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UNIT I - INTRODUCTION TO SHE ASPECTS .................................................................................................... 2

UNIT II - TYPES AND SEVERITY OF ACCIDENTS ............................................................................................ 21

UNIT III - SAFETY POLICY, ORGANIZATION, MONITORING AND REPORTING ............................................. 33

UNIT IV - PROCESS SAFETY MANAGEMENT ................................................................................................ 44

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UNIT V - EMERGENCY/ DISASTER MANAGEMENT PLAN............................................................................... 57

UNIT VI - FIRST AID ...................................................................................................................................... 67

UNIT VII - PERSONNEL RISK IN MANUFACTURING PLANT .......................................................................... 76

UNIT VIII - PERSONNEL RISK IN CHEMICAL PLANT ...................................................................................... 83

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 UNIT 1 - INTRODUCTION TO SHE ASPECTS

Objectives:

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After completing this unit, you will be aware of
• HSE management framework

• Regulatory framework for safety management

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INTRODUCTION:

The industrial operations have been constantly developing, upgrading and improving their design
and operating techniques in terms of economy of scale, high quality products and energy
optimization to meet the stiff market competition. All this has increased the potential of major
risks. Major accidents like Bhopal , Mexico city ,Seveso , Flexiobro and others in the last two
decades or so have shaken the confidence of general public about they safety of the people,
property and environment. In fact, some companies have been closed down on account of poor
safety and environmental performance. After these major disastrous government authorities,
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human activist groups and corporate houses in many countries including have taken a number of
steps to evolve a strategy to avert major mishaps in the installations which have the potential to
cause loss of human life, property and environmental damage. No doubt, health, safety and
environment issues are very critical in the industrial operations in the current scenario.

HSE MODEL AND ITS INTEGRATION WITH BUISNESS:

HSE is an integrated management comprising discipline of occupational, health and environment

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and fire protection. What ever way you look at these functions, industrial hazards- unsafe acts
and situations are the basic problems to be managed. When an industrial hazards leads to an
immediate or sudden accidents like an injury, fire, explosion or toxic release. It becomes a safety
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issues and safety management comes in the picture. When the hazards have chronic health
effects like stress, musco-skeltal disorders and other industrial diseases, it becomes occupational
health problems. On the other hand, when the effect on the unsafe situations is long term and
spread over larger areas beyond the boundary limit it becomes an environmental problem.

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 No doubt, HSE efforts of many organizations are driven by statutory requirements and they do
whatever minimum is required to avoid litigation and fines. However an efficient and

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enlightened corporate see HSE in much broader perspective. For them good HSE performance is
an integral part of efficient and profitable business management. They are committed to improve
their health, safety and environment and fire protection performance on a continuous basis and
on the sustainable way, i.e. meeting the needs of present without compromising the ability of
future generations to meet their needs. The compulsion of integrating HSE functions with

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business can be well appreciated by looking in to the cost of an accident/ incident. Consider the
following direct or indirect costs of major accidents/ incidents:

✓ Injury/ loss of life to self or co-workers

✓ Workman compensation
✓ Cost of injury/ investigation
✓ Loss of property and material
✓ Loss of profits
✓ Punitive sanctions and fines
✓ Closure/ shutdown of the installation
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✓ Public litigation
✓ Environmental pollution
✓ Ecological damage
✓ Loss of business
✓ Shareholders wrath

The above does not include the cost of psychological and social factors associated with major
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accidents. Considering all these it is sensible to integrate HSE as an important management

functions like production, maintenance, finance marketing and human resources etc.
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 HSE MANAGEMENT FRAME WORK:

As said before, numerous associations attempt to meet just the base administrative prerequisites.

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Be that as it may, this isn't sufficient in the present business and social necessity. Controls alone
can not ensure the wellbeing of modern complex. The greater part of the administrative offices
set down principles and controls, which are the base fundamental necessities for the sheltered
outline and task of an establishment. Sound and safe designing practices are similarly essential
however are not enough tended to in their prerequisites. The statutory and law implementing

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offices are for the most part moderate in refreshing their guidelines and prerequisites to keep
pace with the innovative and social changes. Further, numerous administrative offices don't have
satisfactory framework and labor to practice superintendence and control of modern security
execution consistently. For instance, number of wellbeing investigators, heater reviewers and
ecological pro are far not as much as that would e required to attempt important assessment visits
to an expansive number of establishments under their locale. Assist the back pole and preparing
that numerous assembly line laborers have, their visits to industrial facilities are limited to
checking fundamental enhancements like emergency treatment offices, watches for the
machines, individual defensive hardware, consumable water and flask offices and so on. They
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most likely don't have right preparing and fitness for distinguishing the many procedure dangers
which are not all that self-evident.

The regulatory requirements are just very minimum requirements to obtain license and operate
an installation, the petroleum operations which is hazardous industry. Lot of self regulatory
initiatives by the management is required to maintain a high level of safety. So the best
framework of HSE management is to comply with the regulatory requirements and have highly
efficient self regulatory system in house.
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REGULATORY REGIEME:
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To control or reduce industrial hazards, various regulatory authorites have framed various rules
and regulations to safe guard the workers. Sustainable development and environmental
safeguards are important societal issues. These regulations specify minimum mandatory
requirements to be compiled by the industry. The industry should take these regulations in the

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 right spirit and be fully committed in their compliance. These regulations should not be
considered contrary to the interest of business and hindrance to its development.

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REGULATORY/ STATUTORY AGENCIES:

Following is the list of various regulatory/statutory agencies having jurisdiction over the
different industries.

✓ Central Pollution Control Board ( CPCB) under the Ministry of Environment and Forest

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✓ Respective State Pollution Control Board under the Ministry of Environment and Forest
of The State
✓ Chief Controller of Factories Of The Respective State (CIF) Under The Ministry Of
Labor
✓ Chief Controller Of Explosives (CCE) , Ministry of Heavy Industry, Dept of Explosives
✓ Director General of Civil Aviation ( DGCA) under The Ministry of Civil Aviation,
National Air Port Authority Of India
✓ Tariff Advisory Committee (TAC) Under the Association of Indian Companies
✓ Bhaba Atomic Energy Commission (BARC) Under Ministry of Atomic Energy
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✓ Director General Mines Safety (DGMS) under the Ministry of Mines
✓ Regional Transport Authority (RTA) under the Ministry of Surface Transport
✓ Director General Of Dock Safety (DGDS) under The Ministry of Shipping
✓ International Maritime Organization (IMO) under United Nations
✓ Oil industry safety directorate (OISD) under the ministry of petroleum and natural gas

VARIOUS REGULATIONS/ REQUIREMENTS:

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The different agencies of listed above framed various regulations under their purview.
Needless to say that over the years, these agencies have played a significant role in
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promoting industrial safety and environmental protection.

Important regulations are briefly discussed below.

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 PETROLEUM ACT , 1934

The statutory prerequisites of the oil are represented by oil Act, 1934 and oil Rules. 1976 under

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the purview of boss controller of Explosives. These standards manage the wellbeing
rules/controls for import, transport, stockpiling, refining mixing and testing of oil and its
fractions/ hydrocarbons. Under the petroleum Act, the petroleum products are classified into
class –A having flash point below 23 degree Celsius, Celsius and class-B with flash point
between 23 to 65 degree Celsius and class-C having flash point above 93 degrees Celsius are

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exempted petroleum and do not fall under the purview of petroleum rules.

The petroleum rules, 1976 detail the procedures and safety norms to be observed for approval of
containers, import, delivery and dispatch, loading, transport, storage, refining and blending of
petroleum and requirement for storage , refining and blending of petroleum and requirement for
storage and safety distances, testing and maintenance of pipelines, electrical apparatus and
degree of safety and license/ approval procedures, under these rules, license is required for.

➢ Import, storage and refueling

➢ Transport by ships/vessels in bulk
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➢ Decanting from tank trucks in unlicensed premises
➢ Transport by pipelines
➢ Refining and blending
➢ Fabrication of tank trucks
➢ Manufacture of safety fittings
➢ Construction of tanks
➢ Design of containers
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THE INDIAN EXPLOSIVES ACT, 1884

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The compacted or condensed gas filled in holders under strain are told by the Government of
India as explosives and brought under the domain of hazardous act., 1884 of every 1938.The
chief controller of Explosives administration used for various purposes like mines/ rock
blasting, crackers etc.

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 THE STATIC AND MOBILE PRESSURE VESSELES, SMPV (UNFIRED) RULES, 1981

These standards stipulate different wellbeing rules for the capacity and transport of compressed

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and condensed gases filled in weight vessels (surpassing 1000 liters limit) at a weight
surpassing 1.5 kg/cm2 15 degrees Celsius. Under these tenets the capacity and transport vessel
ought to be intended for the particular gas, greatest working temperature and working weight,
legitimate material of development, limit shape, sizes and so forth as indicated by IS 2825 or
some other affirmed code. The central controller of explosives ought to support its

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outline/illustrations. The vessel ought to be created by an endorsed fabricator and introduced
according to the wellbeing separations stipulated in the guidelines. The guidelines call for
occasional reconsideration/testing of the weight vessel and its fittings.

THE GAS CYLINDER RULES, 1981

The arrangements of these tenets relate to the filling. Capacity, taking care of and transportation
of gas barrels surpassing weight of 1.5kg/cm2 at 15 degrees Celsius or 2.5 kg/cm2 at 50 degree
Celsius. The tenets control the make of barrels, valves and controllers, checking, stamping and
shading coding of chambers, import of gas chambers, testing of barrels and the strategies for
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selecting able individual approved to attempt the testing and examination of gas chambers.

THE FACTORIES ACT, 1948

The arrangements of this demonstration contained in various sections on wellbeing, security and
welfare are managed by the main overseer of the production lines in the individual state. Each
state has its own particular manufacturing plants rules. The demonstration was reexamined in
1987 to incorporate perilous compound processing plants and some different corrections got the
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production lines tenets of many satiates in 1995

The manufacturing plants act make the occupier of a plant completely in charge of giving and
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keeping up the plant and the frameworks of work that are sheltered and with no dangers to the
wellbeing and security of the specialists and overall population.

General obligations of occupier are recorded underneath.

•Declaring safety policy

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 •Providing the material wellbeing information sheet (MSDS) of each dangerous synthetic
substances

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•Every production line ought to have an elegantly composed nearby crisis plan, unmistakably
characterizing the job of various people if there should be an occurrence of a crisis. The
arrangement ought to be practiced each year and refreshed every occasionally.

ENVIRONMENTAL LEGISLATION:

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Major environmental legislation are

• The water (Prevention and Control of Pollution) Act, 1974

• The water (Prevention and Control of Pollution) Cess Act, 1977

• The air (Prevention and Control of Pollution) Act, 1981

• The Environment ( protection) Act, 1986

• The Environment (protection) Rules , 1986

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• Hazardous and Other Wastes (Management and Transboundary Movement) Amendment
Rules, 2016.

• E-Waste (Management) Rules, 2016

• Solid Waste Management Rules 2016.

• Construction and Demolition Waste Management Rules, 2016.

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• Bio-Medical Waste Management Rules,2016.

