Post on 11-Dec-2021
1
EDITORIAL BOARD
R Parameswaran
W A Balakumaran
P Manoharan
G S Swaminathan
Printed at Sunitha Printers, Chennai – 600 002
VOL: 15 No. 4 OCTOBER – DECEMBER 2016
QUARTERLY JOURNAL OF SAFETY ENGINEERS ASSOCIATION
G1, Vinoth Foundations, 95/5, Sundaramurthy Gramani Street, Virugambakkam, Chennai-600092.
Tel : 044-2377 4060 E-mail: info@seaindia.org Website: www.seaindia.org
INDIAN SAFETY ENGINEERSEA (INDIA)
Inside... Page
Hazard and Operability Study
(HAZOP) 1
HAZOP Study & HAZOP
Review Procedure 3
Lack of maintenance, poor
communication fouled water
for 300,000 people 4
Preventing Diseases through
Healthy Environment 5
MP ranks highest in industrial,
toxic gas deaths 8
Eye Protection 9
Cryogenic Material 10
CASE STUDY
Flash Fire during charging of
Flammable Powder 12
Explosion of Reactor and Settler
Tank during Process
Troubleshooting 12
IN THE NEWS
OSHA issues rule to revise
beryllium regulations 14
E -Waste rising dangerously 14
(Regn No: 1391 / 2000)
[Registered under Societies Act, 1975]
Twodays Workshop on
HAZOP by SEA India
Mr P Bose, Director, Industrial Safety & Health, Govt ofTamilnadu, inaugurated the two days workshop on HAZOPconducted by SEA India at Chennai on 16th & 17th of December,2016.
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The present day Safety System is based oninvestigation of the accidents to establish theroot cause or causes for the accident and alsoto identify any operational failures if any. Oncethe root causes are identified, the fault in thedesign or in the operational methods or humanerrors are f ixed and recti f ication processinitiated.
With this proactive methodology, we learn thepreventive measures through experience.Though this methodology is highly valuable, itcan be expensive in terms of human sufferingsand/or financial loss.
In order to avoid such problems, we need someform of Synthetic Experience which makes iteasy to spot the problems in prospect as it isin retrospect.
Hazard and Operability studies are one of theHazard Identification Techniques applied at thedesign, construction stage of a project. HAZOPshould also be conducted whenever a changein process parameter or alteration in the P & I(piping & Instrumentat ion) diagram iscontemplated. Hazop studies are carried out bya team of members, from various disciplinesfrom the plant. The team will be critically lookinginto the ways in which the plant can mal-functionor be mal-operated. For carrying out this studyin a systematic way, the team members will usea set of Guide Words and apply them at eachstage of the process parameters so as toanalyse the criticality with each step.
To impart thorough and indepth knowledge onHAZOP among the safety professionals, SEAindia conducted a two days Workshop onHAZOP at Chennai on December 16th and 17th
2016.
Thiru P Bose, Director, Industrial Safety andHealth, Government of Tamilnadu inauguratedthe workshop.
M/s W A Balakumaran and P Lakshminarayananconducted the twodays workshop dealing withoutline of HAZOP, case studies in processindustries, HAZOP illustrations, simulated andhands on exercises and conducting HAZOPStudy. Typical group excercises were alsoconducted among the participants.
HAZARD and OPERABILITY study (HAZOP)
A brief introduction on HAZOP by MrLakshminarayanan is given in this journal for thebenefit of SEA members as publication of entireproceedings is not possible. SEA India can takeup detailed training on HAZOP, suitable tospecific industry, SEA India has the expertise toconduct HAZOP studies on requests from themembers.
Around 40 safety professionals from variousparts of Tamilnadu participated in the workshopand appealed to have more such workshops infuture.
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HAZOP STUDY & HAZOP REVIEW PROCEDURE
HAZOP DEFINITION:
A Hazard and Operability
study (HAZOP) is a structured and
systematic examination of the
design of a New Project or Existing
process or operation in order to
identify and evaluate problems that
may produce or have risks to
personnel or equipment and
incorporate appropriate design
protection. HAZOP must be
carried out even in a successful
running operation when ever any
changes (addition/removal) are
done irrespective of the magnitude
of change.
OBJECTIVE:
The objective of a HAZOP
study is to review the integrity of
the design and identify any design
engineering issues (conditions
which could lead to hazardous
situations deviating from the
original design intent) that may
otherwise not have been found.
HAZOP REVIEW TEAM &
METHODOLOGY:
Team consist well experienced
multi-disciplines involved in the
design.
The technique is based on
breaking the overall complex
design of the process into a number
of small simpler sections called
'nodes' which are then individually
reviewed.
The review methodology uses
the “Guide Word” in accordance
with the guidelines published by
the Center for Chemical Plant
Safety (CCPS) of the American
Institute of Chemical Engineers
(AIChE). It is consistent with
Sections 2 and 3 of API 750
Recommended Practice; i.e.,
Mr. P Lakshminarayan, Safety Specialist.
Process Safety Information and
Process Hazard Analysis, in line
with the relevant international
standard (British Standard BS:
IEC61882: 2002 Hazard and
operability studies).
