A Bairagi
Production Manager
Guwahati Refinery : Indian Oil Corporation Ltd
Risk Concept
Risk is defined as the uncertainity of occurence of
any unforseen event/activity in relation to the liklihood
that may occur

Risk comprises of two variables
Magnitude of consequences
Likelihood of occurrence
2
Likelihood
Very Likely -- Could happen frequently
Likely -- Could happen occasionally
Unlikely -- Could happen, but only rarely
Highly Unlikely -- Could happen but probably never will
3
Likelihood
When evaluating the likelihood of an accident,
a factor that will modify the likelihood category, is
exposure.
Very Rare -- Once per year or less
Rare -- A few times per year
Unusual -- Once per month
Occasional -- Once per week
Frequent -- Daily
Continuous -- Constant
4
Individual Perceptions
-- Risk is a very individual concept.
-- It is different for every one.
5
Risk
•Another thing to consider is that peoples’
perceptions change as familiarity increases.
•Therefore the perception of a
HAZARD and its RISKS also
changes.
6
Risk Assessment
Risk:
The possibility of an unwanted event occurring
Likelihood:
The chance of an event actually occurring.
7
Risk Assessment and Criteria
Risk
criteria are to be applied within the context
of a standard methodology.
Several
countries have evolved criteria suitable to
their requirements for the use of risk analysis as an
aid to decision making
8
Risk Assessment and Criteria
Workable
Risk criteria recognises that:
–There is a level of risk that is so high that it is
considered unacceptable or intolerable regardless of the
benefits derived from an activity.
–There is also a level of risk that is low enough as to be
considered negligible.
–Levels of risk in between are to be considered tolerable
subject to their being reduced As Low As is Reasonably
Practicable (ALARP).
9
Risk Assessment and Criteria
- The ALARP Principle
Risks
are only tolerable provided that :
It can be demonstrated that all
Reasonably Practicable measures
have been implemented to reduce the risks.
A reasonably practicable risk reduction measure is one
where the costs of implementation are not grossly
disproportionate to the risk reduction benefits achieved.
10
Principle Of Economics
Cost of
losses
Optimal Point
Cost of
control
11
Intolerable Region
Risk cannot be
justified on any
grounds
Intolerable level
The ALARP region
Tolerable only if risk reduction in
impracticable or if its cost is
grossly disproportionate to the
improvement gained
(Risk is undertaken
only if a benefit is
desired)
Tolerable if cost of reduction
would exceed the improvement
gained
Broadly acceptable
region
(No need for detailed
working to
demnstarate ALARP)
Negligible risk
Levels of Risk and the ALARP criterion
12
Risk Assessment
13
Risk Assessment
‘QUALITATIVE’
Walk Through Audits
QUANTATIVE’
Structured Safety Tours
Safety Audits
Risk Analysis
Group Risk Assessments
Job Safety Analysis
‘WHAT IF’ Analysis
Fault Tree analysis
HAZOP
14
Risk Analysis
15
Release Incidents