• Plastic Waste Management Rules 2016

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 THE INDIAN BOILERS ACT, 1923

It is an obligatory for an owner to get his boiler registered under this act. The act stipulates

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requirement for safety of steam boilers and steam pipes. For the purpose of the act, a boiler
means any closed vessel exceeding 22.75 liters in capacity which is used exclusively for
generating steam under pressure and include any mounting or other fittings attached to such
vessel which is wholly or partially under pressure when steam is shut off.

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A steam pipe under the act means any pipe through which a steam passes from a boiler to a
prime mover or other user if the pressure at which steam passes through such pipe exceeds 3.5
kg/cm2 above atmosphere or such pipes exceeds 254 mm in diameter

These regulations cover the design, construction and workmanship of boilers and connected
mountings, fittings and pippings.

The regulations specify the stages and procedures for inspection of new boilers and inspection
frequency of boilers in operation.

The regulations also lay down procedure for testing and qualifying welders who are to work on
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boilers.

A registered boiler is permitted for use for a maximum period of one year.

A working certificate showing validity period, maximum allowable pressure etc. is issued after
every annul inspection by the boiler inspector.

The boiler owner is required to display the certificate so the boiler attendants and other
employees associated with boiler operation and maintenance get familiar with the certificate.
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As per the act the owner should provide a qualified person to take charge of boiler.
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A second class boiler attendant can take charge of a single boiler or battery of three boilers, the
total heating surface of which does not exceeded 150 sq. meters.

A first class boiler attendant can take charge of a battery of boilers, the total surface area of
which does not exceed 700 square meters.

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 A proficiency engineer should be appointed for boilers larger than the above sizes.

The following acts/ omissions are treated as cognizable offence under the act.

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• If it is not registered or not having the valid certificate
• Operating the boiler at pressure higher than that allowed in the certificate
• Absence of duly qualified boiler attendant
• Carrying out structural alteration, addition or renewal in or to a boiler without prior

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sanction of chief inspector
• Failure to report any accident to boiler or steam pipe to inspector within 24 hrs.
• Tampering with safety valves.
• Allowing a person to get inside the boiler without affecting disconnection
• Fraudulent engraving of registry on a boiler.

THE INDIAN ELECTRICITY ACT, 1910

In exercise of the powers conferred by section 37 of the Indian electricity act, 1910, the central
electricity board formulated the Indian electricity rules(I.E. rules) in 1937 followed by
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amendments in 1956.

The target of the I.E rules is to control the generation, transmission, appropriation and
utilization of power in a protected way.

It is mandatory that all the electrical installations should confirm to requirements of the Indian
electricity rules.

The I.E rules do not stipulate specific requirements of electrical equipments and lines and due to
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this, the interpretation of the rules by the electrical inspectors vary from state to state. In
addition, the I.E rules do not cover the special requirement for electrical equipment in hazardous
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locations encountered in petroleum installations.

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 THE OIL MINES REGULATIONS, 1984

These regulations were framed under sections 57 read with sections 59 of the mines act, 1952

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and enforced in the 1984 in the oil industry. Consequently all the oil and gas exploration ,
drilling production and transport facilities including general safety and health education
governed by these regulations under the competent authority of the director general of mines
and safety(DGMS).

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Although the basic safety requirements are stipulated in oil mines regulations, 1984, the specific
requirements for certain systems like work permit, fire fighting facilities are not covered.

THE INDIAN AIRCRAFT RULES, 1937

In exercise of the powers conferred by the sections 5,7, and 8 and 9A of the Indian air craft act,
the aircraft rules were framed in 1937, which were amended several times the latest edition was
updated in 1985.

The relevance rules in the case of statuary clearance of the design of tall structure and buildings
are framed under provision 9A of the said act.
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Air warning as stipulated in the rules to be complied with owners of such buildings.

The owner has to forward the layout drawings showing the elevation details, dimensions and
other details of the structures/ buildings in the prescribed format and submit to the nearest
aerodrome officer.

Only after receipt of the approval, the construction can be taken up.
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OIL INDUSTRY SAFETY DIRECTORATE:

Oil industry safety directorate, OISD is a warning body under the service of oil and flammable
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gas. Set up in the 1986 after Bhopal catastrophe, the directorate exhorts the oil and gas industry
in India on all issues of wellbeing, safety and condition. All open area (PSU) oil organizations
are individuals from OISD. Private oil organizations can likewise move toward becoming
individuals on the off chance that they want. Not at all like other administrative organizations,
OISD enables the part to oil and gas organizations to upgrade the level of safety through self-

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 control. OISD has distributed various standard/suggestions rehearse in sitting of oil activity,
methods of insight, examination, upkeep, fire security and so forth it is compulsory for the part

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organizations to utilize these standard and prescribed practices for new establishments and
establishment in tasks. Numerous other statuary offices like CCE and other CITE OISD
norms/suggested rehearses in their technique and prerequisites.

OISD has likewise distributed rules for interior and outside safety reviews. In light of these rules,
formal safety reviews of oil/gas establishments of different PSUs under Ministry of P and NG

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are directed intermittently by an outside group under the authority of OISD. Oil associations can
utilize these rules for their own particular inward reviews. OISD has likewise made a model
fiasco administration plan that can be utilized by an establishment as rules for building up its
own particular calamity/crisis administration plan.

GENERAL AND SUBJECTIVE PROVISIONS:

Certain provisions of regulatory agencies are very general and subjective in nature. This leads to
ambiguities and confusions in their interpretations by users and the inspectors. Besides it is
observed that a large number of cross references to a particular provision of the regulation are
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mentioned.

Permit to Work System

Introduction

As said earlier, most of the industrial operations are hazardous in nature which can lead to
serious accidents or mishaps if proper precautions are not taken. Many a times serious accidents
have occurred because proper precautions were not taken in preparing and handing over
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equipment for repair, inspection or modification. For example, a leaking pipeline was not
completely isolated and made hydrocarbon free. An explosion took place when a welder tried to
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weld it. An electrician was working on electrical switchgear without removing its fuses on the
supply line. He got electrocuted when someone by mistake switched on the supply. There are
numerous cases where people worked without proper isolation of equipment, cutting off
electrical supply, proper personnel protective equipment, etc. Every petroleum installation must
have an approved Permit to Work System in place. The permit is an official record of safe

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 working conditions agreed upon by the issuer and acceptor of the permit for carrying out any
maintenance, repair, inspection or modification work.

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TYPES OF PERMITS

Various permits applicable in a typical industry are listed below:

• Cold Work Permit

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• Hot Work Permit

• Confined Space Entry/Work Permit

• Excavation Permit

• Permit to Work on Electrical Equipment

• Electrical Isolation/Restoration Permit

• Permit for Closure of Roads

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Permit for using a Radioactive Source

• Permit for Working Over/Under Water

• Vehicle/Crane Entry Permit

• Permit for Photography

• Permit for Isolation of Fire Water System

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• Mine/Rock Blasting Operations

Depending upon the nature of activities, some or all of the above permits may be applicable to
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hazardous industry.

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 ELEMENTS OF A TYPICAL WORK PERMIT

Every installation should design work permit formats as per its requirement and nature of

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activities. NSC give guidelines for designing work permit formats. Some important elements a
typical work permit are as below:

• Type of permit

• Date, time of issue and validity

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• Description of location where work is to be carried o

• Brief description of the work

• Detailed safety precautions to be taken

• Name and signatures of person(s) issuing the permit

• Name and signature of the person receiving t permit

• Authorization by senior management person depending on seriousness of the hazard

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• Declaration of completion of job by the receiver with date and time.

PERMIT PROCEDURE

A work permit is generally issued by an operating supervisor called issue of the permit to the
maintenance supervisor a contractor, called the acceptor of the permit after ensuring all the
necessary precautions. The nature and location work to be done must be clearly specified in the
permit the issuer who should explain and show the same to the accepter
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• Wetting the area

• Providing standby firefighting equipment

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• Providing standby rescue team

This is not an exhaustive list and some more precautions may be necessary to meet special work
requirements. Find out what are these before issuing a permit.

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 MANAGEMENT OF PLANT CHANGES

INTRODUCTION

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Over the period of time a process industry may go for several changes/modifications to increase
capacity, reduce specific consumption of raw materials, chemicals catalysts; increase energy
efficiency; and bring in case of operation and flexibility or improve HSE performance. Many
serious accidents have occurred world over because changes were made in plants, processes

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and/or management systems without proper scrutiny and review of any unforeseen, effects. A
classical example is the famous Flixborough accident in the ICI petrochemical complex in
England. It is Imperative that every installation must have in place an approved written
procedure for undertaking changes/modifications to avoid any adverse safety repercussions. This
procedure should take into account change, temporary or permanent, that could affect integrity,
reliability, quality, health and safety of personnel or environment.

DEFINITION OF PLANT CHANGES

The following activities are considered as plant changes

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• Addition, deletion, alteration and relocation equipment, piping, instruments, material
construction, insulation, cathodic protection irrespective of its magnitude.

• Any change to the supports to equipment, piping fittings or changes to the structure, which
could. Its load carrying capabilities including changes to platforms, ladders, etc.

ACCIDENT REPORTING AND INVESTIGATION

In spite of good systems in place and people taking, precautions while doing their work,
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the possibility of, accident cannot be ruled out. It is necessary that each organization
should have a good accident reporting and investigating system in place. Many people, at
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times, tend to look at accident investigation as an exercise to collect some facts for the sole
objective of putting blame or hanging someone for his errors and omissions to set an
example. For from this, accident investigation should be a learning process to prevent
accidents and for many other purposes.

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 The magnitude of accidents sometimes makes them appear to be be yond practical
solution, but a s yst emati c investigation makes it possible to identify all the possible

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circumstances and causes leading to the accident. Like peeling the onion, it enabl es us
to look at the underlying causes of an accident, which may not be so obvious. A proper
investigation helps to identify the root cause(s) of an accident enabling the management to
take appropriate corrective action. Some of the several objectives of an accident
investigation are listed below, the rationale of each being self-explanatory:

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• Define the root cause(s) of the accident to take appropriate corrective measures

• Define management errors

• Satisfy company rules and identify violations of company; procedures

• Satisfy insurance requirements

• Prevent further accidents

• Define operating errors

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• Satisfy regulatory requirements

• Provide protection against litigation

• Comply with workers' compensation rules

The extent of training depends on the target groups. The training received by the new
employees and contractors is called the initial training, which includes comprehensive
classroom and practical training in the various HSE procedures applicable in the
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installation. Everybody working in a industry must receive at least a basic fire fighting training
before he is assigned any work. Those already working should also receive periodic HSE
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refresher training to keep them updated with any changes or developments. Third parties
like truck drivers carrying products in /out of the installation and various vendors should also be
given minimum HSE training so that they understand the basic safety rules to be followed in the
installation. Similarly, visitors should be given a safety brief before entry into the installation
so that they don't do something unknowingly that may put themselves or others into danger.

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 Many good companies issue entry passes/ID cards to those entering the premises only after they
have received the required HSE training.

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METHODOLOGY

HSE training should be a mix of theoretical classroom lectures and practical training in the
use of various fire and safety equipment and appliances. Extensive use of audio-visual aids is
used for effective training. Care should be taken to select the right language(s) to meet the

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requirement of multilingual workforce. Some companies have produced video films, which
are shown to the newcomers, especially contractors, third parties and visitors to give them basic
HSE training with minimum requirement of faculty. Training through video films can also, to
some extent, minimize the language problem.