DRAWINGS REQUIRED FOR
HAZOP RIVEW STUDY:
The HAZOP review is carried
out based on the PFDs, plot plans,
P&IDs, Cause and Effect chart,
interlock table and other
PROJECT related drawings. The
P&IDs used for the HAZOP will
be fully mechanized and show all
instruments, check valves, safety
valves, controllers, pressure and
level switches that are included in
the limits of the supply. The P&ID
set used for the HAZOP review
will be marked “HAZOP Review
P&ID” and will be included in the
HAZOP report.
DOCUMENTS REQUIRED
FOR HAZOP RIVEW STUDY:
The latest issue of all the high
level documents of the design
basis, narratives and procedures
will be used for the HAZOP study.
These documents will be submitted
to the HAZOP team in advance so
that they may review them prior to
the HAZOP study.
HAZOP Review Procedure:
The HAZOP Review shall
cover all the process lines,
equipments and systems that are
part of, or may be affected by the
project facilities. This shall include
existing upstream and downstream
facilities that may be affected by
the new facilities like Process Lines,
Process Vessels, Process Equip-
ment, Off-Site Systems, Fire
Detection Systems, Fire Protection
Systems, ESD Systems, Isolation at
Battery Limits, Interface with other
Facilities. Standard key words like
More, Less, No, Reverse, Other
than are used for each parameter,
Composition and Others to assess
the safeguards in the design.
HAZOP team will list the
possible causes and the
consequences regarding the
operating condition, procedures
and the safety aspects from both
personnel and material point of
view. If the consequences are
considered as being out of the
normal operating range, the
HAZOP team will investigate the
installed safeguards, safety devices
installed, to limit the consequences
of the process upset and
recommend additional safeguards,
if required. Consideration of
transient operating conditions
during start-up, shutdown, plants
upset, emergencies, potential
exposure of employees to chemicals
during routine operations including
maintenance, decontamination
and ease of Maintenance.
The recommendations to the
identified concerns/issues or
hazards will be recorded and
presented in the form of HAZOP
report to ensure the overall
SYSTEMS and facilities are safe,
reliable, easy to operate and
maintain.
HAZOP document is
intended to be viewed as part of
the overall Project Specification
and must be read in conjunction
with the other documents relevant
to other Project documents like
SOR (statement of requirement
and SOW (Scope of work).
4
LACK OF MAINTENANCE, POOR COMMUNICATION
FOULED WATER FOR 300,000 PEOPLE
What can go wrong when an
aboveground tank used to store
harmful chemicals is not inspected
for 10 years?
Drinking water for 300,000
people can be contaminated, and
hundreds end up seeking care for
maladies ranging from rashes to
nausea.
The U.S. Chemical Safety
Board’s (CSB) final report into
the Jan. 9, 2014 release of
chemicals into the water source
for the Charleston, WV, area
concludes Freedom Industries
failed to inspect or repair
corroding tanks.
The spill occurred not far
away from West Virginia
American Water's intake in the
Elk River about 1.5 miles
downstream from the Freedom
facility.
The CSB says the water
company and local authorities
were unable to effectively
communicate the looming risks to
affected residents.
About 10,000 gallons of
crude methylcycloexanemethanol
(MCHM) mixed with propylene
glycol phenyl ethers (PPH) were
released into the Elk River.
Part of the poor
communication: Freedom initially
reported only 1,000 gallons of
crude MCHM had spilled. The
presence of PPH was not
mentioned at first either.
Freedom's inability to
immediately provide information
about the chemicals'
characteristics resulted in
significant delays before a “do not
use order” for water was issued to
the public.
The CSB found the MCHM
tanks were not internally
inspected for at least 10 years.
There was no comprehensive
aboveground storage tank law in
West Virginia. Months after the
spill, the state enacted its
Aboveground Storage Tank Act.
"My message here today is
what happened in Charleston was
preventable," said Vannessa Allen
Southerland, CSB's chairwoman,
in a press conference releasing the
report.
Among the lessons learned
highlighted in the CSB's report:
• Above ground storage tank
owners should regularly
inspect and monitor the
vessels and coordinate with
nearby water utilities and
emergency response
organizations to ensure they
provide adequate
information about their
stored chemicals for effective
planning in case of a leak,
and
• Public health agencies should
coordinate with water
utilities, emergency response
organizations and facilities
storing chemicals near
drinking water sources.
It does not take much tank
corrosion to create a situation like
the one in Charleston. CSB
investigators believe the leaked
chemicals flowed out of the tank
through two holes that were no
larger than pennies. The
chemicals flowed at about 11.5
gallons per minute, but the leak
was not detected for almost 24
hours.
The CSB's lead investigator
said regular inspections would
have found the corrosion.
5
PREVENTING DISEASES THROUGH HEALTHY ENVIRONMENT
The production and use of
chemicals continues to grow
worldwide, particularly in
developing countries. This is likely
to result in greater negative effect
on health, if sound chemicals
management is not ensured.
Multisectoral action is urgently
needed to protect human health
from the harmful effects of
improperly managed chemicals.
Air pollution
Indoor air pollution from solid
fuel use and urban outdoor air
pollution are estimated to be
responsible for 3.1 million
premature deaths world-wide every
year and 3.2% of the global burden
of disease. More than half of the
health burden from air pollution is
borne by people in developing
countries. Air pollutants have been
linked to a range of adverse health
effects, including respiratory
infections, cardiovascular diseases
and lung cancer. Reduction of air
pollution levels will decrease the
global burden of disease from these
illnesses. Pollution prevention
requires policies on air quality and
transport, air pollution control
regulations in cities, emission
controls in industry and promotion
of clean, renewable energy sources.
