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Process Safety and Disaster Preparedness

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Carter J. Kerk, PhD, PE, CSP, CPE. Industrial Engineering Department ... gas leaked into atmosphere, killing and disabling thousands as they slept ... – PowerPoint PPT presentation

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Title: Process Safety and Disaster Preparedness


1
Process Safety andDisaster Preparedness
  • TM 650 Safety Management
  • Carter J. Kerk, PhD, PE, CSP, CPE
  • Industrial Engineering Department
  • South Dakota School of Mines

2
Reading Assignment
  • Chapter 6, Asfahl

3
Process Safety Standard, 1992
  • 29 CFR 1910.119
  • 1 of OSHA General Industry citations address
    this subject
  • Motivation
  • Union Carbide, Bhopal, India
  • Phillips Petrochemical, Pasadena, Texas
  • Purpose
  • Preventing or minimizing the consequences of
    catastrophic releases of toxic, reactive,
    flammable, or explosive chemicals. These releases
    may result in toxic, fire or explosion hazards.

4
Bhopal Disaster (www.bhopal.com)
  • December 3, 1984, Bhopal, India
  • 3800 killed, 40 permanently disabled, 2800
    partially disabled
  • Union Carbide India Limited plant
  • Methyl isocyanate (MIC, used to make pesticide
    and herbicide) gas leaked into atmosphere,
    killing and disabling thousands as they slept
  • Cause A large volume of water entered the MIC
    tank, causing a chemical reaction forcing the
    release valve to open and the gas to leak
  • Questions remain Was it an accident or
    deliberate?

5
Business in Bhopal
  • Read short story from Set Phasers On Stun

6
Phillips Petrochemical Disaster
  • October 23, 1989, Pasadena, Texas
  • 24 killed, 314 injured, 750M facility damage
  • Polyethylene (plastic used to make milk
    containers)
  • Cause Subcontractor maintenance crews using poor
    lockout practices caused escape of process gas
    (isobutane, ethylene, hexene, hydrogen) which
    traveled to an ignition source and exploded with
    the force of 2.4 tons of TNT and then subsequent
    fire

7
Anatomy of a Tragedy
  • Read this article posted on the course website
  • From Occupational Hazards, May 2007, p. 31
  • March 23, 2005, Texas City, TX
  • Owner London-based BP
  • 15 fatalities (all contract employees)

8
29 CFR 1910.119
  • Appendix A (Text Appendix E)
  • list of highly hazardous chemical, toxics, and
    reactives
  • Appendix B (Text Figure 6-1, 6-2)
  • block flow diagram and simplified process flow
    diagram
  • Appendix C
  • compliance guidelines

9
Develop an Information Database
  • Compile info on
  • highly hazardous chemicals used or produced
  • equipment used
  • technology of the process
  • From MSDS and other sources
  • See Case Study 6.1

10
Process Information Before an analysis of a
process can begin, the employer must compile
information on highly hazardous chemical to be
used or produced, the equipment to be used, and
the technology of the process. Potential sources
of information include the MSDS, chemical
dictionaries and reference manuals, and the NIOSH
Registry of Toxic Effects of Chemical Substances
(http//www.cdc.gov/niosh/rtecs/RTECSaccess.html).
Case Study 6.1 shows how published data can be
used to provide the data necessary for analysis
of hazardous processes. Also provide process
chemistry data, maximum intended inventory, and
safe upper and lower limits for temperatures,
pressures, flows, or compositions.
11
Note CAS Chemical Abstract Service number.
TQ Threshold quantity in pounds (amount
necessary to be covered by this standard).
12
Document the Processes
  • Use block flow diagrams and process flow diagrams
  • where possible include flow rates, stream
    composition, temperatures, pressures, etc.
  • include engineering details
  • materials of construction, piping and
    instrumentation diagrams, relief systems,
    ventilation, interlocks, detection and
    suppression systems, etc.

13
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14
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15
Is this only for the petrochemical industry??
  • No, OSHA defines process more broadly
  • poultry processor using chlorine for
    refrigeration
  • metal processing industries using plating
    chemicals (again see Text Appendix E)

16
Process Analysis
  • What can go wrong?
  • How to react?
  • What-If Analyses
  • fault-tree analysis (FTA)
  • failure modes and effects analysis (FMEA)
  • Analyses must be updated every 5 yrs
  • Document and record analyses

17
Operating Procedures
  • After process info has been gathered and
    analyzed, develop effective operating procedures
  • Establish procedures for different modes
  • normal operations
  • temporary operations
  • emergency operations

18
Training Programs
  • Initial training for new operators and new
    operations
  • Refresher training, lt 3 years
  • Verification or testing
  • Documentation

19
Contractors
  • Contracted labor is a growing trend
  • Prime employer is responsible for operations and
    conduct of contract employees
  • Examine contractor safety records prior to
    contract
  • Maintain injury/illness log on contract employees

20
Acts of Terrorism
  • The terrorist attacks September 11, 2001 on the
    World Trade Center and the Pentagon, forever
    changed the challenges for Process Safety
  • We now add terrorist attacks to our concerns for
    Disaster Preparedness
  • Many safety professionals have now had this
    concern added to their responsibilities

21
Terrorist Disaster Preparedness
  • Limit facility access
  • Parking lot design and location
  • Landscaping changes to protect buildings
  • Concrete barricades to limit approaches and
    access
  • Incident management aspects
  • How to protect workers and volunteers after an
    attack?
  • Training on use of equipment and PPE
  • Have a company policy and plan!

22
Workplace Violence
  • Increasing incidences of workplace shootings (and
    school shootings)
  • Homocide is 4th leading cause of fatal
    occupational injury in the US.
  • 551 workplace homicides in 2004
  • http//www.osha.gov/SLTC/workplaceviolence/index.h
    tml
  • Have a company policy and plan!

23
HW11 Chapter 6 Questions
  • Exercises Study Questions
  • 1-25, divisible by 5
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