To ensure that a candidate has understood the instructions, some validation is a must. This can be
an objective type of test at the end of the session. If a candidate has not performed satisfactorily in the
test, he should go through the session once again. Records of training and validation should be
maintained.
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Thorough investigation of an accident is an essential step toward the prevention of accidental
losses of our precious resources including the people, property and environment. A good and
systematic investigation is therefore an important HSE management tool.

The first step is to have a proper accident reporting system. In this direction, every
petroleum installation should make a standard procedure for notification and reporting of any
accident to the concerned officials of the installation and outside agencies. This procedure
should list the contact telephone numbers of key people. In case of any accident, the personnel on
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duty should inform the concerned people as per this procedure. These numbers should be displayed
at prominent locations in the installation.
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Whenever an accident takes place howsoever small, it must be investigated. Depending upon the
nature of accident, an investigation team should be set up which should go into all details-plant
data, log sheets, strip charts, historian, interviews with personnel, photographs, videos of
effected area and equipment, etc. If required, external help of a professional accident
investigator can be taken. Effects and consequence models are available which can be very helpful

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 in the investigation of process type of accidents. The team should make an honest report so
that right decisions can be taken. Many a time’s investigations done by internal teams are not very

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objective. They tend to blame only the hardware and design of the facilities. They are not
comfortable in bringing out the human factors and fixing accountability. If we have to learn from
an accident and take proper corrective actions to avoid recurrence, the investigation report must
be frank and unbiased.

There should be a system to follow up the investigation report. Management should establish a

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system to determine

and document the response to each finding of the report to ensure agreed upon actions are
completed in a time frame. The lessons learnt from the accidents should be disseminated to
all the concerned personnel in the complex. In case of multi Unit Company, the
conclusions of the investigation report should go to all the uni ts of the compan y.
In some cases, the information could also be shared with the industry.

CONTRACTORS' SAFETY
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Employers who use contractors to perform work in and around installations that involve
highly hazardous processes and chemicals have to establish a screening process so that
they hire and use only contractors who accomplish the desired job tasks without
compromising the safety and health of any employee at the installation. For contractors
whose safety performance on the job is not known to the hiring employer, the employer
must obtain necessary references and information on the safety record of the contractors.
In addition, the employer must ensure that the contractor has the required job skills,
knowledge and certifications (for pressure vessels, welding, etc.). Proper safety training to
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contract employees should be imparted.

Maintaining a site injury and illness log for contractors is another method employers must
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use to track and maintain current knowledge of activities involving contract employees
working on or adjacent to processes covered by PSM. Injury and illness logs of both the
employer's employees and contract employees allow the employer to have full knowledge of
process injury and illness experience. This log contains information useful to those

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 auditing process safety management compliance and those involved in incident
investigation.

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Contract employees must perform their work safely. Considering that contractors
often perform very specialized and potentially hazardous tasks, such as confined space entry
activities, and non-routine repair activities, their work must be controlled and properly
supervised by the employer's supervisors in addition to contractor's own supervisors.

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MECHANICAL INTEGRITY OF EQUIPMENT

Every industry must review its maintenance programmes and schedules to see if there are areas
where "breakdown" maintenance is used rather than the more preferable ongoing
mechanical integrity programme. Equipment used to process, store or handle highly hazardous
chemicals has to be designed, constructed, installed, and maintained to minimize the risk of
releases of such chemicals. This requires that a mechanical integrity programme be in place
to ensure the continued integrity of the plant.

Elements of a mechanical integrity programme include identifying and categorizing equipment

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and instrumentation; inspections and tests and their frequency; maintenance procedures; training
of maintenance personnel; criteria for acceptable test results; documentation of test and inspection
results; documentation of manufacturers' recommendations for maintenance, inspection and spare
parts.

PRE-STARTUP SAFETY REVIEW

Safety of a new installation is of special significance. Before starting up a new

installation after completing construction requires a comprehensive programme of pre-startup
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audits/ reviews. For new processes/facilities, the employer will find a PHA helpful in improving
the design and construction of the process from safety, quality and reliability point of view. The
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safe operation of the new process is enhanced by making use of the PHA recommendations before
final installation is completed. P&IDS _should be completed, the operating and safety procedures
put in place and the operating staff trained to run the installation before startup. The completed
plant and facilities are thoroughly checked by a team(s) of plant personnel against P&IDs and
specifications to ensure that the construction has been done according to these approved drawings

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 and specifications. The initial startup procedures and normal operating procedures must be fully
evaluated as part of pre-startup review to ensure a safe transfer into the normal operating mode.

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SUMMARY

This chapter discussed the HSE management framework and regulatory framework
for effective safety management. The process safety management requirements are
also discussed

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KEYWORDS

HSE framework, Regulatory requirements, PSM

REVIEW QUESTIONS

1. List out the major environmental legal legislation

2. What is the difference legal requirement and regulatory requirement?

3. What are the elements of process safety management?

FURTHER READING
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1. Process safety management, U S Department of Labour
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 UNIT II - TYPES AND SEVERITY OF ACCIDENTS

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Objectives:
After completing this unit, you will be aware of

• The definition of accident

• Accident investigation methodology

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WHAT IS AN ACCIDENT?

An unplanned and unwelcomed event which interrupts normal activity

Accidents on compound plants may risk the procedure. The staff or both research on accidents is
applicable, there fore, both to accidents which result in property harm and those which cause
individual damage.

Accident inquire about as a train tends to concern itself principally with those accidents in which
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individuals circular segment included. It is fundamentally concerned, in this manner, with damage
to work force. However, it involves the investigation of the aggregate accident circumstance.
Regularly it involves chance whether this circumstance perils the procedure or the peop1e. Plainly
accident explore is firmly identified with work in different fields, for example, human
components and, specifically, human mistake.

Much work regarding the matter is worried about zones which are not of prime enthusiasm here,
for example, accidents to kids, accidents in the home and auto collisions.
)

Notwithstanding chip away at individual accidents, it is helpful to bargain here quickly with some
chief research programs oil, and test locales for, significant dangers.
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ACCIDENT:

An undesired event that results in harm to people, property, the environment, or corporate
reputation.

21
 INCIDENT:

An undesired event that, under slightly different circumstances, could have resulted in harm to

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people, property, the environment or corporate reputation.

NEAR MISS:

An unsafe act or condition which could have led to an undesired event.

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HAZARD:

A condition or practice that has the potential for resulting in accidental loss; in other words,
anything which has the potential to harm people, the environment or property.
LOSS:

• Avoidable waste of any resource

• Unintended harm or damage that results from sub-standard acts, practices and/or substandard
conditions;
• Includes injuries, illnesses, property damage, performance interruption, quality degradation,
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environmental damage, loss of reputation and profit reduction.

RISK:

• Product of probability or chance of loss and consequence or severity.

Risk Evaluation:

Assessment of:
)

• The potential severity of loss (consequences of a loss);

• Frequency that a loss occurs (based on historical, statistical data)
• Frequency of exposure to hazard(s);
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22
 CLASSIFICATION OF ACCIDENTS

Much work on accidents is worried about accident measurements. These measurements

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are base on trouble accident order or some likeness thereof. Accident arrangements are
along these lines very critical. Except if an order contains a specific classification
which is of intrigue is no methods for recovering data on it.

There are various standard accident orders; these incorporate the grouping utilized by

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the HSE in its yearly Health and Safety Statistics, distributed in the business journal
utilized in the International Labor office. Significant Standards ar e the American
National Standard Institute (ANSI)Three basic types of accidents

1. MINOR ACCIDENTS:

Such as paper cuts to fingers or dropping a box of materials

2. MINOR ACCIDENTS:

More serious accidents that cause injury or damage to equipment or property such as a forklift
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dropping a load or someone falling off a ladder

3. ACCIDENTS THAT OCCUR OVER AN EXTENDED TIME FRAME:

Such as hearing loss or an illness resulting from exposure to chemicals

Accidents have two things in common

They all have outcomes from the accident

They all have contributory factors that cause the accident

)

OUTCOMES OF ACCIDENTS
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a. Negative aspects
▪ Death & injury
▪ Disease
▪ Damage to equipment & property
▪ Litigation costs

23
 ▪ Lost productivity
b. Positive aspects
▪

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Accident investigation
▪ Change to safety programs
Causes of Accidents

Accidents are caused mainly by:-

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* Human error - 88%

* Mechanical failures - 10%

* Other factors - 02%

Majority of the accidents are caused by:

a) The things that people do or fail to do i.e. their acts or omissions.

b) Unsafe working conditions.

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- Accidents involving electricity are very serious.

- About 1 in 30 of all electrical accidents are fatal

-Compared with about 1 in 600 of other types of accidents.

In the manufacturing industry, the major causes of accidents resulting in personal injury can be
grouped as follows:

1. Handling goods and materials - 27 %

)

2. Machinery - 17 %

3. Persons falling from a height - 15 %

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4. Persons stepping on or striking against objects -10 %

5. Falling objects -08 %

6. Transport -08 %

24
 7. Hand tools -08 %

8. Miscellaneous - 07 %

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OTHER CONTRIBUTING FACTORS

1. Environmental
▪ Noise
▪ Vapors, fumes, dust

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▪ Light
▪ Heat
▪ Critters
2. Design
▪ Workplace layout
▪ Design of tools & equipment
3. Systems & procedures
▪ Lack of systems & procedures
▪ Inappropriate systems & procedures
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4. Human behavior
▪ Common to all accidents
▪ Not limited to the person involved in the accident

ACCIDENT INVESTIGATIONS

The primary function is to determine causes of accidents & to prevent its recurrence. Therefore,
it is necessary to examine the background of an accident more carefully in order to determine
)

why unsafe conditions were created or unsafe acts performed.

The factors emerged during such an examination may include: -

(c

* Proper selection of workers:

▪ Educational / technical knowledge,

▪ Medical fitness history in relation to the proposed employment,
▪ Practical ability / experience.

25
 * Training:

To ensure

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▪ Adequate knowledge of hazards,
▪ Safe working techniques & documentation systems.
Supervision: to ensure that there is adequate supervision by properly trained & qualified
persons.

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o Correct and safe working practices are observed.
o Systems of work to ensure safe working:
o Permit to work systems.
o Safe working practices.
o Measures necessary to control hazards.
If any of these factors are missing from the background, then an accident is inevitable.

THE AIM OF THE INVESTIGATION

• Absolve individuals or management

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• Satisfy insurance requirements
• Defend a position for legal argument
• Or, to assign blame

The key result should be to prevent a recurrence of the same accident

The primary point of accident look into is to comprehend accidents with the goal that
they can be forestalled. The endeavor to comprehend an accident is regularly is
)

compared with a look for its motivation.

The idea of the reason for an accident, be that as it may, has turned out to be to some
(c

degree undermined. In accident examination an authoritative necess ity to report a

solitary reason as a rule does not do equity to the many-sided quality of the
circumstance. In accident examine there has been much feedback of work which
secludes and overemphasizes a specific factor.

26
 It is more satisfactory, in this way, to view an accident as emerging from a specific
blend of components rather hit from a solitary reason. there is along these lines a

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propensity to consider connections between factors as opposed to causes.

WHO SHOULD INVESTIGATE?