Interventions to reduce indoor air
pollution include switching from
home use of solid fuel to cleaner
fuels and technology and
ventilation in homes, schools and
the working environment, and
stopping smoking. Efforts to
significantly reduce air pollutants
will also help to decrease
greenhouse gas emissions and
mitigate the effects of global
warming.
The following TEN chemicals
need special consideration to
control the impact on the human.
Arsenic
Soluble inorganic arsenic is
acutely toxic. Intake of inorganic
arsenic over a long period can lead
to chronic arsenic poisoning
(arsenicosis). Effects, which can
take years to develop depending on
the exposure level, include skin
lesions, peripheral neuropathy,
gastrointestinal symptoms,
diabetes, renal system effects,
cardiovascular diseases, and cancer.
Organic arsenic compounds, which
are abundant in seafood, are less
harmful to health, and are rapidly
eliminated by the body. Human
exposure to elevated levels of
inorganic arsenic occurs mainly
through the consumption of
groundwater containing naturally
high levels of inorganic arsenic,
food prepared with this water, and
food crops irrigated with high
arsenic water sources. In one
estimate, arsenic-contaminated
drinking-water in Bangladesh
alone was attributed 9,100 deaths
and 125,000 Disability Adjusted
Life Years (DALYs) in 2001.
Reduction in human exposure
to arsenic can be achieved by
screening of drinking-water
supplies, clearly identifying those
delivering water above the WHO
guideline 10 g arsenic per litre or
national permissible limits,
together with awareness-raising
campaigns. Mitigation options
include use of alternative
groundwater sources, use of
microbiologically safe surface water
(e.g. rainwater harvesting), or use
of arsenic removal technologies.
Asbestos
Most types of asbestos cause
lung cancer, mesothelioma, cancer
of the larynx and ovary, and
asbestosis (fibrosis of the lungs).
Exposure to asbestos occurs
through inhalation of fibres in air
in the working environment,
ambient air in the vicinity of point
sources such as factories handling
asbestos, or indoor air in housing
and buildings containing friable
(crumbly) asbestos materials.
Currently about 125 million people
in the world are exposed to
asbestos at the workplace. In 2004,
asbestos-related lung cancer,
mesothelioma and asbestosis from
occupational exposures resulted in
107,000 deaths and 1,523,000
DALYs. In addition, several
thousands of deaths can be
attributed to other asbestos-related
diseases, as well as to
nonoccupational exposures to
asbestos. Elimination of asbestos-
related diseases should take place
through the following public health
actions: a) recognizing that the
most efficient way to eliminate
asbestos-related diseases is to stop
the use of all types of asbestos; b)
replacing asbestos with safer
substitutes and developing
economic and technological
mechanisms to stimulate its
replacement; c) taking measures to
prevent exposure to asbestos in
place and during asbestos removal
(abatement), and; d) improving
early diagnosis, treatment, social
and medical rehabilitation of
asbestos-related diseases and
establishing registries of people
with past and/or current exposures
to asbestos.
(Contd. on next page)
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Preventing ....(Contd. from previous page)
Benzene
Human exposure to benzene
has been associated with a range of
acute and long term adverse health
effects and diseases, including
cancer and aplastic anaemia.
Exposure can occur occupationally
and domestically as a result of the
ubiquitous use of benzene-
containing petroleum products
including motor fuels and solvents.
Active and passive exposure to
tobacco smoke is also a significant
source of exposure. Benzene is
highly volatile and exposure occurs
mostly through inhalation.
Interventions to reduce both work
and general population exposure
include promoting the use of
alternative solvents in industrial
processes, developing and
implementing policies and
legislation to remove benzene from
consumer products, discouraging
domestic use of benzene-
containing products, stopping
smoking, and promoting building
codes requiring detached garages.
Cadmium
Cadmium exerts toxic effects
on the kidney, the skeletal and the
respiratory systems, and is classified
as a human carcinogen. It is gen-
erally present in the environment
at low levels; however, human ac-
tivity has greatly increased those
levels. Cadmium can travel long
distances from the source of emis-
sion by atmospheric transfer. It is
readily accumulated in many or-
ganisms, notably molluscs (like
oysters) and crustaceans (like crab,
lobster). Lower concentrations are
found in vegetables, cereals and
starchy roots. Human exposure
occurs mainly from consumption of
contaminated food, active and pas-
sive inhalation of tobacco smoke,
and inhalation by workers in the
non-ferrous metal industry. Inter-
ventions to reduce global environ-
mental cadmium releases and oc-
cupational and environmental ex-
posure include increased recycling
of cadmium, minimizing emissions
and discharges from activities such
as mining and waste management,
promoting safe working conditions
for workers manipulating cadmium
containing products, and stopping
smoking.
