Ch2-General Design Considerations Week2
Ch2-General Design Considerations Week2
Ch2-General Design Considerations Week2
General Design
Considerations
Content
INTRODUCTION
HEALTH AND SAFETY HAZARDS
SOURCES OF EXPOSURE
EXPOSURE EVALUATION
EXPOSURE-HAZARD CONTROL
FIRE AND EXPLOSION HAZARDS
FIRE LOSSES KEY REASONS
PERSONNEL SAFETY
SAFETY REGULATIONS
LOSS PREVENTION
FAILURE MODE AND EFFECT ANALYSIS
SAFETY INDEXES
ENVIRONMENTAL PROTECTION
ENVIRONMENTAL REGULATIONS
DEVELOPMENT OF A POLLUTION
CONTROL SYSTEM
AIR POLLUTION ABATEMENT
WATER POLLUTION ABATEMENT
SOLID WASTE DISPOSAL
SAFETY AUDITS
2
Introduction
Before proceeding any further with the development of a process
(ARIA), the
National Institute for Occupational Safety and Health (NIOSH), and the United
kingdom earth and Safety Executive (HSE).
4
Sources of Exposure
For example, mechanical abrasions of solid materials by cutting,
grinding, or drilling can produce small particles which can form an
airborne dust cloud or solid aerosol. Liquid aerosols, on the other
hand, may be produced by any process that supplies sufficient
energy to overcome the surface tension of the liquid. This process
occurs intentionally in spray coating and unintentionally when oil
mist is generated from lubricants or coolants used on
high-speed machinery.
Liquid aerosols can also be produced by condensation.
7
Sources of Exposure
Flammable materials
Contaminant vapors are normally formed by allowing the
liquid to evaporate into the air.
Liquid aerosols may be produced by any process.
Pumps and valves are probably the major source.
Flammable materials
Fugitive Emissions
Solids handling can provide considerable exposure to
contaminants whenever the operation is performed in an
open atmosphere.
Maintenance of any closed system can pose a hazardous
exposure problem.
Spilled materials can become airborne and pose an
inhalation hazard.
8
10
11
Exposure Evaluation
An estimate of the toxicity or intrinsic hazard is needed for each
material identified in the inventory. Such information for many
chemicals in the form of a Material Safety Data Sheet (MSDS)
are required by the OSHA Hazard Communication Standard.
12
13
14
Exposure-Hazard Control
CHEMICAL & DUST
HAZARDS
(cleaning products,
pesticides, asbestos, etc.)
BIOLOGICAL
HAZARDS
ERGONOMIC
HAZARDS
(repetition, lifting, awkward
postures, etc.)
(mold, insects/pests,
communicable diseases, etc.)
WORK
ORGANIZATION
HAZARDS
Things that cause STRESS!
SAFETY HAZARDS
PHYSICAL HAZARDS
(noise, temperature
extremes, radiation, etc.)
15
Lack of
awareness
of safety
and
following
safety
norms
Definitions
Combustion a chemical reaction in
which a substance combines with an
oxidizer and releases energy.
Explosion rapid expansion of gases
resulting in a rapid moving pressure or
shock wave.
Mechanical Explosion due to failure of
vessel with high pressure non reactive
gas.
21
Fire Triangle
Most are familiar with
the Fire Triangle.
In order for a fire to start
or be sustained you need
to have a Fuel, an
oxidizer and an ignition
source.
If one of the three
components is
eliminated, then there
will not be a fire (or
explosion)
22
Extremely Highly
flammable flammable
Irritant
Harmful
Danger to
environment
23
Personnel Safety
CONTROLS: PPE
Personal Protective Equipment
Control of LAST RESORT!
Special Clothing
Eye Protection
Hearing Protection
Respiratory Protection
24
Hierarchy of Controls
Elimination/Substitution
Most Effective
Requires a physical
change to the
workplace
Requires worker or
employer to do
something
Least
Effective
Requires
worker to
wear
something
25
Safety Regulations
The expressed intent of the Occupational Safety and Health Act
(OSHA)originally enacted in 1970 is to assure so far as possible
every working man and woman in the Nation safe and healthful
working conditions and to preserve our human resources. . . .
LOSS PREVENTION
Loss Prevention
Take various steps to reduce the probability of
losses occurring
How do you value the loss of life in the cost /
benefit equation?
27
28
What is HAZOP?
Systematic technique
Operating problems
to
IDENTIFY
potential
HAZard
and
30
31
32
ORIGIN OF HAZOP
Initially prepared by Dr H G Lawley and
associates of ICI at Wilton in 1960s.
Subsequently C J Bullock and A J D Jenning
from ChE Dept. Teeside Polytechnic under
supervision of T.A. Kletz applied the method
at higher institution (post-graduate level).
In 1977, Chemical Industries Association
published the edited version.
33
OBJECTIVE OF HAZOP
For identifying cause and the consequences of
perceived mal operations of equipment and
associated operator interfaces in the context
of the complete system.
It accommodates the status of recognized
design standards and codes of practice but
rightly questions the relevance of these in
specific circumstances where hazards may remain
undetected.
37
Purpose of HAZOP
It emphasizes upon the operating integrity of a
system, thereby leading methodically to most
potential and detectable deviations which could
conceivably arise in the course of normal operating
routine
- including "start-up " and "shut-down" procedures
- as well as steady-state operations.
It is important to remember at all times that HAZOP
is an identifying technique and not intended as a
means of solving problems nor is the method intended
to be used solely as an undisciplined means of
searching for hazardous scenarios.
41
applied
to
specific
piece
of
42
Safety Indexes
The safety and loss prevention guide developed by the Dow
Chemical Company? provides a method for evaluating the
potential hazards of a process and assessing the safety and
loss-prevention measures needed. In this procedure, a
numerical Fire and Explosion Index is calculated, based on
the nature of the process and the properties of the materials.
43
Safety Audits
The principal function of most safety audits in the past has been
to verify the adequacy of safety equipment and safety rules. The
ENVIRONMENTAL PROTECTION
45
Environmental Regulations
46
Developing
pollution
control
system
involves
an
47
49
51
52
53
NOISE CONTROL
The design engineer should include noise studies in the design stage of any
industrial facility.
54
PLANT LOCATION
The geographical location of the final plant can have strong influence on the success
of an industrial venture. Considerable care must be exercised in selecting the plant
site, and many different factors must be considered. Primarily, the plant should be
located where the minimum cost of production and distribution can be obtained, but
other factors, such as room for expansion and safe living conditions for plant
operation as well as the surrounding community, are also important.
The following factors should be considered in selecting a plant site
1. Raw materials availability
2.Markets
3.Energy availability
4.Climate
5. Transportation facilities
6. Water supply
7. Waste disposal
8. Labor supply
9. Taxation and legal restrictions
10. Site characteristics
11. Flood and fire protection .
12. Community factors
55
56
PLANT LAYOUT
After the process flow diagrams are completed and before detailed piping, structural,
and electrical design can begin, the layout of process units in a plant and the
equipment within these process units must be planned. This layout can play an
important part in determining construction and manufacturing costs, and thus must
be planned carefully with attention being given to future problems that may arise.
New site development or addition to
services
Type of buildings and building-code
requirements
57
58
59
PATENT CONSIDERATIONS
A patent is essentially a contract between an inventor
and the public. In consideration of full disclosure of the
invention to the public, the patentee is given exclusive
rights to control the use and practice of the invention. A
patent gives the holder the power to prevent others from
using or practicing the invention for a period of 17 years
from the date of granting.
Trade secrets and certain types of confidential
disclosures can receive protection under common-law
61