Dependent on severity of the accident

INVESTIGATION TEAM

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• Individuals involved
• Supervisor
• Safety supervisor
• Upper management
• Outside consultants
INVESTIGATION STRATEGY

▪ Gather information & establish facts

▪ Isolate essential contributory factors
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▪ Determine corrective actions
▪ Implement corrective actions
▪ Fact gathering
▪ Be impartial & objective
▪ Compile procedures & rules for the area
▪ Gather maintenance records on equipment involved
▪ Isolate accident scene
)

▪ Photos & diagrams

▪ Do not discard or destroy anything
▪ Fact gathering (continued)
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▪ Time is of the essence

27
 Obtain information

▪ Injured

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▪ Witnesses
▪ Supervisors
▪ Other personnel
Interviews (separately)

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▪ What were you doing?
▪ How do you think the accident occurred?
▪ How were you trained for the job?
▪ What is the safety procedure for this job?
▪ Obtain facts not opinions
▪ Make it clear the object of the investigation is to avoid recurrence, not to
apportion blame
▪ Evaluates all factors concerned
Isolate essential contributory factors
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Isolates the key factor(s) by asking the following question....

Would the accident have happened if this particular factor was not present?

Determine corrective actions

INVESTIGATION TEAM

▪ Interprets & draws conclusion

▪
)

Distinction between intermediate & underlying causes

▪ Interprets & draws conclusion
▪ Distinction between intermediate & underlying causes
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▪ Recommendations based on key contributory factors and underlying causes

▪ Recommendations based on key contributory factors and underlying causes
▪ Recommendation(s) must be communicated clearly
▪ Strict time table established
▪ Follow up conducted

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 BENEFITS OF ACCIDENT INVESTIGATION

▪ Preventing recurrence

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▪ Identifying out-molded procedures
▪ Improvements to work environment
▪ Increased productivity
▪ Improvement of operational & safety procedures
▪ Raises safety awareness level

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When an organization reacts swiftly and positively to accidents and injuries, its actions
reaffirm its commitment to the safety and well-being of its employees

COST OF ACCIDENTS

The cost of accidents remains unacceptably high both in human and in financial terms.

▪ Time lost by absenteeism from work due to injury &

▪ Sickness is more than strikes or other industrial disputes.
The cost of an accident can be measured in both financial & human terms. An accident, which is
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apparently minor, can have a major impact on both the company & the victim, when all related
factors are considered.

A) HUMAN ASPECTS – COSTS TO THE VICTIM INCLUDE :-

* Mental strain.

* Suffering.

* Loss of earnings.
)

* Extra expenditure.

* Possibility of a continuing disability.

(c

* Incapacity for some kinds of work.

* Loss of leisure activities.

* Effect on family, friends and colleagues.

29
 FINANCIAL ASPECTS – COSTS TO THE COMPANY INCLUDE :-

* Loss of skilled and experienced workers.

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* Loss of production.

* Loss of profit from injured workers.

* Expense of re-training injured worker or a replacement.

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* Time lost by the effect on other workers.

* Increased insurance premiums.

COSTS TO THE NATION INCLUDE:

* The burden on welfare benefits and other social services provided by government.

* The expense / burden on medical or health services and facilities.

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REASONS OF ACCIDENTS

There are many reasons of accidents. Some of the common reasons are:-

* Lack of knowledge.

* Careless attitudes.

* Horseplay.
)

* Working without authority.

* Lack of ability.
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* Poor tools and equipment.

* Taking short cuts.

Any and all of these reasons have been the cause of many serious accidents.

30
 Analysis of the accident will often reveal that one or more of these factors were present in an
accident.

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RESPONSIBILITY OF MANAGEMENT

Therefore, the management of a company has a responsibility both moral and legal to ensure:

1. A safe place to work. This will include safe means of access and egress during normal
daily work routine as well as in emergencies.

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2. Safe plant and equipment including the maintenance of it.
3. Safe systems of work, including safe working practices and work permits for hazardous
jobs.
4. A safe working environment and adequate arrangements for employee welfare. This
responsibility encompasses many factors including lighting, heating, ventilation, fume
and dust extraction, housekeeping, seating, drinking water, sanitary facilities etc.
5. Safe methods for storing, handling and transportation of goods and substances.
6. Provision of such information, instruction, training and supervision as necessary to
ensure efficient and safe working, compliance with statutory legislation and company
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rules.
7. Consultation with employees, or their representatives, with a view to making and
maintaining adequate and effective arrangements for health, safety and welfare.
8. A written statement with respect to the health, safety and welfare of the employees is
produced, published and revised as often as necessary. Such a statement should be
brought to the notice of the employees, kept up to date and monitored for its
effectiveness. It should contain details of the procedures which will put the policy into
)

effect and define individual responsibilities for safety.

SUMMARY
(c

This chapter discussed the accidents types of accidents, cost of accidental and accident
investigation methodologies. Prompt and positive response is required for effective accident
investigation.

31
 KEYWORDS

Accident, Cost of accident, Accident investigation

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REVIEW QUESTIONS

1. Define accident

2. What is the difference between accident and incident?

3. How you will interview the witness

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4. Explain the cost of accident

FURTHER READING

1. Accident investigation techniques 2nd Edition American Society of Safety Professionals

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32
 UNIT III - SAFETY POLICY, ORGANIZATION, MONITORING AND
REPORTING

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Objectives:
After completing this unit, you will be aware of

• HSE policy

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• Safety and other procedures in industries

INTRODUCTION:

The scope and limitations of various regulations on health, safety and environment have been
discussed in the previous unit. As said already, regulations alone are not enough to maintain a
very high level of safety in petroleum and allied industries, which have many inherent hazards.
In order to prevent major accidents and mishaps and to win confidence of general public,
management leadership and commitment is very essential. Even for implementing and
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compliance of regulatory measures, a committed leadership is necessary. This can be achieved
by establishing an effective and efficient Health, Safety and Environment (HSE) Management
System. This unit covers the planning, organizing, implementing and controlling functions and
outlines the policy, systems and procedures of an effective HSE management in a typical
petroleum installation.

HSE MANAGEMENT PROFILE

There are certain characteristics of an integrated HSE management system that should be in
)

place to ensure that the system functions most efficiently and effectively. These characteristics
are sufficiently generic to apply to any type of installation. Not all characteristics or features may
(c

be needed in every installation; however, these have particular value as a profile of the principal
requirements of an effective HSE management system that can be adopted to suit the particular
needs of the installation. Some important features of an effective and efficient HSE management
system are discussed below.

33
 HSE POLICY

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Each association must have a composed policy on health, safety and condition marked by the
Head of the association with date. The duplicates of this policy ought to be shown at
unmistakable places in the association, so everyone knows about its substance/aims. A few
associations guarantee that each worker gets a duplicate of its HSE policy. HSE policy spells out

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the values, beliefs and commitment of the organization towards health, safety of its employees,
community and at the macro level of the nation. HSE policy of a large company is given below
as a typical example, which can be suitably modified to meet specific requirements.

• Health and safety of personnel and protection of environment overrides all production targets in
our organization

• Production and HSE are complementary to each other

• Safety and environment protection is everybody's business in the organization

• All statutory requirements must be complied with at all times

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• All personnel must use approved safe working procedures without making any risky short cuts

• All personnel-own or contractors-must be given relevant training before assigning them work

• All plants, facilities and work procedures/ systems must be audited periodically by in-house
teams as well as external agencies

• Plant and ambient environment as well as various effluents must be monitored continuously to
)

maintain a clean and safe environment in and around the plants

• A very high standard of housekeeping must be maintained at all places of work-plants, offices
(c

and facilities

• Every employee must be subjected to a pre-employment, periodic and any specific medical
check-up for early identification and treatment of any occupational health hazard

34
 • All employees must keep abreast with the latest codes, standards and practices on health, safety
and environment

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• All accidents, however small, must be investigated and followed up. The lessons learnt from
these accidents should be disseminated to all levels of workforce.

• No modifications in plant, facilities or procedures will be done without proper scrutiny and
approval by an authorized person(s)

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• No contractor will be engaged without ascertaining his safety performance/record

• Non-compliance of this policy will attract severe disciplinary action

HSE ORGANIZATION

In order for the HSE management of an organization to be efficient and effective, it is important
that the Chief of HSE should report to the Head of the organization. HSE should

be an advisory function reporting to the top management and the various line managers should
be directly responsible for Health, Safety and Environment activities pertaining to their
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respective departments. If HSE Chief occupies a junior position in the organizational hierarchy,
he cannot work without fear or clash of interest with other functional managers. He should have
authority and important say in the decision making process. Even some regulatory agencies also
recommend HSE Chief reporting directly to the Head of the organization. HSE Chief should be a
qualified engineer with long experience in various functions. He should have a team of qualified
professionals to advise on safety, occupational health, fire protection and environment. The
number of professionals in HSE will depend on the size and diversity of the organization, but it
)

is recommended to have a leaner set-up. HSE organization should be fully integrated with
various safety and health committees.
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CUSTODIANSHIP/OWNERSHIP

Health, Safety and Environmental management are teamwork. Every member of the team
contributes in maintaining a high level of safety in his area of work. In order to manage HSE
effectively in a petroleum installation or complex which is usually a large entity it is important
and desirable to demarcate each area of the installation/complex and assign the

35
 ownership/custodianship to a senior member of the concerned area. These areas are commonly
called safety districts. A big industrial complex may have 10-15 safety districts. These districts

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should be shown on the layout drawing of the complex with all the boundaries clearly identified
and marked. The objective of safety districts is to decentralize the HSE responsibility to the
functional owner/ custodian of the area who is fully responsible and accountable for all
management functions in his district with specific reference to control/management of health,
safety and environment. HSE department acts as a catalyst.

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PLANS AND PROCEDURES

Plans and procedures is the heart of a good HSE management system. They are the basis of
setting up an effective and efficient management system. A large number of industrial accidents
and mishaps have occurred all over the world due to human errors and the main cause of these
errors has been the lack of written procedures and/or non-compliance of the same. In some cases,
courts have penalized the organizations because victims of the accident did not have written
procedures to be followed by them.

It is essential that well-written and approved operating and safety procedures of all important
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activities/functions performed in any industrial installation are in place and the same are strictly
followed. No short cuts to these procedures should be allowed. The various HSE related
procedures should be developed broadly based on Process Safety Management System, PSM,
which is a well-known framework of HSE management all over the world. All these procedures
should be compiled in the form of an HSE manual-many times called the HSE bible. The various
procedures documented should address the following main elements of PSM:

• Process Technology Information

)

• Process Hazard Analysis

• Operating Procedures
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• Work Permit System

• Management of Change

• Training and Validation

• Contractor Safety

36
 • Incident Investigation and Communication

• Safety and Environment Auditing

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• Quality Assurance

• Mechanical Integrity

• Pre Start-up Safety Reviews

• Emergency Planning and Response

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Following is a broad list of typical procedures on health, safety, and fire protection and
environment functions applicable for most industrial operations. The procedures relevant to a
particular installation should be identified and documented clearly in simple language so that
everybody working in the installation understands these. These procedures should also be
accessible to all concerned. The procedures should be revised and updated periodically to reflect
changes that might have taken place over time.