Dioxins & dioxin-like
substances
Dioxins and dioxin-like
substances, including PCBs
(Polychlorinated Biphenyls), are
persistent organic pollutants
(POPs) covered by the Stockholm
Convention. They can travel long
distances from the source of
emission, and bioaccumulate in
food chains. Human exposure to
dioxins and dioxin-like substances
has been associated with a range of
toxic effects, including
immunotoxicity, developmental
and neurodevelopmental effects,
and changes in thyroid and steroid
hormones and reproductive
function. Developmental effects
are the most sensitive toxic
endpoint making children,
particularly breast-fed infants, the
population most at risk. These
substances are byproducts of
combustion and various industrial
processes, such as chlorine
bleaching of paper pulp and
smelting. While manufacture of
PCBs should have been
discontinued, release into the
environment still occurs from
disposal of large scale electrical
equipment and waste. Human
exposure to dioxin and dioxin-like
substances occurs mainly through
consumption of contaminated
food. Actions to reduce emissions
of these substances are required by
the Stockholm Convention.
Interventions to reduce human
exposure include identifying and
safely disposing of material
containing or likely to generate
dioxin and dioxin-like substances
such as electrical equipment,
ensuring appropriate combustion
practices to prevent emissions,
implementing FAO/WHO
strategies to reduce contamination
in food and feed, and monitoring
of food items and human milk.
Inadequate or excess fluoride
Fluoride intake has both
beneficial effects - in reducing the
incidence of dental caries (tooth
decay) - and negative effects - in
causing enamel and skeletal
fluorosis following prolonged high
exposure. The ranges of intakes
producing these opposing effects
are not far apart. Public health
actions are needed to provide
sufficient fluoride intake in areas
where this is lacking, so as to
minimize tooth decay. This can be
done through drinking water
fluoridation, or, when this is not
possible, through salt or milk
fluoridation. Excessive fluoride
intake usually occurs through the
consumption of ground water
naturally rich in fluoride, or crops
that take up fluoride and are
irrigated with this water. Such
exposure may lead to crippling
skeletal fluorosis, which is
associated with osteosclerosis,
calcification of tendons and
ligaments and bone deformities.
While the global prevalence of
dental and skeletal fluorosis is not
entirely clear, it is estimated that
excessive fluoride concentrations
in drinking water have caused tens
of millions of dental and skeletal
(Contd. on next page)
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Preventing ....(Contd. from previous page)
fluorosis cases world-wide over a
range of years. Although removal
of excessive fluoride from drinking-
water may be difficult and
expensive, low-cost solutions that
can be applied at a local level do
exist. It is important that local
authorities consider the causes of
fluorosis carefully and choose the
best and most appropriate means of
dealing with excess fluoride
exposure taking into account the
local conditions and sensitivities.
Lead
Lead is a toxic metal whose
widespread use has caused
extensive environmental
contamination and health
problems in many parts of the
world. It is a cumulative toxicant
that affects multiple body systems,
including the neurologic,
hematologic, gastrointestinal,
cardiovascular, and renal systems.
Children are particularly
vulnerable to the neurotoxic
effects of lead, and even relatively
low levels of exposure can cause
serious and in some cases
irreversible neurological damage.
Lead exposure is estimated to
account for 0.6% of the global
burden of disease, with the highest
burden in developing regions.
Childhood lead exposure is
estimated to contribute to about
600,000 new cases of children with
intellectual disabilities every year.
Recent reductions in the use of
lead in petrol, paint, plumbing and
solder have resulted in substantial
reductions in blood lead levels.
However, significant sources of
exposure still remain, particularly
in developing countries. Further
efforts are required to continue to
reduce the use and releases of lead
and to reduce environmental and
occupational exposures,
particularly for children and
women of child-bearing age.
Interventions include eliminating
non-essential uses of lead such as
lead in paint, ensuring the safe
recycling of lead-containing waste,
educating the public about the
importance of safe disposal of lead-
acid batteries and computers, and
monitoring of blood lead levels in
children, women of child-bearing
age and workers.
Mercury
Mercury is toxic to human
health, posing a particular threat to
the development of the child in
utero and early in life. Mercury
exists in various forms: elemental
(or metallic); inorganic (e.g.
mercuric chloride); and organic
(e.g., methyl- and ethylmercury),
which all have different toxic
effects, including on the nervous,
digestive and immune systems, and
on lungs, kidneys, skin and eyes. It
has been estimated that among
selected subsistence fishing
populations, between 1.5/1000 and
17/1000 children showed cognitive
impacts caused by the
consumption of fish containing
mercury. Mercury releases in the
environment result mainly from
human activity, particularly from
coal-fired power stations,
residential heating systems, waste
incinerators and as a result of
mining for mercury, gold and other
metals. Once in the environment,
elemental mercury is naturally
transformed into methylmercury
that bioaccumulates in fish and
shellfish. Human exposure occurs
mainly through inhalation of
elemental mercury vapors during
industrial processes and through
consumption of contaminated fish
and shellfish. Interventions to
prevent environmental releases
and human exposure include
eliminating the use of mercury
wherever possible, promoting the
development of mercury-free
alternatives e.g. for manometers
and thermometers, ensuring proper
disposal of mercury-containing
devices, and implementing safe
handling, use and disposal of
mercury-containing products and
waste.
Highly hazardous pesticides
Highly hazardous pesticides
may have acute and/or chronic
toxic effects, and pose particular
risk to children. Their widespread
use has caused health problems
and fatalities in many parts of the
world, often as a result of
occupational exposure and
accidental or intentional
poisonings. Available data are too
limited to estimate the global
health impacts of pesticides,
however the global impact of self-
poisoning (suicides) from
preventable pesticide ingestion has
however been estimated to amount
to 186,000 deaths and 4,420,000
DALYs in 2002. Environmental
contamination can also result in
human exposure through
consumption of residues of
pesticides in food and, possibly,
drinking water. While developed
countries have systems already in
place to register pesticides and
control their trade and use, this is
not always the case elsewhere.