Pump seal leaks

Rupture of a transfer pipe or hose

Valve seal leaks

Flange gasket leaks

Corrosion failure of vessels/pipes

Vessel failure - BLEVE

Over filling

Water draining
16
Escalations

Quantity of LPG release

Weather condition

Ignition sources

Operator response
17
Hazards

Vapour cloud formation and explosion
Damage due to over pressure

Fires

BLEVE
Thermal damage
- Overpressure
- Rocketing tank parts
- Fire ball
18
 RISK ON HAZARDOUS CHEMICAL
19
CHEMICALS
•SOLIDS
•LIQUIDS
•GASES
•VAPOURS
Acts/Rules
Industries handling hazardous chemicals are covered
by the following Acts/Rules:
 The Factories Act, 1948, as amended in 1987
 The Manufacture, Storage and Import of Hazardous
Chemicals (Amendment) Rules, 2000 : (MSIHC Rules)
 The Public Liability Insurance Act, 1991as amended
in 1992
 The Central Motor Vehicles Rules, 1989
 The Railway Red Tariff Rules, 1960 as amended
 The Chemical Accidents (Emergency Planning,
Preparedness and Response) Rules, 1996
Chemical Hazard Due To
• Inhalation
• Ingestion
• Skin Contact
• Accidental
Ammonia : NH3
Routes of Entry : Inhalation, Skin or Eyes
Effects of Exposure/ symptoms 700 ppm causes eye
irritation and permanent injury may result if
prompt medical remedial measures are not taken.
5000 ppm may cause death. Contact of the liquid
with skin freezes the tissues and causes the caustic
burns. Respiratory track irritant. Irritation to
cornea and tearing, liquid contact with eyes,
partial or total blindness if not treated
immediately. Chemical burns and frostbite.
Ammonia : NH3
Personal Protective Equipment
• Avoid contact with liquid or vapours
• Provide rubber boots, safety goggles, selfcontained breathing apparatus, gas mask
and protective clothing in case of liquid
ammonia.
Carbon mono oxide : CO
Routes of Entry : Inhalation, Skin and Eyes
Human systematic effects by inhalation, changes in
psycho-physiological tests and preventing
haemoglobin from binding oxygen. Contact of
liquid CO with skin causes frostbite. Eye contact
causes severe injury.
Carbon mono oxide : CO
Personal Protective Equipment
• Avoid contact with liquid or vapours.
• Provide self-contained breathing apparatus,
face shield or safety goggles, safety shoes,
appropriate canister mask, rubber overclothing, hand gloves.
Chlorine : Cl2
Routes of Entry: Inhalation, Ingestion, Skin and Eyes.
Effects of Exposure/ Symptoms : Causes Eye
irritation, sneezing, copious salivation, general
excitement, restlessness. High concentration causes
respiratory distress and violent coughing, often
with retching. Death may result from suffocation.
Chlorine : Cl2
Personal Protective Equipment
• Avoid contact with liquid or vapour.
• Provide PVC gloves, gumboots, rubber
overcoat, head mask, self-contained
breathing apparatus.
Hydrogen : H2
Routes of Entry : Skin, Inhalation
Effects of Exposure/ Symptoms: If atmosphere does
not contain enough oxygen, inhalation causes
dizziness, unconsciousness or even death. Contact
with eyes or skin or liquid H2 causes freezing similar
to burn.
Hydrogen : H2
Personal Protective Equipment
• Avoid contact with liquid or gas
• Provide safety goggles, face shied, insulated
gloves and long sleeves, trousers Worn over
high top shoes to shed spilled liquid, selfcontained breathing apparatus containing air
(never use oxygen).
Hydrochloric acid : HCl
Routes of Entry :
Inhalation, Ingestion, skin and Eyes
Effects of Exposure/ Symptoms. Inhalation: The major
effects of acute exposure to HCL are usually limited to
upper Respiratory tract. Exposure to the gas causes cough,
burning of the throat and larynx and Choking feeling,
inflammation and ulceration of the nose, throat and larynx.
Exposure to Higher concentration may cause laryngeal
spasm, and oedema of the lungs and vocal Cords.
Prolonged or repeated exposure may cause dental
decolouration and erosion. Gastritis and chronic bronchitis
have also been reported in exposed workers. Giddiness,
Mental confusion and nausea.
Hydrochloric acid : HCl
Skin contact: Cause skin burns and may produce keloid and
rectile scarring. Facial burns May result in serious and
disfiguring scars. Frequent contact with dilute acid may
cause Dermatitis and photo-sensitisation may result from
industrial contact.
Eye Contact: Hydrochloric acid is a strong eye irritant and
contact with the acid may Cause burns, reduced vision and
total blindness.
Ingestion: Ingestion of HCL causes severe burns and
corrosion of mouth oesophagus and Stomach. Symptom
include dysphasia, pain, nausea, vomiting , Diarrhoea and
thirst. Circulatory collapse may occur and ingestion may
lead to fatal effects from oesophagus or gastric necrosis.
Hydrochloric acid : HCl
Personal Protective Equipment
• Approved respirator, Safety goggles,
neoprene, viton or butyl rubber glove and
acid resistant outer clothing
• Mechanical exhaust.
Hydrogen Sulphide : H2S
Routes of Entry : Inhalation, skin & eyes
Effects of Exposure/ Symptoms, Inhalation : If high
concentrations are inhaled, hypernoea & piratory
paralysis may occur. Very high concentration
may produce pulmonary edema.
Skin & eyes: Causes severe irritation.
Hydrogen Sulphide : H2S
Personal Protective Equipment
• Avoid contact with gas.
• Provide rubber framed side covered
goggles, approved respirator, rubber hand
gloves, over-clothing and shoes.
Caustic Soda : NaOH
Routes of Entry :Inhalation, Skin, Ingestion & Eyes.
Effects of Exposure/ Symptoms - Inhalation : Causes
small burns to upper respiratory tract & lungs, mild
nose irritation.
Ingestion : Causes severe damage to mucous
membrane, severe scaring or perforation may
occur.
Eyes: Severe damage.
Skin: Causes severe burns.
Caustic Soda : NaOH
Personal Protective Equipment
• Avoid contact with solid or liquid.
• Provide side covered safety goggles, face
shield, filter or dust-type respirator,
rubber shoes and rubber hand gloves.
Sulphur-di-oxide : SO2
Routes of Entry : Inhalation, Eyes and Skin
Effects of Exposure/ Symptoms Vapour
causes irritation of eyes & lungs with severe
choking. Liquid will cause frostbite.
Vapours are poisonous, if inhaled.
Sulphur-di-oxide : SO2
Personal Protective Equipment
•
•
Avoid contact with liquid or vapours.
Provide air supplied mask or approved
canister, safety goggles or face-shield,
rubber hand gloves, shoes, aprons.
Sulphuric Acid : H2SO4
Routes of Entry: Inhalation, contact, ingestion
Effects of Exposure/ Symptoms : Irritates eyes,
nose, throat, dental erosion, skin and eyes, burn.
Causes deep burn to tissue. Very dilute solution
causes dermatitis. Exposure cause bronchitis.
Sulphuric Acid : H2SO4
Personal Protective Equipment
• Rubber gloves, safety goggles, acid proof
overalls. Provide safety shower, eyewash
Fountain, self contained breathing
apparatus.
Hazard Control
To reduce hazardous exposure methods include
