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Environmental Aspects and Safety

Along with the rapid industrialization in the country, the health and

safety aspects of the personnel and equipments have become very important.

Fires, accidents, explosions, exposure to chemicals are some of the hazards

in the operation of a chemical plant. The following factors also need to be

considered

1. Ventilation:

The plant should be well ventilated so that gas accumulation is

avoided. By local exhaust ventilation, the air contamination is removed before

it comes into the persons breathing zone.

2. Fire prevention and control:

Fire fighting equipment is placed such that it is easily accessible in

case of emergency. An efficient water system is provided along with dry fire

fighting chemicals storage. Fire hydrants are provided throughout the plant to

make water available.

3. Medical hazards:

Machines are well spaced out. Visual warnings of danger like colour

schemes are used to identify potential hazards.

4. Electrical hazards:

Electrical wires are protected from fire and explosions. Proper

maintenance of wiring and equipment and proper enclosure of high voltage

equipment helps to avoid accidents.

5. Medical center:

First aid boxes are kept at various locations in the plant.

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6. Sanitation:

Proper drainage systems, efficient waste and sewage disposal along

with potable water supply and its protection from contamination by plant or

outside sources have to be looked into.

Fire accidents, exposure to chemicals, explosions are some of the major

hazards in the operation of the plant.

General precautions against fire:

1. Fire fighting equipments are provided. They are CO2

extinguishers, DCP and foam.

2. Electrical equipment in flammable area should be flame proof.

3. Lighting conductors should be insulated.

4. Welding should be prohibited. Hot work permits should be

demanded for welding purposes.

5. Smoking should be prohibited in plant area.

6. All leaks in pipelines (process) and elsewhere should be

immediately reported and rectified.

7. Plants should be kept free of accumulations of waste

combustibles, cotton waste, paper, etc.

To ensure adequate consideration of safety during all phases of

companys activities, it is essential to have a sound safety policy. The policy

must include:

1. Managements concern towards safety and health of employees.

2. Acceptable level of operational risks and standards of industrial

hygiene in plant.

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3. Delegation of responsibilities to ensure operational safety down

the line up to supervisors and what is expected from employees

at various levels.

4. Procedure for authorization to adopt process changes /

alterations / modifications / diversifications etc.

5. Standards of operating instructions, their updating and

documentation.

Chemical Hazards:

Various dangerous chemicals like sodium carbonate and product

sodium acetate etc. are handled in the plant. The following precautions need

to be taken while handling these chemicals.

1. Special care is needed when working with chemicals that are

known to have hazardous properties. It is important to

understand the hazard in each case and to take proper

precaution.

2. With newly developed chemicals, there may be no toxicity or

other hazard data available. It is safest policy to treat all

substances as hazardous until they have been proved to be

otherwise.

3. Work in a well-ventilated fume cupboard; use safety screens;

always wear protective clothing; use the appropriate type of

gloves; wear eye protection.

4. Known or suspected carcinogenic substances should only be

used after consultation with senior laboratory management.

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5. Containers of hazardous substances normally carry warning

signs on their labels.

In the event that a plant must be shutdown immediately due to an

emergency situation, the following steps must be followed.

1. Stop pumps if running.

2. Close drains if open.

3. Stop agitators, if running.

4. Close the main process valve and the cooling water, steam line

valves.

5. Leave the plant building checking that nobody is left inside.

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