Guidance and legal frameworks on
the use, management and trade of
pesticides, as well as proper storage
and handling, are available from
international organizations and
international conventions; these
should be implemented globally.
8
MP RANKS HIGHEST IN INDUSTRIAL, TOXIC GAS DEATHS
Madhya Pradesh ranks
highest in terms of deaths due to
industrial accidents and
inhalation of toxic fumes, a recent
report by the National Crime
Records Bureau on accidental
casualties and suicides in India
has revealed.
The report said 213 people
died in industrial accidents
through 2015, of which 55 – the
highest count – occurred in
Madhya Pradesh. It was followed
by Gujarat with 31 deaths,
Rajasthan with 28, Uttar Pradesh
with 23, and Chhattisgarh with
17.
Surprisingly, Madhya Pradesh
had occupied the sixth position
with just 12 cases in 2014.
The state also topped the list
of deaths due to inhalation of
toxic gases, with at least 116 such
cases being registered in 2015. It
was followed by Tamil Nadu with
99 deaths, Gujarat with 51,
Andhra Pradesh with 37, and
Rajasthan with 23. The total
number of such casualties across
the country stood at 394.
Madhya Pradesh had
registered just 14 such cases in
2014, occupying the eighth
position.
This comes as a blow to the
reputation of the state, which had
witnessed the infamous Union
Carbide gas leak in 1984. While
the official death count of that
disaster stood at 5,000, rights
activists pegged it between 20,000
and 25,000 victims.
Directorate of Industrial
health and Safety (Madhya
Pradesh) director PD Narya told
HT that the department was
doing its best to curtail industrial
accidents in the state. “We have
just 20 officers to handle 51
districts of the state. Despite the
staff shortage, we regularly visit
industrial units to spread
awareness on safety measures.
Apart from this, we work in
tandem with the Disaster
Management Institute in Bhopal
to find ways to curb industrial
accidents,” he said.
Narya said a possible reason
for the rise in industrial casualties
might be the inclusion of cases
under the Building Construction
Enforcement (BCE) Act. “The
BCE Act is being implemented
more stringently in the state now.
Cases that occur under it are also
considered industrial accidents,”
he added.
DEATHS DUE TO
INDUSTRIAL ACCIDENTS
IN 2015
1. Madhya Pradesh - 55
2. Gujarat - 31
3. Rajasthan - 28
4. Uttar Pradesh - 23
5. Chhattisgarh - 17
Total deaths in India - 213
DEATHS DUE TO
INHALATION OF TOXIC
GASES IN 2015
1. Madhya Pradesh - 116
2. Tamil Nadu - 99
3. Gujarat - 51
4. Andhra Pradesh - 37
5. Rajasthan - 23
Total deaths in India - 394
9
EYE PROTECTION
A mechanic was using a
hammer and chisel to remove a bit
from the blade of a road grader. As
he struck the chisel with the
hammer, a sliver of metal broke off
the chisel and became embedded
in the mechanic’s safety glasses.
The mechanic was not injured.
Workers are regularly exposed
to work place hazards that pose
dangers to their eyes. Eye injuries
are most often caused by:
• Flying objects
• Chemical splashes, vapors or
dust
• Being stuck by or bumping
into an object
• Sparks or molten metal and
other hot liquid splashes
• Light radiation from welding
Studies show that 90% of
workplace eye injuries can be
prevented when proper eye
protection is worn. Most injuries
occur when a worker is not
wearing eye protection at the time
of the accident. In other instances,
workers were wearing eye
protection but the eyewear did not
adequately protect against the
specific hazard involved.
BEST PRACTICES
• Wear properly rated and
properly maintained
Protective Eyewear before
working in an area were flying
particles may be present;
welding, cutting, working
with molten metal, working
near grinding wheels, riding
in open mantrips, or working
in any other area where eye
hazards may be present
• Ensure eyewear fits properly
and comfortably
• Use safety eyewear that
provides the maximum
protection against the specific
hazard
• Ensure eyewear fits properly
and comfortably
• Inspect protective eyewear
regularly and replace it if a
defect or damage is found
• Store protective eyewear
where it would not become
scratched or damaged, and
keep it clean
• Step away from a potential
hazard if protective eyewear
is removed for cleaning
• Use antifog material on
protective eyewear.
10
CRYOGENIC MATERIAL
Definition
Cryogenic liquids have
boiling points of less than -90º C
(-130º F) at 14.7 psia (1 bar). All
cryogenic liquids are gases at
normal temperatures and
pressures. When cooled and
placed under pressure in specially
designed systems or storage
containers, the gases condense to
a liquid state and maintain very
cold temperatures.
Types of Cryogens & Hazards
Various gases can be used as
cryogenic liquids. The most
common cryogens used are
nitrogen and helium, which are
odorless and colorless. Both liquid
helium and nitrogen are simple
asphyxiants. Therefore, they do
not have associated permissible
exposure limits (PELs) or
threshold limit values (TLVs).
The hazards associated with these
cryogenic liquids are contact with
the skin or eyes, which causes
frostbite; and displacement of
oxygen from the room, which can
create an atmosphere that is
insufficient to support life. While
inert, rapid release of cryogenic
liquids can condense oxygen in
the air thereby creating a localized
oxygen-enriched atmosphere.