•
•
•
•
•
Mechanical ventilation
Process or personnel enclosure
Control of process conditions & modification
Administrative control
PPE
Storage
•
•
•
•
•
Limit quantity of material in storage
Appropriate warning signs.
Keep storage area separate from work areas.
Provision of leak detection and alarm systems
Store cylinders upright on a level, fire proof
floor, secured in position to
a) Protect from damage
b) Keep valve cover on
c) Keep filled cylinders separately from empty
cylinders.
Handling
• Move cylinders by hand truck or cart designed for
that
• Don’t lift cylinders by their caps
• Don’t handle them with oily hands.
• Don’t drop them or permit them to bang against
each other.
• Close all valves when, not in actual use.
• Open & shut the valves at least once a day, while
cylinder is in use, “to avoid valve freezing”.
• Have emergency equipment readily available.
HAZCHEM CODIFICATION
HAZCHEM Code is based on pictorial representations consist of
a diamond, as shown in the figure, divided into 4 parts. These
parts, starting from left block (in clockwise direction), represent
Health Hazard, Flammability Hazard, Reactivity Hazard and
Space for additional information such as water reactivity,
oxidant and radiation hazard. The colour codes for these hazards
are : blue for health, red for flammability, yellow for reactivity
and colourless for additional information. The intensity of
hazard is grouped into five classes with numerical indications as
0, 1, 2, 3 & 4 in the ascending order of hazard intensity. In the
following lines, these hazard intensities are explained, with the
numeral on the left indicating the hazard intensity.
HAZCHEM CODE
Flammability
(Red)
Reactivity
(Yellow)
Health
(Blue)
W
OXY
W :
OXY:
Indicates possible hazard in
use of water.
Indicates oxidizing chemicals.
CLASSIFICATION OF HAZARDOUS SUBSTANCES
The hazardous substances are classified into eight classes. These are as under :
CLASS 1
CLASS 2
CLASS 3
CLASS 4
CLASS 5
CLASS 6
CLASS 7
CLASS 8
EXPLOSIVES
GASES, COMPRESSED, LIQUEFIED, DISSOLVED OR DEEPLY
REFRIGERATED, INFLAMMABLE GASES, POISON (TOXIC) GASES.
INFLAMMABLE LIQUIDS
INFLAMMABL SOLIDS, SUBSTANCES LIABLE TO SPONTANEOUS
CONBUSTION; SUBSTANCES WHICH ON CONTACT WITH WATER
EMIT INFLAMMABLE GASES.
Division 4.1
Inflammable solids
Division 4.2
Substances liable to spontaneous combustion.
Division 4.3
Substances, which in contact with water, emit
inflammable gases.
OXIDISING SUBSTANCES
Division 5.1
oxidizing substances
Division 5.2
Organic peroxides
POISONOUS (TOXIC) AND INFECTIOUS SUBSTANCES
Division 6.1
Poisonous (toxic) substances
Division 6.2
Infectious substances
RADIOACTIVE SUBSTANCES
CORROSIVES
For details, the Central Motor Vehicles Rules may be referred.
MATERIAL SAFETY DATA SHEET
This section includes safety data sheets of most of the hazardous chemicals being
used in Petroleum Industry. The data provided are compiled from various data
sources as given in Reference. The identity of the chemical is defined in para 1 of
the safety data sheet and important physical and chemical properties of each
chemical have been given in para 2 of the safety data sheet. The fire & explosion
data, reactivity data, health hazardous data have been given vide Para 3, 4 & 5
respectively. The preventive measures and emergency & first aid measures and
additional information / references, if any, are given in Para 6,7 & 8 respectively.
Individual data sheets are to be supplemented with the following as item 9 and 10.
9.
10.
MANUFACTURER’S / SUPPLIER’S DATA
Name of Firm
Contact Person in Emergency
Mailing Address
Telephone/Telex Nos.:
Local Bodies involved.
Telegraphic Address :
Standard Packing
Details / Ref.
Other
DISCLAIMER
Information contained in this material data sheet is believed to be. It is up
to the manufacturer / seller to ensure that the information contained in the
material safety data sheet is relevant to the product manufactured or sold
by him, as the case may be.
RISK ON
HYDROCARBON
INDUSTRY
DEFINITIONS
HAZARD
SITUATION WITH
ENVIRONMENT.
EX
A POTENTIAL
: FIRE / EXPLOSION
FOR
DAMAGE
TO
MEN,
MACHINES
AND
MAJOR REFINERY POTENTIAL HAZARDS
•
FIRE HAZARD
•
EXPLOSION HAZARD
•
ELECTRICAL HAZARD
•
TOXIC GAS RELEASE HAZARD
•
HAZARDOUS CHEMICAL HAZARD
•
OIL SPILLAGE
•
RADIATION HAZARD
•
FALL FROM HEIGHT
Special Risks Associated with
Petroleum Refining
 Highly flammable material
 High Temperature/Pressure
 Harmful Chemicals/Solvents/Catalysts used in the
Process
 Corrosivity /Reactivity
 Self Ignition on Leakage from System
 Uncontrolled Process Reactions
 Loss of Containment/Accidental Releases
WHAT IS FIRE ?
Fire is a phenomenon which evolve heat and light
energy upon burning a carbonaceous material.
Chemically, it is an exothermic chemical reaction
resulting from the combination heat, fuel and oxygen.
Fire involves rapid oxidation at high temperatures
accompanied by the evolution of highly heated gaseous
products of combustion and emission of visible and
invisible radiation
FIRE
FIRE IS A RAPID, SELF-SUSTAINED OXIDATION PROCESS ACCOMPANIED BY THE
RELEASE OF ENERGY IN THE FORM OF HEAT AND LIGHT OF VARYING INTENSITY.
FIRE RESULTS FROM THE COMBINATION OF FUEL, HEAT AND OXYGEN. WHEN A
SUBSTANCE IS HEATED TO A CERTAIN TEMPERATURE CALLED THE ‘IGNITION
TEMPERATURE’ THE MATERIAL WILL IGNITE AND CONTINUE TO BURN AS LONG AS
THERE IS FUEL, THE PROPER TEMPERATURE AND A SUPPLY OF OXYGEN (AIR).
FIRE TRIANGLE
HEAT
OXYGEN
FUEL
FIRE
THREE ELEMENTS ARE NECESSARY FOR INITIATION OF FIRE:
1. FUEL IN THE FORM OF VAPOUR, LIQUID OR SOLID.
2. A SOURCE OF IGNITION SUFFICIENT TO INITIATE & PROPAGATE THE FIRE.
3. OXYGEN IN SUFFICIENT PROPORTION TO FORM A COMBUSTIBLE MIXTURE.
METHODS OF EXTINGUISHMENTS OF FIRE
1. STARVATION
:
ELIMINATION OF FUEL
2. SMOTHERING
:
LIMITING OF OXYGEN
3. COOLING
:
LIMITING TEMPERATURE
STARVATION : STARVATION IS ACCOMPLISHED BY REMOVING COMBUSTIBLES FROM
THE NEIGHBOURHOOD OF THE FIRE OR BY REMOVING FIRE FORM THE MASS OF
COMBUSTIBLE MATERIALS.
IT IS ALSO ACHIEVED BY SUBDIVIDING BURNING
MATERIALS TO SMALL ISOLATED POCKETS OF FIRE.
SMOTHERING : SMOTHERING IS ACCOMPLISHED BY ELIMINATING OR DILUTING THE
AVAILABLE OXYGEN WITH INERT GAS OR COVERING THE FUEL SURFACE BY A
SMOTHERING AGENT LIKE FOAM.
COOLING : IF THE RATE AT WHICH HEAT IS GENERATED BY COMBUSTION IS LESS
THAN THE RATE AT WHICH IT IS GETTING DISSIPATED THEN THE COMBUSTION
CANNOT PERSIST. APPLICATION OF WATER JET OR SPRAY TO A FIRE RESULTS IN ITS
EXTINGUISHMENTS BY THIS FUNDAMENTAL PRINCIPLE.
CLASSIFICATION OF PETROLEUM PRODUCTS
CLASS –A :
LIQUID WHICH HAVE FLASH POINT BELOW 23OC.
CLASS – B :
LIQUIDS WHICH HAVE FLASH POINT OF 23OC AND ABOVE BUT
BELOW 65OC
CLASS – C:
LIQUID WHICH HAVE FLASH POINT OF 65OC AND ABOVE BUT
BELOW 93OC.
EXCLUDED PETROLEUM : LIQUID WHICH HAVE FLASH POINT OF 93OC AND ABOVE.