Safety Related Procedures

• Basic safety rules for employees, contractors and visitors

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• Safe work permit system
• Mechanical isolation
• Pre-start up safety review
• Entering and working in confined spaces
• Working at height
• Safe scaffolding and ladders
• Safe evacuation
)

• Safe handling of hazardous substances

• Safe handling of hydrogen sulfide, chlorine, ammonia etc.
•
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Safe uses of hoses

• Contactor safety
• Ionization radiation safety
• Traffic safety inside and outside the installation
• Safe use of cranes, hoists and other mechanical devices

37
 • Safety in manual handling of material
• Accident/ incident reporting and investigation
•

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Selection and safe use of personnel protective equipment
• Safe transportation of hazardous materials by road, water and rail
• Management of plant changes and procedures
• Safety audits
• Personnel movement and transportation by road, cranes, basket, boats and helicopters

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• Grinding, welding and cutting
• Safety signage’s labeling and posters
• Onsite emergency and disaster management.

ENVIRONMENT RELATED PROCEDURES

• Air Pollution Control and Monitoring

• Effluent Monitoring

• Industrial Wastes Management

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• Biodegradable and Office Wastes Management

• Fugitive Emission Monitoring

• Ground Water Monitoring

•Environment Inspection and Audit

OCCUPATIONAL HEALTH RELATED PROCEDURES

)

• Occupational health center

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• First-aid

• Health Risk Assessment

• Pre-employment and periodical Medical Checks

38
 • Emergency Medical Care

SAFETY PROCEDURES

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• Basic Safety Rules for Employees, Contractors and Visitors

• Safe Work Permit System

• Mechanical Isolation

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• Pre Start-up Safety Review

• Entering and Working in Confined Spaces

• Working at Height

• Safe Scaffolding and Ladders

• Safe Excavation

• Safe Handling of Hazardous Substances

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• Safe Handling of Hydrogen Sulfide, Chlorine, Ammonia, etc.

• Safe Use of Hoses

• Contractor Safety

• Ionization Radiation Safety

• Traffic Safety Inside and Outside the Installation

)

• Safe Use of Cranes, Hoists and other Mechanical Devices

• Safety in Manual Handling of Material

(c

• Accident /Incident Reporting and Investigation

• Selection and Safe Use of Personal Protective Equipment, PPE

39
 • Health, Safety and Environmental (HSE) Challenges

FIRE PROTECTION RELATED PROCEDURES

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• Fire Services Organization and Job Specifications

• Fire and Emergency Turnouts

• Rescue Operations

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• Mutual Aid Scheme

• Inspection and Maintenance of Fire Protection Systems

• Emergency Drills and Fire Training

• Safe Use of Self Contained Breathing Apparatus and 'c

Other Life Saving Devices

BASIC SAFETY RULES

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Because of inherent hazards in a industrial installation, it is absolutely necessary that all
employees, contractors, visitors, vendors and other third parties must be fully aware of some
basic safety requirements to be followed inside the 'A installation. Management should document
these basic rules/., requirements and anybody entering the premises must be made familiar with
the same. This document should address following items related to the health, safety and
environment aspects of the installation:

• Access/entry to the premises

)

• Restriction on naked lights, sparks, use of cameras and mobile phones

• Prohibition of smoking, alcohol and drugs

(c

• Traffic control

• Use of Personnel Protective Equipment, PPE

• Safe Work Permit System

40
 • Accident/Incident reporting

• Maintaining good house keeping standard

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• Basic color codes of piping/equipment, etc.

• Safety signage's

• Electrical safety

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• Access/Entry to the premises

• Prohibition of smoking, alcohol and drugs

• Hazards of flammable products and chemicals

• Emergency alarms and communication and what to do in such situations

• Some general dos and don'ts

• Other specific rules

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BASIC RULES FOR VISITORS

As a bare minimum requirement, every visitor to the premises must be given a safety briefing
before giving him an entry pass. As an illustration, a safety briefing developed by petroleum
refinery is given below. Every installation should make a similar briefing relevant to its
operations and local conditions.

ACCESS /ENTRY TO THE PREMISES

)

• Visitors should report to security gate for entry pass

• Every person must. display a valid identification badge issued by the security
(c

• Visitor should visit the designated area only for which he has obtained the entry pass

• He should be accompanied by a company employee

• It is forbidden to take children inside the premises

41
 TOBACCO /ALCOHOL RESTRICTIONS

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• The entire.-refinery is a tobacco free zone

• Tobacco in any form-cigarettes, biddies, gutka, etc. , is prohibited

• Use of alcohol and drugs is prohibited

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REGULATIONS ON NAKED LIGHTS AND SPARKS

• Matchboxes, lighters, flashlights and cameras are not allowed inside the premises

• Only intrinsically safe mobile phones are allow inside

• No shoes with nails in the soles to be worn inside premises

• Use of 100% nylon or synthetic clothes inside t1 premises is prohibited

TRAFFIC RULES

• Vehicles should have valid access pass to enter the premises

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• All vehicles entering hazardous areas should have spark arrestor and a unit entry permit

• Maximum speed limit inside the premises is 30 km/hr

• Park the vehicle at designated places

• Overtaking is prohibited

• In case of an emergency alarm, stop the vehicle and take to the side of the road and wait for
)

clearance.

GENERAL
(c

• Visitor shall be responsible for his own safety

• Photography inside is prohibited

• Never go to the site in case of any fire or other emergency

42
 • Visitor is not allowed to touch any equipment interfere with the plant activities

• All persons must wear safety helmets and safe shoes in process areas. Requirement of any

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other personal protective equipment will be advised by plant personnel

SUMMARY

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This chapter discussed the significance and requirements of safety policy and
various procedural requirements for effective safety management. The basic safety
rules are also discussed.

KEYWORDS

Safety policy, Safety procedures

REVIEW QUESTIONS

1. What are the significance and requirements of safety policy

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2. What is are the minimum environmental procedures in factories ?

FURTHER READING

1. Occupational Safety and Health Guidance Manual for Hazardous Waste site Activities U
S Department of Health and Human Services.
)
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43
 UNIT IV - PROCESS SAFETY MANAGEMENT

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Objectives:

After completing this unit, you will be aware of Process Safety Management

• Elements of PSM

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• workplace

INTRODUCTION

Process Safety Management is a control, proclaimed by the U.S. OSHA, proposed to

keep a debacle like the 1984 Bhopal Disaster. "Startling arrivals of lethal, receptive, or
combustible fluids and gases in forms including very unsafe synthetic compounds have been
accounted for a long time. Occurrences keep on occurring in different ventures that utilization
very unsafe synthetic substances which might be dangerous, responsive, combustible, or
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unstable, or may display a blend of these properties. Despite the business that uses these
profoundly dangerous synthetic compounds, there is a potential for an unplanned discharge
whenever they are not legitimately controlled. This, thus, makes the likelihood of catastrophe. To
help guarantee protected and healthful working environments, OSHA has issued the Process
Safety Management of Highly Hazardous Chemicals controls.

Just as Process safety is a line management, responsibility, the same can be said
of risk management. To be able to manage this risk a coordinated program needs to be
)

established that will assists the line manager in his duties. This program, process safety
management, includes the following:

❖ Process documentation
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❖ Operating Procedure
❖ Training
❖ Incidents Investigation
❖ Hazard Identification

44
 ❖ Risk Assessment
❖ Preventive Maintenance
❖ Management of Change

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❖ Safety Reviews
The first thing the manager must do is establish an organization to coordinate the activities of the
program. This organization must prepare standards defining the local program. The content, as
determined by the organization, must be based on the special characteristics of the process

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including complexity, batch or continuous, and process condition.

PROCESS DOCUMENTATION

Requirements to consider for the process documentation section include:

❖ Process Transmittal
❖ Engineering Calculation
❖ Flow Sheets
❖ P and ID’s
❖ HAZOP’S
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❖ ORR’s
❖ Reaction grids
Usually these items are generated at some point during the evolution of a process but often are
not stored in an organized way so that when they are needed they are not available.

The process transmittal is the information generated in the research and process development.
The chemistry, side reaction, corrosion testing, process development, and reaction kinetics all are
part of a process transmittal.
)

Engineering calculation includes reactor sizing, agitation requirements, line sizing, heat transfer
area, and other design criteria.
(c

Flow sheets and P& ID’s are the engineering diagrams generated by the design engineers. Part of
the program must be to keep these drawing up-to-date.

HAZOP’s are the hazard identification reviews made during the design phase and subsequently
on approximately three year intervals.

45
 The updating of the drawing is important to conducting a comprehensive HAZOP.

An ORR is an operational readiness Reviews which is the last look at a process before start-up.

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ORR type reviews should also be done at regular intervals during the life of the process this
again assures that the process is being run correctly.

Reaction grids are a matrix of all the chemicals used in the process and their interaction. They
are developed as part of the HAZOP to answer the question of changing errors.

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These items, along with data generated from other parts of the program, make up the process
documentation file that must be maintained to assure a safe chemical process.

OPERATING PROCEDURES

Comprehensive written procedures serve as the basis for effective training and as a resource for
the operator. They must be kept current or their usefulness is diminished. Procedures should be
written for any job, routine or infrequent, which requires specific skills or knowledge, which, if
not followed, could result in an hazard. Procedures should be explicit and continuous- that is, the
operator response should be specified for each perceived condition or combination of conditions.
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Specifically, the following steps should be covered:

❖ Safety and health consideration

❖ Start up
❖ Normal operations
❖ Normal shutdown
❖ Abnormal operations
❖ Emergency shutdown
)

And should include :

❖ Simplified process flow sheets

(c

❖ Process description defining the operation and indicating flows, temperature, and
pressure
❖ Description of abnormal or emergency condition including operator responses and
recovery steps

46
 ❖ Pre start-up activities including checklist to assure readiness
❖ Start –up sequences
❖ Shutdown procedures, both normal and emergency

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❖ Post shutdown activities including storage of materials in equipment and clean-
out methods
❖ description of critical equipment such as pressure relief devices, interlocks, and
alarms, with the activation level of each

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❖ Sampling procedures including sampling methodology, analytical procedures, and
sampling schedules
❖ Maintenance preparation and inspection activities including relevant checklists to
assure completeness
❖ MSDS sheets for all raw materials, finished products, and isolated intermediates
❖ Personal protective equipment requirements
❖ Symptoms of and first aid treatment for chemical exposures
❖ Utility failure procedures
A method for upgrading operating procedures should be developed as part of the
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management of change. Otherwise they should be reviewed at least every two years to
assure that current practices are reflected.

TRAINING PROGRAMME

A formal training program must be developed to assure safe operation. All personal involved,
including management and engineers should participate in the training program.

Included in the program are the following:

)

❖ A written job description which details the duties, responsibilities, education,

experience, and qualifications of each position.
❖ Methods to determine whether an operator has developed the ability to perform
(c

the duties of the job.

❖ A schedule for completing each segment of the program.
❖ Documentation of the training.
❖ Qualification and validation of instructors.

47
 The training should contain, as a minimum, the following elements.

❖ Site orientation including rules, practices, and safety and emergency procedures.

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❖ Classroom training which includes unit specific safety procedures, operating
procedure, MSDS’s, safe material handling practices, unit hazards, and
emergency procedures relating to process fires, explosions, or leaks.
❖ On the job training including equipment familiarization; data collection and
recording; and process start-up, operation, control, and shutdown.

