PLANT SAFETY AND

HEALTH
DKK 2473

MOHD BIJARIMI MAT PIAH

Email: [email protected]
 Chapter 1

Introduction
 INTRODUCTION
Since 1950, significant technological advances have been
made in chemical process safety and health
Today, safety is equal in importance to production and has
developed into a scientific discipline
Example of technology of safety:
Hydrodynamic models representing two-phase flow
through a vessel relief.
Dispersion models representing the spread of toxic
vapour through a plant after a release.
Mathematical techniques to determine the various ways
that processes can fail and the probability of failure

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 INTRODUCTION
Use of appropriate technological tools to provide information
for safety decisions with respect to plant design and
operation.
“Safety”- used to mean the older strategy of accident
prevention through the use of hats, safety shoes and a variety
of rules and regulation. >>>> workers safety!
Recently, the word safety has been replaced by “loss
prevention”. Includes hazard identification, technical
evaluation and design features to prevent loss.
Chemical plants contain a large variety of hazards
mechanical hazards workers injuries from tripping, falling or
moving equipment. Chemical hazards fire and explosion
hazards, reactivity hazards and toxic hazards.

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 SAFETY PROGRAMMES
A successful safety program requires several ingredients:
S:system
To record what needs to be done to have an outstanding
safety program
To do what needs to be done
To record that the required tasks are done

A:attitude
F:fundamentals
E:experience
T:time
Y:you

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 SAFETY PROGRAMMES
The most effective means of implementing a safety program is
to make everyone responsible in a chemical process
plant.
All employees have the responsibility to be knowledgeable
about safety and to practice safety
Safety or loss prevention is the prevention of accidents
through the use of appropriate technologies to identify the
hazards of a chemical plant and eliminate them before an
accident occurs.

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 WHY WE NEED SAFETY ?
The importance of safety are:
Prevents the valuable equipments from totally damaged and
losing a large amount of investment.
Assures the prolonged human resource contribution to profit
the chemical plant.
To avoid other indirect cost

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 HAZARD AND RISKS
A hazard is not always identified until an accident occurs.
Hazard is a chemical or physical condition that has the
potential to cause damage to people, property or the
environment.
Danger is arisen when one exposed with the hazard.
Risk is a measure of human injury, environmental damage or
economic loss in terms of both the incident likelihood and the
magnitude of the loss or injury, severity.

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 ACCIDENTS AND LOSS
STATISTICS
Accident and loss statistic are important measures of the
effectiveness of safety program.
These statistics are valuable for determining whether a
process is safe or whether a safety procedure is working
effectively.

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 ACCIDENTS AND LOSS
STATISTICS
There are three systems considered
OSHA incidence rate.
Fatal accident rate (FAR)
Fatality rate or deaths per person per year

OSHA – Occupational Safety and Health Administration

Responsible for ensuring that workers are provided with a
safe working environment

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 ACCIDENTS AND LOSS
STATISTICS

OSHA incidence rate (based on injuries and illness)

Number of injuries and illness x 200,000

Total hours worked by all employees during period covered

OSHA incidence rate (based on lost workdays)

Number of lost workdays x 200,000

Total hours worked by all employees during period covered
Assumption.
•100 worker years. A worker year is assumed to contain 2,000 hrs (50 work
weeks/year x 40 hrs/week).
• OSHA incidence rate based on 200,000 hrs of worker exposure to a
hazard

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 ACCIDENTS AND LOSS
STATISTICS

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 ACCIDENTS AND LOSS
STATISTICS

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 ACCIDENTS AND LOSS
STATISTICS
Fatal accident rate (FAR)

Number of fatalities x 108

FAR 
Total hours worked by all empployeesduring period covered

Number of fatalities per year

Fatalities rate 
Total number of peoplein applicable population

Assumption.
• The FAR reports the number of fatalities based on 1000 employees
working their entire lifetime.
• The employees are assumed to work a total of 50 years.
• Thus the FAR is based on 108 working hours.

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 RESPONSIBLE CARE
Responsible Care is the chemical industry’s global voluntary
initiative under which companies, through their national
associations, work together to continuously improve their
health, safety and environmental performance, and to
communicate with stakeholders about their products and
processes
CICM (Chemical Industries Council of Malaysia) is the
Malaysian steward for the Responsible Care Programme
(RCP), which is a global initiative adopted by chemical
companies to continuously improve all aspects of safety,
health and environment (SHE) protection of their operations
and products in manner responsible to the concerns of the
public.

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 RESPONSIBLE CARE
Responsible Care is a well organised, pro-active approach to
managing health, safety and environmental aspect of our
plants and business as that goes beyond legislative
requirements
Responsible Care is about Dialogue, Action, Performance of
total life cycle of chemicals from initial research to final
disposal
It is a voluntary initiative that commits CICM members to
continuous improvement in health, safety and
environmental performance and encourages sensitivity
and responsiveness to public concerns

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CODES OF MANAGEMENT
PRACTICES
At the heart of the Responsible Care initiative are the 6 Codes
of Management Practices, which focus on specific areas of
chemical manufacturing, transportation, research and
handling.
Companies must in good faith make continuous efforts to
attain the goals of each Code.

•Improve performance in health, safety and

environmental quality.
•Listen and respond to public concerns.
•Publicize their progress, and
•Assist each other to achieve optimum Performance.

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CODES OF MANAGEMENT
PRACTICES
DISTRIBUTION CODE (Aug 3, 95)
to reduce the potential for harm posed by the distribution
of chemicals to the general public, employees and the
environment
COMMUNITY AWARENESS AND EMERGENCY
RESPONSE CODE (Nov 2, 96)
to work with nearby communities to understand their
concerns and to plan and practice for emergencies
POLLUTION PREVENTION CODE (Nov 25, 97)
to achieve ongoing reductions in the amount of all
pollutants released into the environment

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CODES OF MANAGEMENT
PRACTICES
PROCESS SAFETY CODE (May 19, 99)
to prevent fires, explosions and accidental chemical
releases
EMPLOYEE HEALTH AND SAFETY CODE (May 19, 99)
to protect and promote the health and safety of people
working at or visiting company sites.
PRODUCT STEWARDSHIP CODE (Nov 17, 99)
to make health, safety and environmental protection a
priority in all stages of a product's life, from design to
disposal.

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 CASE STUDIES
Flixborough, England
Bhopal, India
Seveso, Italy
Pasadena, Texas
Texas City, Texas
7
Significant
Jacksonville, Florida Disasters
Port Wenworth, Georgia
How did it happened?
Why did it happened?
What can be done to avoid the same disaster from
happening?
Presentation on ______________________

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CSB Releases New Computer Animation of 2010 Explosion
and Fire that Killed Seven Workers at the Tesoro Refinery in
Anacortes, Washington.
The five-minute animation illustrates the process of "high
temperature hydrogen attack," which over the years damaged
and weakened a nearly forty-year-old carbon steel heat
exchanger, leading to a catastrophic rupture on the night of
the accident.
CSB investigation concluded that the accident at Tesoro could
have been prevented had the company replaced the
vulnerable carbon steel heat exchangers with inherently safer
alloys that were already well known within the industry, but not
required.
http://www.csb.gov/csb-releases-new-computer-animation-of-2010-explosion-and-fire-
that-killed-seven-workers-at-the-tesoro-refinery-in-anacortes-washington/

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