This localized oxygen-rich
atmosphere may pose a fire risk in
the presence of organic matter
and an ignition source.
Less common cryogens, such
as propane, hydrogen, and
oxygen, present risk of fire due to
their inherent flammability, while
others are toxic. Consult the
Material Safety Data Sheet
(MSDS) for the particular
cryogenic liquid being used for a
complete discussion of associated
hazards.
Cryogen Containers
Cryogenic liquids are generally
shipped in low-pressure, vacuum-
insulated, multi-walled
containers; and may be
transferred to non-pressurized
containers for everyday use. The
vacuum-insulated wall design is
intended to keep the surrounding
heat away from the liquid
contained in the vessel. All
containers will “leak”. Heat which
causes the liquid to slowly change
to a gas thereby creating pressure.
As the gas exits the container
(through a pressure release valve
or loose fitting lid), a visible fog
and/or frosting on the container
will be seen. Shipping containers
are equipped with pressure relief
valves and rupture disks that vent
excess pressure. Holding
containers such as dewar flasks
are equipped with loose fitting lids
to allow excess pressure to vent.
These pressure venting features
are critical to the safe operation of
cylinders and containers.
• Liquid dewar flasks. Liquid
dewar flasks are non-pressurized,
vacuum-jacketed vessels. Dewars
are equipped with loose fitting
caps or plugs. Dewars are available
in sizes ranging from 5 to 200
Litres.
• Liquid cylinders. Liquid
cylinders are low-pressure,
stationary or portable, and are
specifically designed for cryogenic
liquids. Cylinders are available in
sizes ranging from 80 to 450
Litres. Cylinders designed for
liquid withdrawal and generally,
operate at less than 20 psig.
Cylinders designed for gas
withdrawal generally operate in
the range of 5-150 psig.
Safe Work Practices
• Contact of the skin with
cryogens or items that have
been supercooled by a
cryogen can cause severe
burns or frostbite.
• Wear eye protection and a
face shield when opening
valves, dispensing cryogenic
liquids, or placing items into
or removing items from a
cryogen. Remove jewelry or
other items that could trap
spilled liquids against the
skin. Use thermal or leather
gloves when touching items
that have been in contact
with cryogens. Use tongs to
remove or place items into
cryogenic liquids. Splattering
will occur anytime an item is
placed into or removed from
a cryogenic liquid. Items
removed from a cryogen will
change temperatures/
pressures very rapidly, which
can result in container failure
sending shards of plastic
everywhere. Thus, eye and
face protection is critical. Use
potholders when opening
valves or dispensing
cryogens. If eye or skin
contact with frostbite occurs,
remove restrictive clothing,
flush the affected area with
(Contd. on next page)
11
tapped (Not Hot) water and
seek medical attention. Do
not rub the affected area or
use dry heat to warm.
• Cryogenic gases can cause
asphyxiation by displacing
oxygen in the air because of
their very large expansion
ratios (700 – 900). As an
example, an abrupt release of
only 3 liters of liquid nitrogen
in a 12x12x8 room would
result in an oxygen deficient
atmosphere (</= 19.5%
oxygen)1. Indoor use,
storage, and dispensing areas
should be mechanically
ventilated (minimum of six
air changes per hour). Passive
ventilation is not
recommended. An oxygen
sensor and alarm (or sensor
specific to the gas in use)
should be used in areas
where the size of the largest
container exceeds the
available room capacity to
the extent that an oxygen
deficient atmosphere could
occur in the event of a
release; and in areas
equipped with stationary
containers that are filled
from a delivery truck and the
equipment is not vented to
the outdoors. Oxygen
sensors/alarms are
recommended for gases that
are simple asphyxiants and
that do not have good
warning properties (i.e.,
odor). Specific gas monitors/
alarms are recommended for
gases that present other
hazards (i.e., toxic,
flammable).
• Pre-plan for spills.
• Know the maximum amount
that can be spilled or released
in the area without creating
an oxygen deficient
atmosphere or other hazard
(i.e., fire, toxic atmosphere,
etc.). If a spill occurs that
exceeds this amount,
immediately leave the area,
shut doors, and contact the
notified Operator. If the
amount spilled or released is
such that it could impact
nearby areas or create a
secondary hazard of fire or
toxicity, initiate building
evacuation procedures.
• If the amount is small and
does not create a secondary
hazard, ensure ventilation of
the area, and notify the
notified Operator. If it is safe
to do so and a fume hood is
nearby, the cylinder or
container can be located in
or in front of the operating
hood to assist with
ventilation.
• Pressure relief valves on
cylinders serve an important
safety function- they allow
gases to escape to prevent
over-pressurization. Do not
block, seal, or otherwise
tamper with the valves. Caps
on dewars are designed to be
loose-fitting to allow for gases
to escape. Never completely
seal a dewar.
• Never use a thermos bottle
or other device that has not
been specifically designed for
cryogenic service.
• When working with
cryogenic liquids, ensure that
equipment is scrupulously
clean. Greases, waxes, or
other impurities could react
with the liquid/gas or
condensed room oxygen to
cause a fire. Use and store
cryogens away from ignition
sources.
• Store and move cylinders
only in an upright position.
