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