LPG DO NOT FALL UNDER THIS CLASSIFICATION BUT FORM SEPARATE CATEGORY.
DEFINITIONS
FLASH POINT
THE FLASH POINT OF A LIQUID IS THE LOWEST TEMPERATURE AT WHICH SUFFICIENT
VAPOUR GIVEN OFF TO FLASH ON THE APPLICATION OF FLAME IN THE PRESENCE OF
AIR.
AUTO – IGNITION
THE LOWEST TEMPERATURE TO WHICH A SOLID ,LIQUID OR GAS REQUIRES TO BE
RAISED TO CAUSE SELF-SUSTAINED COMBUSTION WITHOUT INITIATION BY A SPARK
OR FLAME.
FLAMMABLE OR EXPLOSIVE LIMIT
In the case of gases or vapour, which form flammable mixtures with air,
there is a minimum concentration of vapour in air below which the
propagation of flame does not occur in contact with a source of ignition.
This is called Lower Explosive Limit (LEL). Similarly, there is a
maximum concentration of vapour above which the propagation of
flame does not occur on contact with a source of ignition. This is called
Upper Explosive Limit (UEL). This range of minimum to maximum
concentration is termed as Flammable or Explosive range.
The flammable limits are not appreciably changed by normal variations
in atmospheric pressure and temperature. However, at high
temperatures, the upper limit is raised and the lower limit lowered,
resulting in greater flammable or explosive range. The effect of high
pressures on the limits is different for each gas or vapour depending
upon its nature.
AUTO IGNITION, FLASH POINT AND EXPLOSIVE LIMITS
OF SOME OF THE PETROLEUM PRODUCTS
S.
NO.
MATERIAL
AUTO IGNITION
TEMPERATURE
oC
FLASH POINT
OC
EXPOSING RANGE VOLUME %
IN AIR LOWER LIMIT UPPER
LIMIT
1
CRUDE OIL
DEPENDS UPON
THE NATURE OF
CRUDE
19
DEPENDS UPON THE NATURE
OF CRUDE
2.
HYDROGEN
585
GAS
4.1
74.0
3
METHANE
538
GAS
5.0
15.0
4
ETHANE
514
GAS
3.0
12.5
5
PROPANE
466
GAS
2.4
9.5
6
BUTANE
430
GAS
1.5
9.0
7
BENZENE
563
-11
1.3
7.1
8
TOLUENE
536
4.5
1.2
7.2
9
NAPHTHA
288
-18
1.1
5.9
10
GASOLINE
245
-7
1.4
7.6
11
ATF
254.4
38
0.7
5
12
SKO
254
35
0.7
5
AUTO IGNITION, FLASH POINT AND EXPLOSIVE LIMITS
OF SOME OF THE PETROLEUM PRODUCTS
S.
NO.
MATERIAL
AUTO IGNITION
TEMPERATURE
FLASH POINT
OC
13
EXPOSING RANGE VOLUME %
IN AIR LOWER LIMIT UPPER
LIMIT
HSD
256
32
0.7
5
14
LDO
-
66
-
-
15
LSHS
316
66-166
-
-
16
HSHS
-
65.6-148.9
-
-
17
FO
262-407
-
-
-
18
BITUMEN
485
205
-
-
19
RAW COKE
-
315.6
-
-
20
PHENOL EXTRACT
715
80
-
-
21
SLACK WAX
245
198.9
-
-
22
MINERAL TURPENTINE
OIL
253.3
32.2
-
-
23
LPG
405-450
GAS
1.8
9.6
LIQUEFIED PETROLEUM GAS (LPG)
PHYSICAL PROPERTIES:
•
IT IS A MIXTURE OF PROPANE & BUTANE.
•
COLOURLESS BOTH AS A LIQUID AND A VAPOUR.
•
LPG IS ODOURLESS, BUT USUALLY ADDED TRACE QUANTITIES OF
ODORING AGENT(MERCAPTAN) TO ENABLE DETECTION BY SMELL.
•
DENSITY: LIQUID LPG IS ONLY HALF THE WEIGHT OF WATER.
: LPG AS A GAS IS TWICE THE WEIGHT OF AIR.
•
EXPLOSIVE LIMIT
: 1.8-9.6% VOL.IN AIR.
•
IGNITION TEMPERATURE
: 405-450 Oc.
•
LIQUID TO GAS EXPANSION: 1:250
•
VAPOUR PRESSURE AT 37.5 Oc = 7.7 kg/cm2(Appox)
LIQUEFIED PETROLEUM GAS (LPG)
FIRE HAZARD:
•
EXTREMELY FLAMMABLE GAS
•
DANGEROUS WHEN EXPOSED TO HEAT OR FLAME. IT BURNS WITH A
BLUE FLAME WHEN MIXED WITH CORRECT PROPORTION OF AIR. IF
THE AIR SUPPLY IS INSUFFICIENT, THE FLAME BURNS YELLOW AT THE
EDGES. NO SMOKE IS PRODUCE DURING BURNING.
HEALTH HAZARD:
•
LPG CONTAINS NO TOXIC COMPONENTS SUCH AS CARBON MONOXIDE
AND IS THEREFORE NON POISONOUS.
•
INHALATION: EXPOSURE TO HIGH CONC. OF LPG WILL PRODUCE
UNCONSCIOUSNESS & SUBSEQUENT ASPHYXIATION.
•
SKIN AND EYE CONTACT: IF LIQUID LPG COMES INTO CONTACT WITH
UNPROTECTED SKIN AND EYES THEY WILL EVAPORATE QUICKLY AND
THE COOLING EFFECT COULD PRODUCE FROST BITE OR COLD BURNS.
•
TLV(TWA): 1000 PPM
LIQUEFIED PETROLEUM GAS (LPG)
BLEVE
•
A BOILING LIQUID EXPANDING VAPOUR EXPLOSION IS STARTED BY THE
HEATING OF A VESSEL CONTAINING FLAMMABLE LIQUID BY AN EXTERNAL
FIRE.
•
CONTENT IS HEATED ABOVE ITS BOILING POINT AND PRESSURE IN THE
VESSEL INCREASES
LIQUEFIED PETROLEUM GAS (LPG)
•
IF FLAMES IMPINGE ON THE UN WETTED SURFACE OF THE TANK ON OR NEAR
THE EMPTY SPACE, THIS AREA WILL BE WEAKENED AND MAY FAIL AS INTERNAL
PRESSURE DEVELOPS.
•
THE VESSEL RUPTURES AND PIECES CAN BE PROPELLED CONSIDERABLE
DISTANCES
•
THE SPILLAGE OF THE OVERHEATED LIQUIDS AND THEN IGNITION CREATES A
LARGE FIREBALL WITH EXPLOSION PRESSURE EFFECTS.
SOLUTION:
•
KEEP TANK COOL
•
EXTINGUISH EXTERNAL FIRES
LIQUEFIED PETROLEUM GAS (LPG)
D. UVCE
•
AN UNCONFINED VAPOUR CLOUD EXPLOSION IS AN EVENT WHERE A FLAMMABLE
FUEL/AIR CLOUD BURNS IN FREE SPACE, GENERATING SHOCK WAVES.
•
COMBUSTION MECHANISM STARTS FROM A POINT OF IGNITION SOURCE, WITH
THE FLAME FRONT ACCELERATING FROM A LOW INITIAL VELOCITY TO SONIC
VELOCITY.
MAGNITUDE OF BLEVE:
•
PIECES OF CONTAINER CAN SHOOT OFF SOME 1000 METRE OR MORE DISTANCE.
•
DEATH FROM SUCH MISSILES MAY OCCUR UPTO 250 M.
•
FIRE BALLS OF 30 METRE (HUNDRED FEET) DIAMETRE IS NOT UNCOMMON.
•
SEVERE BURN DAMAGE IN A 300-400 M RADIUS.
•
A SHOCK WAVE FROM BLEVE CAN BREAK WINDOWS SEVERAL KILOMETER AWAY
•
FLAME TEMPERATURES AS HIGH AS 1200 deg C.
REMEMBER: THERE IS NO SAFETY PERIOD, A BLEVE CAN OCCURS AT ANY TIME.`
LIQUEFIED PETROLEUM GAS (LPG)
RELIEF VENT OPENS AT 17.6 kg/cm2
HOT AREA
VAPOUR
UNEXPOSED
SHELL
LIQUID
SUPPORT
SLOP
TANK SHELL OVERHEATED ABOVE LIQUID LEVEL
LIQUEFIED PETROLEUM GAS (LPG)
FIRE FIGHTING PROCEDURES-BLEVE SITUATIONS
•
WHEN THERE IS NO RISK TO LIFE OR PROPERTY, SERIOUS CONSIDERATION
MUST BE GIVEN TO EMPLOYING A “NON ATTACK STRATEGY.
•
IF A DECISION IS MADE TO ATTACK THE FIRE THEN IMMEDIATE, MASSIVE
WATER-COOLING MUST BE APPLIED CONCENTRATING ON EXPOSED VAPOUR
SPACE.
•
PERSONNEL SHOULD BE FULLY BRIEFED AND MADE AWARE OF THE DANGER
CONFRONTING THEM.
•
CHANGE FROM HAND HELD BRANCHES TO GROUND MONITORS
•
USE OF WATER SPRAY ON EXPOSED CREW TO GIVE PROTECTION AGAINST
FIRE EFFECTS.
•
EVACUATION OF THE SURROUNDING ARES MIN. 1000 M.
•
REMEMBER THAT RELATIVELY HIGH RISK AREA IS AN “END ON” DIRECTION.
HOWEVER, FRAGMENTS AND MAJOR TANK SECTION CAN FLY IN ANY
DIRECTION.
VAPOUR CLOUD
WHEN LIGHT HYDROCARBONS LIKE NAPHTHA, MS OR FLAMMABLE GASES LEAK IT
VAPOURISES AND FORMS AN EXPLOSIVE MIXTURE WITH AIR. WHEN THE LEAK IS
HEAVY AN EXPLOSIVE CLOUD IS FORMED. THIS CLOUD IS KNOWN AS A VAPOUR
CLOUD.
WHENEVER THIS VAPOUR CLOUD COMES IN CONTACT WITH A SOURCE OF IGNITION
IT CAN EXPLODE AND CAUSES FROM THE VEHICLES, SMOKING OR OTHER SOURCES
OF IGNITION.
FORMATION OF VAPOUR CLOUD
1. LEAKAGE FROM PIPELINES:
IT MAY BE ON THE ROAD SIDE, INSIDE THE UNITS
OR IN THE TANK FARM.
2. LEAKAGE FROM TANKS OR TANK OVERFLOW:
IT MAY BE IN THE TANK FARMS
OR FROM THE TANKS IN THE UNITS AREA.
3. LEAKAGE FROM TANKERS OR OVERFLOW OF TANKER: IT MAY BE IN WAGON
LOADING GANTRY AREA.
VAPOUR CLOUD
4.
LEAKAGE OF LPG: IT MAY BE IN THE FOLLOWING AREAS;
i)
INSIDE PROCESS UNITS OR ALONG ROAD SIDE LINE LEAKAGE .
ii)
LEAKAGE FROM ROAD TANKER, WAGONS, FILLING HOSES, HORTON SPHERES OR
FROM CONNECTING PIPES.