Do not drop, tip, or roll
containers. Use mechanical
handling devices for safely
moving large containers and
secure the container during
transport.
• Avoid transporting
containers or cylinders in a
passenger elevator.
• Recognize that many
materials can become brittle
and prone to failure in
contact with the extremely
cold temperatures of
cryogens.
• Use only cryogenic storage
vials that are designed
specifically for this purpose,
and visually inspect each vial
prior to use to ensure that
there are no defects. Do not
reuse vials.
• Allow vials and other
containers that have been in
contact with cryogens to
warm slowly to minimize
sudden pressure differentials.
• Placard use and storage areas
in accordance with the EHS
SOP, Door Posting for
Emergency Purposes. Label
cylinders and dewars with
“Cryogenic gas/liquid” and
the name of the product (i.e.,
Liquid Nitrogen).
Cryogenic ....(Contd. from previous page)
12
Causal Analysis
Evaluation of loss • One worker injured
Type of contact • Flash fire
Immediate cause(s) • Introduction of sparks into a flammable atmosphere
Basic cause(s) • Failure to conduct risk assessment
Failure of OSHMS • Hazard identification, risk assessment and risk control
• Operating procedures and safe work practices
• Consultation and communication
• Control of hazardous substances
CASE STUDY
CASE STUDY 1:
FLASH FIRE DURING
CHARGING OF FLAM-
MABLE POWDER:
Description of Incident
An operator was pouring a sack of
chemical powder manually into
the hopper of a blending machine.
The charging process took place
while a welder was installing a
product specification board (sign
board) within the vicinity of the
hopper. When the welder started
a test spark, a spark fell into the
hopper and a flash fire occurred.
The operator who was loading the
chemical powder suffered burns
and sustained cuts while escaping
from the fire.
Possible Causes and Contribut-
ing Factors
Medium
• The chemical powder being
charged into the hopper was
flammable.
Management
• There was no PTW issued for
this hot work to ensure that
the necessary checks were
made before commencing the
welding works.
• There was no enclosure to iso-
late the welding sparks from
the hopper.
• Proper means of communica-
tion (e.g., via walkie-talkies)
were not provided to the
workers.
Recommendations and Learning
Points
• Conduct a general workplace
risk assessment to identify all
sources of flammable material.
• A PTW must be issued to en-
sure that the necessary
worksite checks are made, a
gas test is performed and the
work has been authorised be-
fore any hot work is allowed to
proceed.
• Set up a fire blanket enclosure
around the hopper opening to
shield against sparks generated
from any nearby welding
works.
• Improve communication and
coordination between differ-
ent teams of workers by pro-
viding walkie-talkies or por-
table radio handsets to the
workers.
• Equip all workers handling
flammable substances with
suitable PPE (e.g., a fire retar-
dant uniform) for basic protec-
tion against fire.
CASE STUDY 2:
EXPLOSION OF REACTOR
AND SETTLER TANK DUR-
ING PROCESS TROUBLE-
SHOOTING:
Description of Incident
Several workers were carrying out
troubleshooting on process line
no. 1. The pump supplying hydro-
gen peroxide (H2O2) to process
line no. 1 was still in operation.
The same pump supplied hydro-
gen peroxide to process line no. 2
as well. There was a valve located
after the pump that controlled the
supply of hydrogen peroxide to a
reactor via process line no. 2. As
the valve was not fully isolated,
the hydrogen peroxide reacted
with the remnants inside the re-
actor and downstream settler tank
which caused an explosion. The
explosion ripped off the shell of
the reactor and the top of the
settler tank. None of the workers
were injured in this incident as
they were working at the other
(Contd. on next page)
13
end of the production building.
Possible Causes and Contribut-
ing Factors
Medium
• Hydrogen peroxide reacted
exothermically with the rem-
nants (concentrated sulphuric
acid, H2SO4, and isopropanol,
(CH3)2 CHOH in both the
reactor and settler tank, re-
sulting in an increase in the
system pressure.
Machine
• The cooling water jacket of
the reactor was not in opera-
tion as the reactor was shut
down. As such, the tempera-
ture increase in the reactor
could not be controlled.
• The relief vents for both the
reactor and settler tank were
inadequately sized to relieve
the rising pressure in each
vessel.
Man
• The workers failed to ensure
that the isolation valve was
fully closed.
Case Study ....(Contd. from previous page)
Causal Analysis
Evaluation of loss • Property damage
Type of contact • Explosion
Immediate cause(s) • Over-pressurisation of process vessels
Basic cause(s) • Failure to ensure positive isolation of critical valve
Failure of OSHMS • Process safety information
• Hazard identification, risk assessment and riskcontrol
• Operating procedures and safe work practices
• Some of the workers involved
in the troubleshooting were
unaware that the same pump
supplied hydrogen peroxide to
the reactor via process line no.
2 as well.
• The workers did not know
that sulphuric acid and hydro-
gen peroxide were incompat-
ible and should not be mixed.
Management
• The management failed to
carry out a thorough Hazard
and Operability (HAZOP)
study and a Quantitative Risk
Assessment (QRA) on the re-
actor and associated process
lines.
• There was a lack of instru-
mentation for the monitoring
of key process parameters like
process temperature, system
pressure, vessel liquid level,
etc.
• Proper means of communica-
tion (e.g., via walkie-talkies)
were not provided to the
workers.
