXPERIENCED MANPOWER. LACK OF PROCEDURES, INFORMATION, FACILITY AND CUSTODY. SUBSTANDARD/ OLD VESSEL TAKEN IN USE. LACK OF CONTROL/ MONITORING SYSTEM. LACK OF SAFE GUARDS. ( INSULATION, PRESSURE AND TEMPERATURE PROTECTION, LIGHTENING PROTECTION, DIKES, RECOVERY SLOPES/ SUMPS) IMPROPER LAYOUT.

MATERIAL SAFETY DATA SHEET OBJECTIVE: AND METHODS OF PROTECTION, SYSTEMATIC APPROACH TO EDUCATE/ INFORM/ CAUTION ON CHEMICAL HAZARDS AND METHOD OF PROTECTION, TACKLING, FIRSTAID, AVOIDING FIRES/ TACKLING FIRES, LEAKS. USEFUL DATA DISASTER HANDLING, CUSTOMER EDUCATION, EMPLOYEE EDUCATION, COMMUNITY EDUCATION.

MATERIAL SAFETY DATA SHEET

COMPONENTS OF DATA: NAME, TRADE NAME, FORMULA, HARMFUL INGREDIENTS, PRODUCT USE. PHYSICAL DATA ( STATE, APPEARANCE, SOLUBILITY, DENSITY, & OTHER CONSTANTS) FIRE AND EXPLOSION HAZARD. REACTIVITY DATA ( STABILITYINCOMPATIBILITY, REACTIVITY, DECOMPOSITION PRODUCT) TOXICOLOGICAL PROPERTIES DATA. ( ROUTE OF ENTRY, EFFECT- ACCUTE, CHRONIC, TLV etc. ) PREVENTIVE MEASURES ( PPE, LEAK/ SPILL HANDLING, DISPOSAL, HANDLING/ STORAGE REQUIREMENTS) FIRST- AID.

HAZOP STUDY
TO VISUALISE THE WAYS IN WHICH A PLANT CAN MAL-FUNCTION OR BE MAL OPERATED.

METHODOLOGY:
COLLECT DATA (PROCESS, PARAMETERS, PROCESS TYPE, CHEMICAL PROPERTIES,REACTIONS AND SIDE REACTIONS) BREAK PROCESS INTO STAGES, PROCESS EQUIPMENT, DESIGN INTO PARTS. STATE FUNCTION/ INTENTION OF EACH PART. IMAGINE AND CONCLUDE WHAT WORST CAN HAPPEN? IF THE PART CAN MALFUNCTION OR IS ABSENT AND IF THE PROCESS PARAMETERS ARE UPSET. DESIGN SAFETY MEASURES/ SYSTEMS.

RISK ANALYSIS
COMPONENTS OF RISK ANALYSIS. QUANTUM OF RISK ( HOW BIG IS ? ) QUALITY OF RISK( FIRE RISK, TOXIC RISK, EXPLOSION RISK, etc.) PROBABILITY OF RISK( CAN IT HAPPEN ? HOW FREQUENTLY ?) SEVERITY OF RISK AND ITS CONSEQUENCES.

FAULT TREE ANALYSIS:

IMAGINE FAILURE OR DANGEROUS EVENT. TRACE BACK TO ITS CAUSATIVE FACTORS, FIX THE MOST PROBABLE FACTOR.

SAFETY FOR PETROCHEMICAL PLANTS PRINCIPAL RISK: FIRE, EXPLOSION, RUNAWAY REACTION, POISONOUS GASES- CHEMICALS

SAFETY:

BASE SAFETY MEASURES ON HAZOP, RISK ANALYSIS, SAFETY AUDIT. LAY OUT NORMS AND SAFETY DISTANCES TO BE OBSERVED. SAFETY TO BE ENSURED IN DESIGN STAGE, BUILTIN SAFETY ON MACHINES AND EQUIPMENTS. FLAME PROOF EQUIPMENTS AND FITTINGS. CONTROL ON STATIC ELECTRICITY. SAFETY IN TANK CLEANING ( PYROPHORIC RESIDUES) STRICT OBSERVANCE OF OPERATING PARAMETERS- INFORMATION OF DEVIATION TO BE KEPT POSTED TO COCERNED RESPONSIBLE AUTHORITIES, SAFETY, FIRE. STRENGTHEN SUPERVISION IN SUCH SITUATIONS. STRICT OBSERVANCE OF SAFETY PERMIT. SPECIAL FIRE PROTECTION SYSTEMS, FIRE PREVENTION MEASURES. SYSTEM FOR LEAK RECTIFICATIONRECYCLING. RELIABLE & FAIL- SAFE INSTRUMENT VALVES etc. ALTERNATE WATER, POWER, FUEL, AIR ARRANGEMENT FOR EMERGENCY NITROGEN AVAILABILITY AND PURITY. SAFE STORAGE, TRAINING . SAFETY GADGETS,

CHEMICAL/ PETROCHEMICAL PLANTS

COMMONLY OBSERVED ACCIDENT CAUSES
FAILURE TO ISOLATE: ( NO ISOLATION, ISOLATION REMOVED TOO SOON, INADEQUATE ISOLATION, ISOLATION NOT REMOVED) FAILURE TO TAG, FAILURE TO INDICATE CORRECT JOB. WRONG LABELLING, CONFUSING LABEL. FAILURE TO REMOVE HAZARD, FAILURE TO CLEAN PROCESS EQUIPMENT. FAILURE TO USE PPE. COMMUNICATION FAILURE TOTAL DEPENDANCE ON AUTOMATION TREATING SYMPTOMS INSTEAD OF TREATING DISEASE. FAILURE TO REVIEW MODIFICATIONS. IMPROPER/ INCORRECT ASSEMBLING. ASSUMPTION AND WRONG OPERATION. IGNORING WARNING/ ALARM. OVERFILLING/ OVERPRESSURISING. IGNORING RISK OR FAILURE TO ANTICIPATE RISK.( AIR. O2, N2, WATER, STATIC ELECTRICITY, STEAM)