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❖ Annual refresher training that includes review of MSDS’s, incidents, procedural
and equipment changes, and safety procedures.
INCIDENT INVESTIGATION

All incidents which resulted in or could have resulted in a release of toxic or flammable materials
should be investigated by a trained investigation team as soon as possible after the incident.
Additionally, all relief device release should be investigated.

The incident should be investigated timely to reduce the possibility that information or evidence
will be destroyed, altered, or forgotten during clean-up or mitigation efforts.
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The incident report must be prepared for each incident and shall include;

❖ Location
❖ Date and time
❖ Investigation team member
❖ Equipment involved
❖ Quantity of chemicals released
❖ Employees involved
)

❖ Comprehensive description of the incident

❖ Consequences of the release
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❖ Incident facts
❖ Cause of the incident, basic and contributory, direct or indirect
❖ Corrective actions to prevent recurrence
❖ Implementation schedule for corrective actions including those responsible for
completion

48
 Follow up should be done systematically to assure that all recommendations are addressed.
Distribution of the report should include all other plants that have similar operations and should

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be reviewed with all personal involved both operation and maintenance.

Incident investigations should become part of the process documentation file.

HAZARD IDENTIFICATION

Identification, evaluation and control of hazards in processes are essential to loss prevention and

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require a comprehensive knowledge of the chemical and physical aspects of the unit being
studied. Unrecognized hazards have been created in existing process by changes in process
conditions, operating practices, or equipment; inadequate knowledge of reactions; or behavior of
materials of construction.

An accurate assessment of the potential of each identified hazard will assure that releases of
hazardous materials and the resulting injuries and property loss will be minimized. Sound
engineering knowledge must be applied to formulate corrective measures.

These hazard identification activities can be accomplished by trained plant personal working
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with outside specialists where required. It is their responsibility to study the P&ID’s or the
production unit thoroughly, identifying all the potential hazards, and recommending changes or
reviews to eliminate or control the identified hazards.

An organized approach is essential to effective and efficient process hazard reviews. The
HAZOP, qualitative fault tree, event tree, or failure modes and effects methodology all meet this
systematic requirement.
)

A written report of the hazard identification should be issued. Included should be:

❖ Participants
❖ Methodology
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❖ List of documents such as P&ID numbers and issue

❖ Summary of the findings
❖ Recommendations for further study
Follow up should be done until all items of concern are addressed through periodic starts reports.

49
 All hazard identification reports, status reports, and documentation should become part of the
process documentation file.

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All process should be re-reviewed every two to four years based on the hazards of the process.

RISK ASSESMENT

A risk assessment should be conducted whenever a potential release can result in a toxic or
flammable release that can affect the neighbors.

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A risk assessment consists of:

❖ An estimate of the potential release quantity

❖ A quantitative evaluation of the frequency of the event
❖ A dispersion model of the release
❖ Consequence analysis of the effects of the toxic or flammable release both on and off
site
❖ The consequences should be evaluated based on the frequency to determine if the risk
is acceptable. If is not acceptable, then recommendation must be made to decrease the
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frequency or the consequences. The consequences may be lowered by reducing the
amount released, the resulting dispersion, or by mitigation methods. The frequency
can be affected by redundant equipment or by increasing reliability.
Risk assessment should be performed by trained, experienced personal.

Again, a follow-up system to report the status of recommendations is needed.

The risk assessment, recommendation, and status reports shall be part of the process
)

documentation.

PRENTIVE MAINTENANCE
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A comprehensive preemptive maintenance program is a necessary part of a total process safety

management system. The program should include;

❖ Identification of all equipment requiring preventive maintenance.

50
 ❖ Schedules for the inspections of vessels. These schedules should be based on
corrosion rates calculated from inspection history.
❖ Proof-testing of critical equipment such as pressure relief devices, interlocks, fire

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pumps, emergency generators, and alarms. Test methods, completion checklists, and
inspection intervals are required for this program.
❖ Quality control procedures to ensure that fasteners, valves, and replacement parts
meet quality specification.

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Any documentation of the PM program shall be part of the process documentation file.

MANAGEMENT OF CHANGE

A procedure for handling changes of process or equipment should be developed. Included in the
procedure should be:

❖ An adequate review by all concerned personnel

❖ Documentation of the technical basis for the change
❖ Authorization by appropriate management
❖ Communication of the changes and training personal in the details and consequences
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of the change.
❖ Updating of drawings and operating procedures
For temporary changes a system should be developed to track these changes and, to then, revert
to the original condition. If made permanent, the management of change should be used.

All changes should become part of the process documentation file.

SAFETY REVIWES
)

Two types of reviews should be part of a Process safety Management Program. The first is the
operational readiness review (ORR) which is conducted on all new processes. Recommendations
(c

resulting from the ORR must be addressed by plant management before the introduction of
chemicals.

The second type, operating plant survey (OPS) is conducted on existing processes. The OPS
includes:

51
 ❖ Comparisons of the process documentation file to verify that plant practices match the
information.
❖ A review of current operations versus company, regulatory, or accepted industry

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practices.
All reviews also become part of the documentation file.

These are the nine elements of a comprehensive Process safety Management Program that will
provide a system to ensure an operation that will be safe and efficient.

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HEALTH, SAFETY & ENVIRONMENTAL AUDIT

Statistics show that the root cause of many major accidents and mishaps all over the world
is human error. And the main cause of human errors has been the lack of written
procedures and/or non-compliance of the same. New plant facilities get normalized over a
period after meeting the initial challenges of commissioning and stabilization.
Thereafter people tend to start relaxing and the systems) procedures/facilities are not
followed as in the earlier times. Many a times systems/procedures are not followed, and
hardware is not maintained, inspected and tested as intended. Sometimes they are
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bypassed because of negligence, over-confidence and complacency. Various health,
safety and environment programmes including their management systems require thorough
auditing to exercise proper control and ensure that the systems are working effectively.
Such audits are conducted periodically on the systems, procedures and operational
aspects to ensure that a desired level of health, safety and environmental standards are
maintained as per the requirements of company policy and statutory requirements.
A brief discussion on the objectives, methodology and procedures of conducting such audits
)

is given below as guidelines based on which each organisation should develop its own audit
programme.
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 OBJECTIVES OF AUDITS

Major objectives of audits are:

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• Ensure that all statutory requirements are met fully.

• Ensure that set procedures are complete, up to date and compliant with
applicable standards, codes, company policies, good engineering and process safety
practices.

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• Ensure that the management systems in place are effective.

• procedures can be strengthened.

• Identi f y opp ortunities where the s ystems

o ensure that set procedures are complete, up to date and compliant with
applicable standards, codes, company policies, good engineering and
process safety practices.

o ensure that the management systems in place are effective.

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• Identify opportunities where the systems and procedure can be strengthened

TYPES OF AUDITS

HSE audits are broadly categorized as internal audits or external audits.

INTERNAL AUDITS

Internal audits can be periodic detailed audits of one or more plants/facilities of an installation
)

conducted by a multi-disciplinary team drawn from various departments of the installation. In a

company having more than one site, inter-site audits by combined teams drawn from various
(c

sites can also be a good method of conducting internal audits. An internal audit may take 3-4 days
by a team of 4-5 professionals from different disciplines. The audit team reviews the systems,
procedures and facilities for complete and updated documentation and their compliance. Each
plant/facility of an installation should be audited every two to three years.

53
 Besides detail or comprehensive internal audits, there are mini audits. A mini safety audit is of
short duration (typically 2-3 hours) conducted by a two-men team using checklists to ensure the

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compliance of a particular procedure at a time. Such audits are done more frequently to cover
various procedures relevant to the installation. This is a very useful and quick method of finding
the weaknesses/ deficiencies in the system. _

Another type of internal audits is called BSC audits. These are self-audits based on British Safety
Council's standard checklists. Each plant/department maintains these checklists for various

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systems pertaining to its activities.

EXTERNAL AUDITS

The external audits are done by outside or third parties approved by statutory authorities to meet
the requirements under various statuary rules and regulations.

In leading companies, external audits are done not only to meet statutory requirements
but also to bring in a fresh approach and additional objectivity through a third eye. It
must be understood that external audits are supplementary to the internal audits. External
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audits are generally mot global covering the entire premises/installation. Some typical
external audit agencies approved by various statutory, authorities include

• OISD
• British Safety Council (5-star audit)
• National Environmental Engineering Research' Institute, NEERI
• Central Labor Research Institute, CLRI
• Loss Prevention Association, LPA
• National Safety Council, NSC
• Engineers India Limited, EIL
•
)

Lloyds Register of Shipping

• Det Norske Veritas
• Comet Consultancy Services
• Netal Chromatographs
(c

• SGS India Limited

• Others as approved from case to case.

54
 METHODOLOGY OF AUDITS

Though each external audit agency might have its o wn methodology and approach to

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conduct an audit, a common methodology for conducting internal audits is given below:

COMPOSITION/SELECTION OF AUDIT TEAM

The team for a comprehensive internal audit comprise member each from operation,
engineering/maintenance technical services/technology, HSE and any other specific

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discipline if required. The chief of the installation through an office order nominates the
team.

The Chief of HSE nominates the team for a mini audit in consultation with individual
departments. The team comprises of two members-one from the area/department to be
audited and the other from HSE. The programme of such audits is published by HSE
through procedures audit schedule published by him every month.

CONDUCTING THE AUDIT

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To start with, the team gets organized and holds a kick-off meeting to discuss the plan of
action. They try to collect all relevant data of the area/plant/department they are going to
audit. The team visits the area and talks to various personnel there to get feedback
about their plant/area. The team checks the various systems/procedures and records. The
safety aspects of the plant are checked using checklists. These checklists could be standard
lists made as part of a written audit procedure and supplemented by specific checklists
made for special systems/equipment by each team before starting the audit. Checklists are
very useful as they save a lot of time and also to ensure that all aspects or sub-systems have
)

been looked into and not missed inadvertently.

In case of mini audits, the two-man team goes to the area where audit is to be done. The
(c

team ensures the compliance of the procedure under audit by using a standard checklist
made for the particular procedure (see some sample checklists in Appendix-2). They
check the level of compliance to each checklist item by talking to the plant personnel and
seeing the situation in the field and rate the item on a 1-5 scale (1 is least compliant, 5
full compliance). The overall compliance level is indicated in percentage.

55
 AUDIT REPORT

After completing an audit, the team prepares a draft report which is presented to the custodian/

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manager of the area and his team. After discussion, the final report with action plan for
implementing the agreed recommendations is issued by the leader of the audit team to the
concerned action parties with copies to top management team.

In case of mini audits, the audited checklist is itself the report. This is issued to the

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concerned custodian/manager of the area immediately on the same day after the audit is
done.

FOLLOW-UP

The effectiveness of the audit lies in the degree o implementation of the agreed
recommendation. Therefore it is essential to monitor the implementation programme HSE
plays a pivotal role in monitoring the recommendation; of various audits and presenting the
implementation statutory to the top management. Record of an audit report is
maintained with the custodian and HSE till all the recommendations agreed to be
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implemented are liquidated

SUMMARY

This chapter discussed the significance and requirements of process safety

management as per OSHA requirements. The 14 elements of OSHA PSM were
discussed.