iii) LEAKAGE FROM CYLINDERS, FILLING MACHINES, PUMPS OR CONNECTING
PIPES.
HOW TO IDENTIFY VAPOUR CLOUD:
i)
BY SMELL: IF IT IS EXTRA ORDINARY ON HIGHER SIDE.
ii)
BY MIST : IN MOST OF THE CASES MIST FORMATION TAKES PLACES.
iii) BY LEAK: IF HYDROCARBON LEAK IS VISIBLE.
VAPOUR CLOUD
IMPORTANT DO’S AND DON’TS IN CASE OF VAPOUR CLOUD:
DO’S
INFORM
CONCERNED
DON’TS
UNIT NEVER ALLOW ANY VEHICLE TO ENTER IN
PERSONNEL AND FIRE STATION .
THE
AREA.
DO
NOT
OPERATE
ANY
ELECTRICAL SWITCHES.
CORDON-OFF THE AREA
NEVER ALLOW ANY VEHICLE TO START IN
THE AFFECTED AREA.
GUIDE THE UNIT PERSONNEL/FIRE IF VEHICLE IS ALREADY IN THE AFFECTED
PERSONNEL
AREA, REMOVE IT BY PUSHING.
IN CASE OF VAPOUR SMELL, TRY TO DURING PATROLLING IF STRONG SMELL OF
DETECT THE SOURCE OF LEAK
HYDROCARBONS OR ANY LEAK DETECTED
STOP THE ENGINE IMMEDIATELY AND MOVE
ON FOOT TO DETECT THE LEAK.
STOP ALL HOT JOBS AND SMOKING NEVER SMOKE OR ALLOW THE SMOKING
BOOTHS
INSIDE THE BATTERY AREA.
Effect of Blast Overpressure
BLEVE Fireball
Fireball radius :
R = 29 M1/3 .
Where R= Fireball radius (in meters).
M=Mass of fuel (te).
Fireball duration :
t = 4.5 M1/3 .
Where t= duration (in sec).
M=Mass of fuel (te).
BLEVE Fireball
M is usually taken as half the tank capacity,
I.e. for a 50 te LPG tank, M=25te .
If , however , storage is in a close grouping of three
or more vertical tanks, it is recommended that M is
taken as 90 percent of tank capacity.
BLEVE Fireball
The radiative flux incident on a target some distance
away from the LPG tank is given by : qt = EFT .
Where ,
qt = radiative flux incident on target (kWm-2 ).
E= surface emission power (kWm-2).
F= view factor.
T= atmospheric transmissivity.
E is taken as 270 kWm-2 for cylinder , horizontal and
vertical tanks .
and 200 kWm-2
for spheres .
F is taken as R2 r / (R2 + r2 )3/2
BLEVE Fireball
Where r is the ground level distance between target
and LPG tank.
(r should be greater than 2R.)
T is determined by the relationship
T= 1-0.058 In r.
Once qt has been determined , than a thermal dose or
pulse can be calculated as qt X t.
Where t= duration of fireball.
BLEVE Fireball
For example , the incident thermal radiation flux of a
BLEVE fireball at a distance of 300m from a 100te
LPG tank.
R=29M1/3 = 29 X 501/3 = 107m.
t=4.5M1/3 = 4.5 X 501/3 = 16.6 sec.
E= 270 kWm-2.
T = 1-0.058 In r = 1-0.058 In 300 = 0.67.
F= R2r / (R2+rr)3/2 = 1072 X 300 / (1072 + 3002)3/2=0.016.
qt = EFT = 270 X 0.106 X 0.67 = 19.2 kWm-2.
thermal dose or pulse = qt X t = 19.2 X 16.6 = 317 kJm-2
BLEVE
Quantity,
MT
Fire Ball Size
M
Exclusion Zone
M
1
5
10
50
100
30
50
63
110
140
90
190
230
420
500
Speed of Missiles :
Horton Sphere
Bullet
Distance traveled by fragments
: 200 m/sec
: 150 m/sec
Horton Sphere :
Bullet
:
600 M
1200 M
84
Vapour Cloud Explosion
Assumptiona. LPG tank full when catastrophic failure causes quasi –
instantaneous release.
b. Vapour / aerosol cloud is twice adiabatic flash fraction at
150 C , I.e. 62 percent and 34 percent of the tank
contents for propane and butane respectively.
c. 1te LPG = 0.42te TNT.
For example , detrmine the overpressure at a distance of
300m from a 100te propane tank:
Scaled distance = distance / (0.42M X 62)1/3
Where M = mass of fuel in cloud (te).
= 300 / (0.42 X 62)1/3 = 101 m te1/3 .
Vapour Cloud Explosion
Scaled distance versus overpressure can
determined by the graph in the following slide
be
For example , the Overpressure of a BLEVE fireball
at a distance of 300m from a 100te LPG tank.
The Overpressure = 2.23 psig
Chlorine
The consequence of release of toxic gases like
chlorine are:
-
Time depended and,
-
Will vary with distance and prevailing weather
conditions.
Concentration and duration can be estimated using
computer model which combine a physical description
of the gas cloud Behaviour with experimental data.
Chlorine
Box type computer model are frequent used to
predict the dispersion behaviors of gases like
chlorine which are denser than air .
A model known as DENZ can be used for
instantaneous release ( e.g. failure of a storage
vessel) and gives information as shown by the
graph in the following slide
Chlorine
Chlorine
HYDROGEN H2
PHYSICAL / CHEMICAL PROPERTIES :
1.
PHYSICAL APPEARANCE
:
COLOURLESS
2.
ODOUR
:
ODOURLESS
3.
VAPOUR DENSITY
:
0.07 AT 25 DEG. C (AIR=1) LIGHTEST
GAS
4.
FLAMMABILITY
:
HIGHLY FLAMMABLE / EXPLOSIVE
5.
FLAMMABILITY LIMIT
:
4% TO 75% IN AIR
6.
FLASH POINT
:
<-50 DEG.C
7.
AUTO IGNITION TEMPERATURE :
500 DEG CENTIGRADE
8.
INCOMPATIBILITY
OXYDISING MATERIALS E.G. CHLORINE,
:
BROMINE ETC.
9.
MINIMUM SPARK IGNITION
ENERGY AT 1 ATM IN AIR
:
0.02 MJ.
HYDROGEN H2
HAZARDOUS PROPERTIES OF GASEOUS HYDROGEN
•
UNDETECTABILITY: HYDROGEN GAS IS COLOURLESS, ODOURLESS AND NOT
DETECTABLE BY HUMAN SENSES. HYDROGEN LEAKS ARE MORE FREQUENTLY
HEARD THAN SEEN.
•
FLAMMABILITY : MIXTURES OF HYDROGEN WITH AIR, OXYGEN OR OTHER
OXIDIZERS ARE HIGHLY FLAMMABLE OVER A WIDE RANGE OF COMPOSITIONS.
•
AUTOIGNITION : TEMPERATURES OF ABOUT 1050OF (565OC) ARE USUALLY
REQUIRED FOR MIXTURES OF HYDROGEN WITH AIR OR OXYGEN TO AUTO
IGNITE
AT 14.7
PSIA.
HOWEVER,
AT PRESSURES
AUTOIGNITIONS HAVE OCCURRED NEAR 650OF(343OC).
FROM
3-8
PSIA,
HYDROGEN H2
•
IGNITION AT LOW ENERGY INPUT : HYDROGEN AIR MIXTURES CAN IGNITE
WITH VERY LOW ENERGY INPUT, 1/10TH THAT REQUIRED TO IGNITE A GASOLINE
- AIR MIXTURE FOR REFERENCE, AN INVISIBLE SPARK OR A STATIC SPARK FROM A
PERSON CAN CAUSE IGNITION.
•
LACK OF FLAME COLOUR : HYDROGEN – OXYGEN AND HYDROGEN – PURE AIR
FLAMES ARE COLOURLESS (ANY VISIBLE FLAME IS CAUSED BY IMPURITIES).
COLOURLESS HYDROGEN FLAMES CAN CAUSE SEVER BURNS.
HYDROGEN H2
EMERGENCY PROCEDURE
•
MAKE SURE THAT SOURCE OF IGNITION IS AVOIDED. EVEN AFTER ENSURING
THAT THERE IS NO SOURCE SUSPECT THE PRESENCE OF A SOURCE OF IGNITION.
•
AS SOON AS LEAKS ARE DETECTED, IMMEDIATELY STOP OPERATIONS, SHUT OFF
THE SOURCE OF SUPPLY, AND RELIEVE THE LINE OR SYSTEM OF ANY PRESSURE.
•
DON’T ACTUATE ELECTRICAL OR OTHER DEVICE HAVING QUESTIONABLE NON
SPARKING CHARACTERISTICS RESUME OPERATIONS ONLY AFTER THE REPAIRS
ARE COMPLETED.
HYDROGEN H2
DO THE FOLLOWING IN CASE OF LEAKAGE OF HYDROGEN
•
TAKE ACTIONS TO ENSURE THE SAFETY OF PERSONNEL (I.E. DON’T ALLOW
PERSONS TO ENTER THE AREA AS THERE CAN BE FIRE / AND EXPLOSION).
•
CALL FIRE SERVICE
•
EVACUATE THE AREA
•
COOL DOWN ADJACENT EQUIPMENT TO PROTECT IT FROM POSSIBLE FIRE.
FIRE FIGHTING TECHNIQUES:
HYDROGEN H2
FLAME TEMPERATURE OF THE ORDER OF 3800OF (2093OC) CAN BE EXPECTED IN
HYDROGEN GAS FIRES.
CATASTROPHIC RESULTS FROM FIRES CAN BE
PREVENTED BY TRAINING PERSONNEL TO :
•
PREVENT THE FIRE FROM SPREADING AND LET IT BURN UNTIL THE HYDROGEN
IS CONSUMED (USE OF WATER TO KEEP ADJACENT EQUIPMENT COOL, DON’T
ARREST THE FIRE.
•
BE AWARE THAT IF THE FIRE IS EXTINGUISHED WITHOUT STOPPING THE
HYDROGEN FLOW, AN EXPLOSIVE MIXTURE MAY FORM, CAUSING A MORE
