By

Iqra Saleem

Department of Chemical & Polymer Engineering

University of Engineering & Technology Lahore (FSD Campus)

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The prevention of accidents by the use of appropriate technologies to identify the hazards of a chemical plant and to eliminate them before an accident occurs.

The policy of this concerning safety department is that all employees shall comply with all appropriate OSHA regulations, as well as to perform work in the safest possible manner consistent with good work practices.

The prevention of accidents is considered as important as any other part of our operations and must be an essential part of the planning for every phase of each job.

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No Smoking : risk of igniting flammable material in air.

Protective Clothing: protective clothing such as Hard hats : to prevent against injury from falling

material. Goggles : To protect eyes from coming in contact

with hazardous chemicals and tiny solid particles.

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Face Shields: used when Working with acids Performing grinding or chipping operations

(usually in workshops) Gloves must be worn. Safety shoes: must be worn for protection

against spillages. First Aid kit must always be handy.

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•Alarms

Know WHERE the nearest fire alarm box is located. Know HOW to turn in an

alarm. Know how the alarm sounds and the proper EVACUATION ROUTE

Extinguishers

Know where the nearest fire extinguisher is located. Know how to operate it.

Know the type of fire it should be used on

Refueling

Equipment shall not be refueled while running or hot.

Smoking

Smoking is permitted only in approved smoking areas.

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Numerous hazards exist in a Chemical plant for it’s Workers. The main ones are:

InhalationInhalation: contaminants are picked up by the air which the workers breathe.

LeaksLeaks: leaks of flammable or toxic material poses a risk for workers.

Small Solid particlesSmall Solid particles: when transported in open environment – these may also be inhale and become a health hazard.

Hazards for maintenance workersHazards for maintenance workers: If maintenance of a closed system is performed while system is running, safety of worker is endangered by contaminant release, but also noise, and thermal radiation.

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Occupational Safety and Health Administration

Assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, education and assistance

This aids in making a risk estimation which is the first step in minimizing work place safety risks.

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Equipment Safety is of crucial importance to make sure the safety of the workers is not compromised.

For this purpose, plants make use of1. Relief Valves2. Safety Interlocks3. Process Hazard Analysis.

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Relief Systems

▪ Relief System are used to control the pressure in plant vessels.▪ There are several types of relief valves

Safety System Interlocks

High Temperature Interlock Low Temperature Interlock High Pressure Interlock

“Interlocking is a method of preventing undesired states in a machine, which can include any electrical, electronic, or

mechanical device or system”

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Process Hazard Analysis Identify possible problems in the

process Identify possible causes and

results Develop prevention techniques Evaluate the current system and

operations

Process safety management is an analytical tool focused on preventing releases of any substance defined as a "highly hazardous chemicals" by the EPA or OSHA.

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Operating Procedures Initial Startup Normal Operations Emergency shutdown Emergency operations

Safety and Health Considerations Precautions to prevent exposure Control measures if exposure occurs

Training Initial Training Refresher Training Training Documentation

Pre-Startup Safety Review Walk through the completed facilities to make sure the

building looks like the design and to look for safety hazards

Mechanical Integrity Inspection and Testing Preventative Maintenance

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Safe Work Practices Hot Work Permits, Confined Space

Training/Permit, Lockout/Tagout Emergency Planning and Response

Plant-wide Program Provisions for hazardous waste

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Management of Change Outlines the minimum requirements for making

changes Evaluation must occur before any change EVERYTHING must be updated and approved Employee training

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Incident Investigation A crucial part of the process safety management program

is a thorough investigation of incidents to identify the chain of events and causes so that corrective measures can be developed and implemented.

PROMPT, no longer then 24 hrs. Report must be submitted

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The basic principle: the faster and more effective the initial response, the smaller the consequences for men, environment and economy

Accidents may happen even in most modern plants. They cannot be planned, but they should be considered.

Workers are risks and resources for safety

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