KEYWORDS
)

Process Safety Management

REVIEW QUESTIONS
(c

1. What is process safety management?

2. What are the elements of OSHA PSM ?

FURTHER READING

1. Process safety management, U S Department of Labour

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 UNIT V - EMERGENCY/ DISASTER MANAGEMENT PLAN

Objectives:

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After completing this unit, you will be aware of

• The definition disaster

• Emergency management plan

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INTRODUCTION

Disasters are real mischances which cause broad interruption of human and business
exercises. Ordinarily, normal mishaps are consumed by the network, yet disasters are real
mischances and network can't retain them with their own particular assets. The greater part
of the disasters, normal or mechanical (man made) have sudden beginning and give short
notice or not thing to keep the event. Disasters may cause loss of human life, wounds and
long haul disablement of individuals working in the association and nearby network around
the mechanical territory. Regularly, loss of lives, aggregate or fractional ina bility have
more effect on the network than harm to the properties. Harm to the property has a long
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haul social effect like loss of income, business and revamping cost and prompt separate
monetary limitations.

The probability of disaster require be predicted, as the past encounters show. In this
manner, if disasters are predictable, the relieving endeavors can be arranged ahead of time.
Fundamental in significance ought to be given to secure human life and condition, in such
arranging.
)

In spite of hazardous industries are following sound design, engineering and management
practices, the possibility of a major accident or disaster cannot be ruled out. The threat of a
major fire, explosion, toxic release or natural disasters involving employees, property,
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public and environment is always there. When an emergency situation like this
develops, it is necessary that a concise and well -written emergency plan should be in
place in every installation which can be put into action without loss of any time. Most of the
emergency situations can be controlled by careful evaluation of the anticipated possible

57
 events and evolving a plan to meet such situations and organize suitable drills or rehearsals
for effective implementation at the time of emergency.

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DEFNITION OF EMERGENCY:

The sort of emergency fundamentally thought to be here is the significant emergency which
might be characterized one which can possibly make genuine threat people and/or harm to
property and which tends to cause disturbance inside and/or outside the site and may require the

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utilization of outside assets.

Emergency is a general term suggesting unsafe circumstance both inside and outside the
production line premises. In this way the crises named "nearby" when it keeps itself to the
production line despite the fact that it might need outer support and "off-site" when emergency
reaches out past its premises. It is to be comprehended here, that if an emergency happens inside
the plant and couldn't be controlled, it might prompt an off - site emergency

EMERGENCY PLANNING:

A major emergency in a works is one which has the potential to cause serious injury or loss
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of life.

• May cause serious disruptions both inside or outside the works

A major emergency can develop due to failure of operating and containment systems or due
to natural disasters like cyclones, earthquakes, floods, lightning, etc. In case of natural disasters,
not much can be done to avoid their occurrences, but a good disaster/emergency plan can
minimize the casualties and damages by well conceived evacuation, rehabilitation and
clean-up programmes.
)

ACTIVITIES THAT CAN REDUCE THE RISK OF ACCIDENTS:

• Good Design
(c

• Good Operation
• Good Maintenance
• Good Inspection

58
 BASIC OF MAJOR EMERGENCY MANAGEMENT PLAN

A major emergency plan also called On-site Emergency Plan or a Disaster Management Plan

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is a master plan containing the emergency response, responsibilities of key members,
communication means and response strategies to control a range of major incidents. The word
"disaster" refers to those emergency situations where the number of casualties is very large
like in natural calamities. However, the term is used quite broadly for any major emergency.
This plan is drafted after a careful analysis and assessment of various risks associated with

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the installations. The plan should also follow the provisions of Section 41-B of the Factories
Act, 1948 and the guidelines from the Chief Inspector of Factories of the state. OISD also
gives guidelines for developing an emergency plan.

The civic authorities of the area usually prepare disaster plans for emergency situations
outside the premises. The management of the installation should give full cooperation to the
civic authorities in preparing what is called as Off-site Emergency Plan. This is of
importance especially in case of emergencies arising during transportation of
petroleum and other hazardous products from/to an installation.
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OBJECTIVES OF EMERGENCY PLAN

The overall objectives of a major emergency management plan are summarized as below:

To localize the emergency and if possible eliminate it or to minimize the effect of accident on
people and property.

• To contain and control emergency incidents.

• To prevent loss of life and minimize the risk of bodily injuries to employees and
)

neighboring population.

• To minimize damage to company installation and public property.

(c

• To minimize impact on environment.

• To provide maximum possible safety to the emergency response personnel.

59
 • To inform employees, public, and authorities about the risks assessed, safeguards
provided and role of the organization.

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• To dovetail properly with the off-site plan of the local authorities.

• To seek help from the company's corporate office, sister companies and outside
agencies.

EMERGENCY/DISASTER SCENARIOS

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Every petroleum installation should identify the possible major emergency situations for
which a disaster plan has to be made. A list of probable emergency scenarios applicable to
petroleum installations is given below:

• Fire

• Explosion

• Toxic Release

•
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Blow-out

• Drowning

• Oil spill on water

• Oil spill on land

• Cyclone/Storm

•
)

Earthquake

• Flood
(c

• Air raid

• Product/Transport emergency

60
 CATEGORIZATION OF EMERGENCIES

As a general practice, emergency situations are categorized into three levels depending upon

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their magnitude and consequences. These levels are:

LEVEL-1

The emergency situation arising in any section of one particular plant/area which is minor
in nature and can be controlled within the affected section itself with the help of in-house shift

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staff. Such an emergency does not have the potential to cause serious injuries or damage to
property, environment and the domino effect to other sections of the installation.

LEVEL-2

The emergency situation arising in one or more plants/areas which has the potential to cause
serious injuries, property loss and/or environmental damage in the installation. Such an
emergency situation always warrants to mobilize all the resources available in-house and /or
outside to mitigate the emergency. The impact of this level of emergency is however, within the
installation.
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LEVEL-3

If level-2 emergency by virtue of its consequences can spread and affect the nearby community
outside the premises, it is termed as level-3 emergency.

ON-SITE EMERGENCY PLANNING

a. FORMULATION OF PLAN AND EMERGENCY SERVICES:

)

They are site specific. They should include the following elements.

Assessment of nature of extends of hazard or accidents.

(c

Formulation of plan and lioson with outside authorities.

61
 Procedures

• Raising the alarm

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• Communication both within and outside works
Appointment of key personnel

• Works incidents controller

• Works main controller

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EMERGENCY CONTROL ROOM

• Action on-site
• Action off-site

ELEMENTS OF A MAJOR EMERGENCY MANAGEMENT PLAN

A good and effective emergency or disaster plan should have the following elements:

• Emergency Organisation with responsibilities of key members

•
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Key Members and their contact numbers

• Emergency Control centre

A brief explanation of these elements is given below which can be helpful in preparing disaster
plan of any installation.

b. ALARM AND COMMUNICATION MECHANISM:

Communication is a crucial factor any employee should be able to raise the emergency
)

alarms so that action can be taken immediately.

C. APPOINTMENT OF PERSONNEL
(c

The site or works incident controller responsibilities i nclude.

• To assess the situation

• To invite emergency procedure
• To divert rescue and firefighting control fire brigade activities.

62
 • To search for casualties to arrange evacuation of non -essential persons
• To set –up communication with emergency control centre
•

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To ensure the responsibilities of site main controller until he arrives, the site
main controller often chosen from senior management has the responsibility of
diverting from emergency control centre. After retiring the incident controller for
overall control.
• Emergency Organization and Responsibilities of Key Members

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Management of a major emergency in an installation requires a well-coordinated team with a
senior member of the installation acting as head of the emergency team. He is called the
Chief Emergency Commander. An organogram of the emergency management team
showing the reporting of various key members should be made. The responsibilities of each
key member should be clearl y written and made known to the member. The members
should be made familiar with their roles by regular drills/rehearsals as explained later on.

KEY MEMBERS AND THEIR CONTACT NUMBERS

A key member for coordinating each of the following functions of an emergency should be
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identified:

i. Operations

ii. Security

iii. Medical

iv. Rescue/Evacuation
)

v. Human Resources

vi. Emergency Maintenance and Repairs

(c

vii. Emergency Materials

viii. Technical and Engineering Services

ix. Transportation

63
 x. Public Relations

A list showing the contact telephone numbers of all the key members should be made which

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should be regularly updated to incorporate any changes. This list should be available to each
member to be kept handy in his wallet.

• EMERGENCY CONTROL CENTRE

An emergency control centre in a safe place in the installation should be ident ified. This

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centre should be equipped with necessary communication equipment-telephones,
walkie-talkies, VHF radio sets, mobile phones, etc. and essential documents of the
installation. The chief emergency commander and most of the emergency team members will
operate from this centre.

• EMERGENCY COMMUNICATION

A reliable system of informing the various people in the installation should be in place.
This can be a siren or an alarm system, which is audible in the whole installation. VHF
radio can be used to communicate the emergency situation to civic authorities and other
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outside agencies, which need to be informed of the emergency who have already become the
victims of the emergency. Alternate locations for housing the evacuees should be identified.
A safe assembly point should be identified for each plant/area in the installation where people
not required during the emergency will assemble from where they can be easily taken out to
alternate locations. This aspect of the emergency plan is very critical during natural disasters
when a large-scale evacuation/rescue is called for.

• END OF EMERGENCY
)

The plan should identify the arrangements for declaring the end of emergency. There should be a
proper siren/ alarm to be given under the direction of the Chief Em ergenc y C om m ande r
(c

t o decl are t h e end o f emergency.

• EMERGENCY RESOURCES

The plan should include lists of important consultants/ agencies from whom additional help could
be obtained in case required during emergency situations. Lists of important suppliers and

64
 vendors of medicines, safety equipment, fire fighting equipment and materials, pollution
control equipment and consumables, etc. should also be included. All the information

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on emergency resources should be nicely compiled in the annexure to the emergency plan.

MOCK DRILLS.

The emergency plan should be rehearsed regularly by conducting mock drills to keep
the emergency team members refreshed with their roles during an emergency. Based on the

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weaknesses or shortcomings observed during the mock drills, the emergency plan
should be updated. As required by the statutory authorities, mock drill of a major on-site
emergency plan should be conducted at least once every year. Organization may opt for
more frequent drills.

MUTUAL AID

Some times the internal resources of an organization may not be adequate to handle a major
emergency situation. In such situations, external help can be sought from the neighboring
units and government agencies. A written agreement should be made with the
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neighboring organizations in the area to help each other with additional resources in case of
any emergency situation arising in their installations. The contact numbers for all these
organizations should be available with each organization. Regular mock drills should be
conducted to check the response of the mutual-aid members. Tariff advisory committee
(TAC) allows certain rebates in the insurance premiums to those organizations which are
members of the local Mutual aid schemes.

Some industrial areas like Vadodra; Mumbai, Ankleshwar etc. have very effective mutual
)

aid schemes. Member industries in each of these areas have pooled their resources to set up a
round the clock emergency/disaster management control room in the area, which coordinates the
mutual aid efforts of various agencies involved. Besides rendering mutual aid to each other
(c

in case of on-site emergencies, these control rooms have also helped in many off site
emergencies like road accidents involving vehicles carrying hazardous goods, gas leaks, etc.