SERIOUS HAZARD THAN THE FIRST ITSELF.
•
THE INVISIBLE FLAME CAN BE MANY FEET LONG AND CAN SHIFT QUICKLY WITH
THE SLIGHTEST BREEZE. THEREFORE, PERSONNEL SHOULD WEAR PROTECTIVE
CLOTHING WHILE FIGHTING HYDROGEN GAS FIRES.
FIRE RISK MANAGEMENT
FIRE RISK IS ‘THE CHANCE/POSSIBILITY OF LOSS DUE TO FIRE’.
THREE ASPECTS TO DEAL WITH FIRE RISK MANAGEMENT ARE:
• FIRE PREVENTION
• FIRE PROTECTION
• FIRE FIGHTING
FIRE PREVENTION
OBJECTIVE : TO ELIMINATE THE OCCURRENCE OF FIRE
REGULATIONS FOR THE PREVENTION OF FIRE
FIRE
&
EXPLOSION
HYDROCARBON
REFINERY.
CONTRIBUTE
PROCESSING
A
INDUSTRY
SERIOUS
LIKE
HAZARD
A
TO
PETROLEUM
THE FOLLOWING REGULATIONS SHOULD BE STRICTLY
FOLLOWED FOR PREVENTION OF FIRE.
REGULATION – 1:
FIRE OR NAKED LIGHT, MATCHES, PETROL OR OTHER LIGHTERS,
CELLULAR PHONE OR ANY APPARATUS WHICH IS CAPABLE OF
CAUSING IGNITION IS NOT PERMITTED TO BE TAKEN WITHIN THE
BATTERY AREA BY ANY PERSON.
FIRE PREVENTION
REGULATION – 2
NO FIRES SHALL BE LIT AND NO MATCHES IGNITED IN ANY PART OF
THE BATTERY AREA UNLESS A VALID HOT WORK PERMIT HAS BEEN
OBTAINED FROM THE AUTHORISED FIRE PERMIT SIGNATORIES OF
THE AREA AND REGISTERED AT THE FIRE STATION
REGULATION-3
SMOKING IS PROHIBITED IN ALL PARTS OF THE BATTERY AREA EXCEPT
IN THE SMOKING BOOTHS/LOCATIONS DULY APPROVED FOR THIS
PURPOSE.
REGULATION – 4
1. CYCLE LAMPS, OTHER THAN DYNAMO OPERATED , ARE NOT
ALLOWED IN THE REFINERY BATTERY LIMITS. THE CYCLIST WILL
SWITCH OFF EVEN THE DYNAMO AS SOON AS HE ENTERS THE
PLANT AREA.
FIRE PREVENTION
2. ORDINARY TORCHES WILL NOT BE USED WITHIN THE BATTERY
AREA.
FLAME
PROOF
TORCHES/LAMPS
OF
APPROVED
MANUFACTURERS AS SUPPLIED BY THE REFINERY, SHALL ONLY BE
USED.
REGULATION-5
ALL VEHICLES ENTERING / TRANSPORTING PETROLEUM PRODUCTS
FROM THE REFINERY MUST BE FITTED ONLY WITH APPROVED TYPE
OF SPARK ARRESTORS .
REGULATION-6
PERSONS ENTERING THE REFINERY BATTERY LIMIT SHALL DEPOSIT
MATCH BOXES, LIGHTERS, MOBILES ETC WITH THE SECURITY AT THE
MAIN ENTRANCE GATE OF THE REFINERY.
FIRE PROTECTION
OBJECTIVE : TO CONTAIN THE SPREAD OF FIRE
FIRE PROTECTION PHILOSOPHY:
FIRE PROTECTION PHILOSOPHY IS BASED ON LOSS PREVENTION &
CONTROL.
BECAUSE OF THE INHERENT HAZARD A REFINERY
CARRIES. NO PLANT IS ABSOLUTELY SAFE.
A FIRE IN ONE
PART/SECTION OF A PLANT CAN ENDANGER OTHER SECTIONS OF
PLANT AS WELL
TYPES:
• ACTIVE FIRE PROTECTION SYSTEM
• PASSIVE FIRE PROTECTION SYSTEM
FIRE PROTECTION
FOLLOWING FIRE PROTECTION FACILITIES SHALL BE PROVIDED
DEPENDING ON THE NATURE OF THE INSTALLATION AND RISK
INVOLVED:
• FIRE WATER SYSTEM
• FOAM SYSTEM
• CLEAN AGENT SYSTEM
• CO2 SYSTEM
• DCP EXTINGUISHING SYSTEM
• DETECTION AND ALARM SYSTEM
• COMMUNICATION SYSTEM
PASSIVE FIRE PROTECTION SYSTEM
• DYKE WALLS
• SAFETY VALVES ON EQUIPMENT
• WATER SEAL IN SEPARATORS
• RUPTURE DISC IN PROCESS PIPING
• FIRE PROOFING OF STRUCTURES
• FIRE RETADANTS PAINTS ON CABLES
• FIRE BARRIERS
• POSITIVE PRESSURIZATION
• FLARING / VENTING
FIRE FIGHTING
OBJECTIVE : TO EXTINGUISH THE FIRE WITH MINIMUM LOSS
IT IS THE LAST LINE OF THE DEFENSE. IT COMES INTO FORCE WHEN
THERE IS ACTUAL FIRE. MAIN PURPOSE IS TO EXTINGUISH THE FIRE
WITH SUITABLE EQUIPMENT AND MATERIALS WITH AN AIM TO REDUCE
DAMAGE DUE TO FIRE
• PORTABLE FIRE FIGHTING EQUIPMENT
• MOBILE FIRE FIGHTING EQUIPMENT
• FIXED FIRE FIGHTING SYSTEM
FIRE FIGHTING
PORTABLE FIRE FIGHTING EQUIPMENT SHALL BE PROVIDED IN
REFINERY/PROCESS PLANT AS INDICATED BELOW:
DESCRIPTION
NORMS/CRITERIA TO DETERMINE THE QUANTITY NEEDED
DRY
CHEMICAL
POWDER
FIRE
EXTINGUISHERS 10 KG CAPACITY
TO BE LOCATED IN PROCESS UNITS, OFF-SITE AREAS , PLANT
BUILDINGS , POWER DISTRIBUTION AREAS ETC.
THE NUMBER SHOULD BE DETERMINED BASED ON THE MAX.
TRAVELING DISTANCE OF 15 mtrs IN ABOVE AREAS.
AT LEAST ONE FIRE EXTINGUISHER SHOULD BE PROVIDED
FOR EVERY 250 sq. mt. OF HAZARDOUS OPERATING AREA.
DRY
CHEMICAL TO BE LOCATED IN CRITICAL OPERATING AREAS. AT LEAST
POWDER
FIRE ONE FIRE EXTINGUISHER SHOULD BE PROVIDED FOR EVERY
EXTINGUISHERS
750 sq. mt. OF HAZARDOUS OPERATING AREA.
25/50/75
kg
CAPACITY
FIRE FIGHTING
DESCRIPTION
NORMS/CRITERIA TO DETERMINE THE QUANTITY
NEEDED
CO2
EXTINGUISHERS TO BE LOCATED IN SUBSTATIONS AND POWER STATIONS.
OF 4.5 Kg OF 6.8/9.0 THE NUMBER SHOULD BE DETERMINED BASED ON THE
kg ON WHEELS
MAX.
TRAVELING DISTANCE OF 15 mtrs..
AT LEAST
ONE FIRE EXTINGUISHER SHOULD BE PROVIDED FORE
EVERY 250sq. Mt. OF HAZARDOUS OPERATING AREA.
STEAM LANCERS (AS A FOR FIGHTING INCIPIENT FIRES AT FLANGE LEAKAGE &
PART
OF
UTILITY HOT PUMPS.
STATION)
RUBBER HOSE REEL
TO BE LOCATED IN PROCESS (25 mm) UNIT BATTERY
LIMITS AND OTHER PROCESS AREA.
FIRE FIGHTING
S.
NO.
TYPE OF FIRE
RISK
EXAMPLE OF
OCCUPANCIES
SCALE OF EQUIPMENT
1 A)
CLASS ‘A’ LIGHT
HAZARD
OFFICERS (OTHER THEN
RECORD ROOM) SCHOOL
CLUBS, ETC.
FOR EVERY 600 M2 FLOOR
AREA 1 NO. 9L WATER
TYPE, MAX. DISTANCE 25 M
B)
CLASS ‘A’
ORDINARY
HAZARD
ORDINARY RECORD
ROOM TAILORING SHOP.
BOOK BINDER ETC.
FOR EVERY 600 M2 FLOOR
AREA 2 NOS. 9L WATER
TYPE MAX. DISTANCE 15 M
C)
CLASS ‘A’ EXTRA
HAZARD
LARGE TIMBER YARDS
‘DO’ + SOME EXTRA
SAW MILLS HOUSE OF
PROVISION AS PER LOCAL
COMBUSTIBLE MATERIALS AUTHORITY.
D)
CLASS ’A’
SPECIAL HAZARD
IMPORTANT OFFICE
RECORDS, LIBRARIES
DATA PROCESSING
FOR EVERY 100 M2 1 NO.
4.5 KG CO2. MAX.
DISTANCE -10 M
2 A)
CLASS ‘B’ SMALL
QUANTITY
HANDLED
WORKSHOP. GARAGE
ETC.
2 NOS. FOAM / DCP PER 50
M2 AREA. MAX. DISTANCE –
10 M
FIRE FIGHTING
S.
NO.
TYPE OF FIRE
RISK
EXAMPLE OF
OCCUPANCIES
SCALE OF EQUIPMENT
B)
CLASS ‘B’ BULK
STORAGE OTHER
THEN TANK
FARMS
FLAMMABLE LIQUIDS IN
CAN, DRUMS ETC.
3 NOS. FOAM /DCP PER 100
M2 AREA. MAX. DISTANCE –
10 M
3.
CLASS ‘C’
HANDLING /STORAGE OF
GAS CYLINDERS, GAS
PLANT ETC.
2 NOS. DCP/CO2 (6.8 kg)
PER 200 M2 AREA. MAX.
DISTANCE – 10 M.
4..
CLASS ‘D’
REACTIVE METAL
STORAGE
2 NOS. DCP PER 50 M2
AREA. MAX. DISTANCE – 10
M.
5.
MIXED
OCCUPANCY
(ELEC. RISK)
W/SHOP, X-MERS
MOTORS, TEL, EXCH.,
ETC.
1 NO. DCP/CO2 PER 100M2
AREA.
FIRE FIGHTING
MOBILE FIRE FIGHTING EQUIPMENT
•FOAM TENDERS
•DCP TENDERS
•FOAM NURSER
•TRAILER FIRE PUMP
•TROLLEY MOUNTED MONITORS
•FIRE FIGHTING HOSE & OTHER ACCESSORIES LIKE FOAM BRANCH, NOZZLES ETC.
•FIRE FIGHTING CHEMICALS LIKE FOAM COMPOUND, DRY CHEMICAL POWDER ETC.
GENERAL LOSS CONTROL RULES
•NO MATCH BOX/ LIGHTER / MOBILE IS ALLOWED IN REFINERY
• N0 SMOKING IS ALLOWED IN REFINERY EXCEPT AT DESIGNATED PLACES
• NO VEHICLE IS ALLOWED INSIDE BATTERY AREA WITHOUT SPARK ARRESTOR
• NOBODY IS ALLOWED TO ENTER THE REFINERY WITHOUT SHOES.
• NO OUTSIDER IS ALLOWED INSIDE ANY OPERATIONAL PLANT / UNIT AREA
WITHOUT PERMISSION OF AREA IN CHARGE.
• NO DEBRIS/OBSTACLES ALLOWED ON ROADS
•NO PHOTOGRAPHY/VIDEOGRAPHY IS ALLOWED WITHOUT PERMISSION
• NO MAINTENANCE WORK SHOULD BE STARTED WITHOUT VALID PERMIT &
CLEARANCE.
GENERAL LOSS CONTROL RULES
•NEVER ENTER WORK AREA WITHOUT HELMET WITH CHIN STRAP IN PLACE