Recommendations and Learning
Points
• Conduct process hazard analy-
sis and implement suitable
layers of protection to mitigate
all identified risks.
• Review all the existing operat-
ing procedures and safety
checklists to ensure they are
written clearly and all the
identified risks (e.g., chemical
incompatibility) have been
highlighted and sufficiently
addressed.
• Provide competency training
to ensure that the workers un-
derstand the process flow and
the risks associated with mix-
ing of incompatible chemicals.
• Ensure positive isolation of
process lines through the use
of double block valves and
bleed with spading to prevent
accidental mixing of incom-
patible chemicals.
• Implement process instrumen-
tation, control and alarm sys-
tems so that key operating
parameters like process tem-
perature and pressure can be
easily monitored.
• Re-design the relief vents for
the worst-case pressure relief
scenario.
• Establish and implement pro-
cedure on the steps and mea-
sures to be taken in the event
of a runaway reaction.
DISCLAIMER: All information contained in this Journal, were obtained from sources, believed to be reliable and are collated, based ontechnical knowledge and experience, currently available with the Editorial Board of SEA (India). While SEA (India) recommends referenceto or use of the contents by its members and subscribers, such reference to or use of contents by its members or subscribers or thirdparties, are purely voluntary and not binding. Therefore the Editorial Board of this Journal or SEA (India) assumes no liability or responsibilitywhatsoever towards any bad or undesired consequences.
14
IN THE NEWS
OSHA issues rule to revise beryllium regulations
A new rule issued by OSHA lowers the allowed levels of a chemical that can cause devastating lung
diseases.
The final beryllium rule reduces the eight-hour permissible exposure limit from the previous 2.0
micrograms per cubic meter (µg/m³) to 0.2 µg/m³. The rule also establishes a short-term exposure
limit of 2.0 µg/m³ over a 15-minute sampling period. The previous exposure limit goes back 40 years.
OSHA has issued three separate sets of rules for general industry, construction and shipyards.
The chemical is highly toxic when beryllium-containing materials are processed in a way that releases
airborne dust, fumes or mist which can damage the lungs.
Recent scientific evidence shows workers who inhale even low levels of airborne beryllium can develop
a lung condition called chronic beryllium disease. Occupational exposure to beryllium has also been
linked the lung cancer. Beryllium is classified as a human carcinogen by the U.S. Department of Health
and Human Services.
At air levels above the eight-hour PEL, employers must take steps to reduce the airborne concentration
of beryllium. The rule also requires additional protections, including personal protective equipment,
medical exams, other medical surveillance and training.
OSHA estimates the rule will save the lives of 94 workers and prevent 46 new cases of beryllium-
related disease each year.
Workers in foundry and smelting operations, fabricating, machining, grinding beryllium metal and alloys,
beryllium oxide ceramics manufacturing, and dental lab work represent the majority of the estimated
62,000 U.S. workers at risk of exposure.
To give companies enough time to meet the new rule's requirements, the regulations come with
staggered compliance dates. The rule will take effect 60 days after its publication date (Jan. 9, 2017)
in the Federal Register. Then employers will have one year from the effective date to implement most
of the standard's provisions. Some exceptions: Change room and shower requirements begin two years
after the effective date; engineering control requirements begin three years after the effective date.
E -Waste rising dangerously
Electronic waste or e-waste is rising sharply across Asia as higher incomes allow hundreds of millions
of people to buy smartphones and other gadgets, with serious consequences for human health and
the environment, according to a UN study .
E-waste in Asia has jumped 63 per cent in five years, the report by the United Nations University said,
as it warned of a need for most nations across the region to improve recycling and disposal methods.
"For many countries that already lack infrastructure for environmentally sound e-waste management,
the increasing volumes are a cause for concern," said Ruediger Kuehr, the report's co-author and head
of the UN University's Sustainable Cycles Programme.
For many years, China and some other parts of Asia have been a dumping ground for discarded
electronics from the developed world, recycling the waste in often unsafe but ultracheap backyard
factories.
But the report said that in recent years, Asia has rapidly emerged as a major source of electronic waste,
due to increasingly affluent consumers buying items such as phones, tablets, refrigerators, personal
computers and televisions.
15
IN THE NEWS
China more than doubled its own generation of e-waste between 2010 and 2015, the period of the
study, according to the report.
Per capita, the worst-offending economy in the region was Hong Kong, with each person in the Chinese
territory generating an average of 21.7kg (47.8 pounds) of e-waste in 2015.
Singapore and Taiwan were also big e-waste dumpers, with just over 19kg per person generated in
2015, according to the study.
Cambodia, Vietnam and the Philippines were among the lowest e-waste generators with an average
of about 1kg for each person.
Meanwhile, improper and illegal e-waste dumping means increased exposure to extremely toxic
chemicals, leading to severe health and environment consequences.
Acids that are used to separate the metals in the electronic products are a particular concern, with
inhalation or exposure to them causing serious health problems.
In the Chinese town of Guiyu, which built its economy on recycling waste from overseas, heavy metal
contamination has turned the air and water toxic, according to a 2014 study by researchers at Shantou
University Medical College.
Children in the town also had high lead levels in their blood, the university study found.
When a study team visited Guiyu in 2014, electronic remnants were strewn in a nearby stream, and
the air was acrid from the burning of plastic, chemicals and circuit boards.
16