NO CLIMBING/WORKING ALLOWED WITHOUT SAFETY BELT ABOVE 2 METRE
HEIGHT
 DO NOT WALK ON PIPELINES OR FALSE CEILINGS

DO NOT STAND UNDER SUSPENDED LOADS
 DO NOT TAMPER WITH FIRE FIGHTING EQUIPMENT OR FIRE HYDRANTS
 DO NOT EXCEED SPEED LIMIT OF 25 KMPH WITHIN THE REFINERY
PREMISES.
 REPORT ALL ACCIDENTS/INCIDENTS TO AREA INCHARGE AND FIRE &
SAFETY.
 IN CASE OF TOXIC GAS RELEASE/DISASTER, ASSEMBLE AT
DESIGNATED LOCATIONS.
MAKE SAFETY A HABIT
SAFETY ASPECTS
NEED FOR SAFETY
ECONOMIC
ASPECTS
LEGAL
ASPECTS
HUMAN
ASPECTS
SOCIAL
ASPECTS
• LOSS OF
PRODUCTION
(STATUTORY
OBLIGATION)
• PHYSICAL
INJURY
• GENETIC
• LOSS OF
CAPITAL
• REPARATION
ON FAMILY
• LOSS OF
MANPOWER
• MORAL LOSS
• MEDICAL
COMPENSATION
• COST OF
TRAINING
• LOSS OF WAGES
• BUSINESS
INTERRUPTIONS
• ECOLOGICAL
• LOSS TO NATION
• POLLUTION OF
STREAM AND
AIR
SUPERVISORS
ROLE IN SAFETY
DUTIES OF SUPERVISORS IN PROMOTING SAFETY
• EACH SUPERVISOR SHALL EXERCISE CLOSE SUPERVISION OVER HIS
MANPOWER..
• SHALL ENSURE THAT PERSONS WORKING UNDER
COMPETENT TO PERFORM THEIR WORK SAFELY.
HIM
ARE
• HE MUST TAKE IMMEDIATE CORRECTIVE ACTION WHENEVER UNSAFE
CONDITIONS / PRACTICES ARE OBSERVED.
• SUPERVISOR SHALL EXPLAIN IN DETAIL THE PARTICULAR HAZARDS
WHERE THE EMPLOYEE IS WORKING AND THE PRECAUTIONS TO BE
TAKEN TO ENSURE SAFETY.
• HE SHALL DEVELOP SAFETY AWARENESS IN THE MINDS OF ALL
EMPLOYEES.
• SUPERVISORS SHALL ENSURE THAT THE SAFETY REGULATIONS ARE
UNDERSTOOD, THAT ALL HAZARDS ARE ELIMINATED WHEREVER
POSSIBLE AND ALL MEANS OF EGRESS/EXIT, STAIRWAYS AND
SIMILAR MEANS OF ESCAPE ARE CLEAR, WORKABLE AND
THOROUGHLY KNOWN TO ALL HIS MEN.
DUTIES OF SUPERVISORS IN PROMOTING SAFETY
• HE MUST SET A GOOD EXAMPLE IN KNOWING AND OBSERVING ALL
SAFETY RULES AND PRECAUTIONS.
• SUPERVISORS SHALL INVESTIGATE AND REPORT THE ROOT CAUSES
OF ACCIDENTS THAT TAKE PLACE IN THEIR AREAS.
• SUPERVISORS ARE REQUIRED TO MAKE CONTACTS WITH PERSONS
WORKING IN ISOLATED PLACES.
• BY REGULAR AND SYSTEMATIC INSPECTION, SUPERVISOR SHALL
ENSURE THAT ALL TOOLS, EQUIPMENT, MACHINERIES AND PREMISES
ARE IN SAFE AND OPERATIVE CONDITIONS.
• SUPERVISORS MUST TAKE CORRECTIVE ACTION WHENEVER RULES
ARE NOT OBSERVED BECAUSE A SINGLE VIOLATION MAY BECOME A
SOURCE OF MAJOR ACCIDENT AND MAY PUT THE SAFETY OF AN
INDIVIDUAL OR A GROUP IN JEOPARDY.
SAFETY OUR FIRST JOB
SAFETY MANAGEMENT SYSTEMS
WHY SAFETY IS OUR FIRST JOB
 To protect human life
 To protect company property
 To protect surrounding environment/ community
 To efficiently run the business & reduce Losses
 To enhance productivity
 To build up morale & team spirit
 To enhance corporate image
Safety Management
 In the early stage of industrialization safety was
managed through training and following safe
procedures, compliance of rules and regulations, etc.
 Next stage witnessed enhanced safety feature
through technological up-gradation safe processes,
safety features in built in design and prescriptive
statutory rules.
 Finally safety is managed through systems approach.
The ‘Cullen Report’, 1990 on Piper Alpha Disaster
stressed the need for formal safety management
system.
Safety Management System
An integrated approach of Management, Leadership
Commitment
and
Coordinated
Technical
Interventions from concept to commissioning to
commercial operations
Elements of Safety Management
Systems
 Management Leadership, Commitment and Accountability
 Employee Participation
 Process safety Information
 Process Hazard Analysis
 Operating Procedures
 Training
 Contractors
Elements of Safety Management
Systems
 Pre-commissioning Checks and Audits
 Work Permit System
 Mechanical Integrity
 Incident Investigation
 Management of Change
 Emergency Planning and Response
 Safety Audits
 Regulatory Compliance
Management Commitment &
Leadership
 Corporate safety policy
 Allocation of resources
 Development of systems & guidelines
 Performance of systems & guidelines
 Nurturing positive safety culture
Management Commitment &
Leadership
 Rewarding outstanding performance
 Occupational Health
 Compliance with Regulations
 Environmental Protection
 Community Awareness
Employee Participation
 Abide by safety rules/regulations
 To follow safe operating practices
 Actively participate in safety committees
 Feed back on unsafe practices and acts
 Train co-workers and assist them in performing
safely
 Help in controlling safety and environmental
incidences
 Use Personal Protective Equipment (PPE)
Process Safety Information
 Complete and accurate information about
 Process Chemicals
 Process Technology
 Process Equipment
Process Safety Information
 Process Chemicals

Physical Properties like vapour pressure, boiling point etc.

Fire & Explosion Hazards like flash point, auto-ignition
temperature, explosive limits etc.

Reactive hazards (tendency to react violently)

Health hazard (toxicity)

Corrosive properties
Process Safety Information
 Process Technology

Written down process description

Process chemistry

Safe Operating limits

P&ID
Process Safety Information
 Process Equipment
 Materials of construction
 Design Specifications
 Electrical classification
Process Hazard Analysis
 What - if - analysis
 Check-list
 Hazard & Operability Studies (HAZOP)
 Quantitative Risk Analysis (MCA based)
 Strategies to minimise risk
 Process safety information provides input for such
studies/task
Operating Procedures
 Comprehensive operation, maintenance & Inspection
Manuals
 Equipment operation, normal start up and shut
downs, emergency handling procedures
 Interlocks and safe shut-down instrument functions
& its special features
 Contains work permit system, equipment hand-over,
fire protection/fighting facilities etc.
Training
 Employees, contractors, security personnel, Truck
drivers/khalasis
 Core Safety training
 Skill training
 Refresher training
 Use of modern training aids - simulators
Pre-commissioning Safety checks &
Audit
 Carried out by multi disciplinary team on a well
structured check list
 To ensure construction as per design
 To ensure compliance with regulations
 To
ensure
proper
procedures, training
documentation,
operating
Pre-commissioning Safety checks &
Audit
 To ensure that all protections are provided, tested
and put in place
 Work permit system in place
 All personnel protective equipment provided for
ready use.
Mechanical Integrity
The objective is to ensure
 Reliable and safe operation
 Higher equipment life
 Higher on-stream factor
Mechanical Integrity




Condition Monitoring
Preventive /Predictive Maintenance
Residual Life Assessment
Periodic Testing of Relief Valves, Interlocks,
Alarms, shut down systems etc.
 Documentation of monitored data to guide corrective
actions
 Only nominated officers approve by-passing of
TRIPS/Interlocks etc. Restoration on top priority.
Management of Change
 Procedure for evaluating potential impact,
authorising and control
 Proposed changes are reviewed by various
functions/departments
 Operating/maintenance personnel are imparted
training
 Documents are updated and changes are
communicated to all concerned
 Same control is exercised for temporary as well as
permanent changes
Safety Audit
 To check and affirm System Effectiveness
 Done on structured check list by Multi Disciplinary
Teams
 Internal Audit - Every Year
 External Audit (once in 3 years) & Surprise Audit
(once in a year) by OISD
 Implementation of recommendations
 Review
Statutory Compliance
 The Factories Act, 1948
 The Petroleum Rules, 1976
 The Gas Cylinder Rules, 1981
 The SMPV (U) Amendment Rules, 2000
 The MSIHC Rules, 2000
 The EP Act, 1986
and other relevant rules like Indian Electricity Act, Boiler
Regulations, Central Motor Vehicle Rules etc. to be
followed.
Risk Management
206
Risk Management
From
Cradle ...
… to Grave
207
Risk Management
“Public” assessment of Risk
“Expert” assessment of Risk
Intuitive
Scientific
Yes/No
Probabilistic
Safety
Acceptable Risk
Is it or Isn’t it
Changing knowledge
Discrete events
Comparative risk
Personal consequences
Population averages
It matters how we die
A death is death
208
HIERARCHY OF CONTROL
Control:
The measures we take to eliminate or reduce the
risk to an acceptable level.
Hierarchy of Control:
The order in which controls should be considered
When selecting methods of controlling a risk.
209
HIERARCHY OF CONTROL
Elimination
Substitution
Isolation
Engineering Controls
Administrative Controls
Provide Personal Protective Equipment .
210
HIERARCHY OF CONTROL
ELIMINATION
The Best method of dealing with a hazard is to
eliminate it.
Once the hazard has been eliminated the
potential for harm has gone.
211
HIERARCHY OF CONTROL
SUBSTITUTION
This involves substituting a dangerous process
or substance with one that is not as dangerous.
This may not be as satisfactory as elimination as
there may still be a risk (even if it is reduced).
212
HIERARCHY OF CONTROL
ISOLATION
Separate or isolate the hazard from people.
This method has its problems in that the hazard has
not been removed.
The guard or separation device is always at risk of being
removed or circumvented.
213
HIERARCHY OF CONTROL
ADMINISTRATION
Administrative solutions usually involve modification
of the likelihood of an accident happening.
This can be done by reducing the number of people
exposed to the danger reducing the amount of time
exposed and providing training to those people who
are exposed to the hazard.
214
HIERARCHY OF CONTROL
PERSONAL PROTECTIVE EQUIPMENT
Provision of personal protective equipment should only
be considered when all other control methods are
impractical, or to increase control when used with another
method higher up in the Hierarchy of Control.
215
MONITORING AND REVIEW
KEY POINT
A review follow-up is always essential.
Review is an important aspect of any risk
Management process.
It is essential to review what has been done to
Ensure that the controls put in place are effective.
216
The Risk Management Process
The total procedure associated with
-
Identifying a HAZARD,
-
Assessing the RISK,
-
Putting in place CONTROL MEASURES,
AND REVIEWING THE OUTCOMES.
217
Hazard Identification
218
Risk Assessment
219
CONCLUSION
•Hazard identification, risk assessment, control and review
is not a task that is completed and then forgotten about.
•Hazard identification should be properly documented even
in the simplest of situations.
•Risk assessment should include a careful assessment
of both LIKELIHOOD and CONSEQUENCE.
•Control measures should conform to the recommendations
of the hierarchy of control.
The risk management process is an
ON GOING ONE
220