65
 EMERGENCY INVENTORIES

It is necessary for every installation to maintain a minimum inventory of various emergency

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consumables and equipment for fire fighting, medical, pollution control and safety. A list of
these inventories should be a part of the emergency plan. Regular physical check of stock
levels of these inventories should be done against this list and immediate action should be
taken to replenish them if required.

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In spite of all the precautions and safe procedures followed, the chance of an emergency
arising in a industrial operation cannot be ruled out. Therefore a good written
emergency/disaster management plan should be in place. This unit discussed important
guidelines for making emergency plan specific to your installation. The importance of
rehearsing this plan periodically was also discussed

SUMMARY

This chapter discussed the significance and requirements of process safety

management as per OSHA requirements. The 14 elements of OSHA PSM were
discussed.
U
KEYWORDS

Emergency, disaster management plan

REVIEW QUESTIONS

1. What is process safety management?

2. What are the elements of OSHA PSM ?

)

FURTHER READING

1. Process safety management, U S Department of Labour

(c

66
 UNIT VI - FIRST AID

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Objectives:
After completing this unit, you will be aware of

• The importance of first aid

• Considerations to be adopted while administrating first aid for different

emergencies

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First aid may be defined as skilled assistance to the victim in case of accidents or sudden illness.
The person who renders skilled assistance is called the First Aider.

First aid is primarily a temporary measure to arrest the worsening of victims condition till arrival
of a doctor. This first aid is no substitute for treatment by a qualified doctor, which must be
sought at once.

It is very important that one should get immediate treatment for every injury, regardless how
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small you think it is.

Many cases has been reported where a small unimportant injury, splinter wound or puncture
wound, quickly led to infection, threatening the health and limb of the employee. Even the
smallest scratch is large enough for the dangerous germs to enter, and in large bruises or deep
cuts , germs comes in by the millions. Immediate examination and treatment is necessary for
every injury.
)

The health and safety (First Aid) Regulations 1981 require from the owner of the plant to provide
adequate and appropriate equipment, facilities and personnel to enable first aid to be given to the
employees. If they are injured or become ill at work.
(c

What is adequate and appropriate will depend on the circumstances in the workplace and in
general first aid needs are:

The minimum first –aid provisions on any work site are:

67
 A suitably stocked first –aid box

An appointed person to take charge of first aid arrangements

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It is important to remember that accidents can happen at any time . First aid provision needs to
be available at all times people are at work,

Many small firms will need to make the minimum first-aid provision. However, there are factors
which might take greater provision necessary. The following checklist covers the point you

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should consider.

GENERAL CONTENTS OF FIRST AID BOX:

There is no standard list of items to put in a first aid box. It depends on what you assess the needs
are. However, as a guide, and where there is no special risk in the workplace , a minimum stock
of first aid box should contain:

1. A leaflet giving general guidance on first-aid e.g. HSE leaflet basic advice on first-aid at
work.
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2. 20 individually wrapped sterile adhesive dressings
3. Two sterile eye pads
4. Four individually wrapped triangular bandages.

INSTRUCTIONS TO FIRST AIDER:

1. Gather information as to how the accidents or illness came about.
2. Look for signs such as swelling, bleeding and immobility etc.
3. Looks out whether victims feels nausea, cold, pain etc.
)

4. Pay special attention to severe bleeding , failure of breathing and shock.

5. Arrange for speedy removal of victim to proper medical care.
DO’S & DON’T OF FIRST AID:
(c

• Do the first thing first quickly, quietly and calmly

• Stop severe bleeding if any
• Administer artificial respirators if required and continue it till doctor arrives.
• Treat for shock

68
 • Boost up the morals of victims
• Avoid crowding around victims
• Unless required don’t remove clothes

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• Don’t try to achieve too much
• Don’t soak victim to wake him up.
• Unless victim complains of cold , don’t rap with blanket or coat.

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REPORT ALL INJURIES TO YOUR SUPERVISOR:

As with getting medical attention for all injuries, it is equally important that you report all
injuries to your supervisor. It is critical that the employer check into the causes of every job-
related injury, regardless how minor, how it happened. There may unsafe procedures or unsafe
equipment that should be corrected.

FIRST AID FOR SPECIFIC ACCIDENT OR ILLNESS:

TREATMENT FOR SHOCK:

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1. Keep patient warm
2. Keep head lower than feet
3. Cover with blankets or coat
4. Give hot coffee or hot tea

TREATMENT FOR SUNSTROKE:

)

Measure temperature with a clinical thermometer

If the temperature is high put the naked victim into a tub of cold water or gave full bath or apply
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wet sponge over his body

If there is a rise in temperature apply ice bag or clothes wing in cold water.

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 TREATMENT FOR ORDINARY WOUNDS:

1. Prevent touching of wound

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2. Don’t apply ordinary water since it may contain infectious germs
3. don;’t use strong antiseptics like dichloride or mercury on carbolic acid
4. Cover the wound with several layers of sterile gauze and bondage firmly but not tightly
5. Call the doctor as early as possible.

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TREATMENT FOR ACID AND ALKALI BURNS:

1. Wash off which copious amount of clean water

2. Place several layers of clean water over burn. Saturate with 5% tannic acid if available
and apply bandages
3. For serious burns on body remove all clothing carefully and treat it.
4. If there are signs of collapse keep the victim warm and give sips of warm offer or warm
tea , if not unconscious.
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TREATMENT FOR GAS POISIONING:

1. In all cases of gas poisoning, call the doctor at once.

2. Remove victim to fresh air if possible
3. Put the victim on a bed in a comfortable position that he is quite & conscious.
4. In case of unconscious victim is having difficulty in breathing, administer artificial
respiration at once.
)

FIRST AID FOR POISONS:

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These are few instructions in case of poisoning.

Administer 4 or more glasses of an emetic ( salt & Luke warm water or soapy warm water)

NOTE: do not induce vomiting if poison is corrosive

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 FIRST AID FOR POISONS:

1. Induce the vomiting by putting the finger down the victims throat.

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2. Administer the antidote if you know the exact cause.
3. After emptying the stomach and cleaning it give a soothing drink such as milk or water.
4. In case the patient is weak and faints he should lie down without pillow and should drink
coffee or tea. He may use smelling salt
5. Induce the vomiting by putting the finger down the victim’s throat.

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6. Administer the antidote if you know the exact cause.
7. After emptying the stomach and cleaning it give a soothing drink such as milk or water.
8. In case the patient is weak and faints he should lie down without pillow and should drink
coffee or tea. He may use smelling salt

FOLLOW THESE INSTRUCTIONS FOR UNCONSCIOUSNESS PATIENTS:

• Don’t feed anything into the mouth

• Don’t cause vomiting
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• Keep patients in lying position on left side and keep head low
• Remove chewing gum, tobacco or other foreign objects from mouth
• If patients is not breathing, place in prone position and apply artificial respiration
• Keep patients warm
• If breathing is shallow or skin, lips Cass finger, nail beds are blue give oxygen with CO2
or commercial oxygen.
• If poison is unknown give the universal antidote but only after the patients regains
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consciousness.
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ARTIFICIAL BREATHING:

If breathing is stopped artificial respiration should be applied immediately to restore the

normal breathing and prevent death- by means of artificial respirator, breathing is re-
established.

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 First of all clear the passage by pinching for a movement and clearing it by handkerchief.
Remove foreign object if any .

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MOUTH TO MOUTH METHOD:

The patient is laid on his back with his head is slightly sloping down, a pillow or rolled coat
placed under his shoulders. The head is tilted so that the lower jaw is higher than the upper

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jaw. The patient’s mouth is opened after a deep breath; the helper places his mouth over the
victim’s mouth making air tight contact. Patient’s nose is pinched and patient’s mouth is
blown till his chest rises. The helper’s mouth is removed for the victim’s to exhale. The first
8-10 breaths are as rapid and thereafter rate is slowed down to 12-15 times a minute.

ARTIFICIAL RESPIRATOR:

Artificial respirator consists of a rubber balloon, a special valve and mouth piece tubing. The
mouth piece is cupped on the patient’s mouth for the artificial respiration. During inhaling
balloon is defatted into patient’s mouth, upon release, the balloon gets inflated from
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atmospheric air entering via the valve. The process is continued till the normal breathing is
restored.

EXTERNAL CARDIAC MASSAGE:

If the patient’s pulse is not felt, heart beat has stopped; in such a case external cardiac
massage is applied.

• The injured person is laid on his back on a firm surface and knelled at his side.
)

• The heel of one hand is placed on the lower half of the person’s sternum.
• Other hand is placed on the top of the first hand and downward pressure is exerted till the
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bones dip by 1.5 inches.

• Then the pressure is released. This cycle is repeated 60 times.

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 UNIVERSAL ANTIDOTE:

Universal antidote is a glass of water a heaping teaspoon full of two parts of activated

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charcoal, one part of magnesium oxide, one part of fullers earth and one part of tonic acid, if
any body is not able to is not able to prepare an antidote, give an emetic of induce vomiting.

To prevent collapse or shock keep the victim warm , quite and lying position with head low.
If there is consciousness give strong tea, or coffee. Give smelling salts or aromatic sprits of

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ammonia may be inhaled.

TREATMENT FOR SPECIFIC POISONS:

ALKOLLOID POISONS:

Observe general instructions for poisons, use universal antidote.

CARBON-DISULPHIDE:

Give a mixture of 93% O2 and 7% CO2 or oxygen. In case of breathing, failure use artificial
respiration.
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BENZENE:

If swallowed, follow general instructions for poisoning, if inhale administered oxygen.

METHYL CHLORIDE:

Administer O2, use artificial respirants . For skin contact use cold water. Don’t use distilled
grease.
)

SULPHUR-DIOXIDE:

Administer oxygen. In case of breathing failure use artificial respiration.

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WHEN TO CALL FIRST AIDER

• Any life threatening or injury situation

• If you are light headed and think you may lose consciousness
• Alone in the facility and seriously injured

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 • When someone is injured seriously
• Any time there is an injury or when someone may need First Aid or CPR
•

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Any time someone is feeling ill or needs to use the First Aid room
• If you notice any type of irregular behavior in your coworker
• If any non Trane employee changes behavior dramatically
GET HELP AS QUICKLY AS POSSIBLE BE AWARE OF YOUR OWN CONDITION
1. Are you dizzy ?

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2. Light headed?
3. Chilled and sweating?
4. Shortness of breath ?
5. Pain in center of chest spreading to neck, shoulder or arms?
6. Something gets caught in your throat
7. Sudden weakness/numbness of the face
8. Loss of speech / trouble talking or understanding speech
9. Sudden severe headache
10. Are you diabetic? eating or checking you blood sugar?
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11. Are you allergic to certain things / been stung by a bee before?

SUMMARY

This chapter discussed the necessity of first aid, dos and don’ts of first aid and first
aid methods for various emergencies.

KEYWORDS

First aid
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 REVIEW QUESTIONS

1. What is first aid

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2. Explain the first aid for following emergencies

a. Sun stroke

b. Cardiac arrest

c. Gas poisoning

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FURTHER READING

1. First Aid Reference Guide, St. Johns Ambulance

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 UNIT VII - PERSONNEL RISK IN MANUFACTURING PLANT

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Objectives:
After completing this unit, you will be aware of

• The personal risks in manufacturing plants

• Control measures to mitigate these hazards

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INTRODUCTION:

Cement manufacturing process consists principally of grinding and blending in a definite

proportion, a material containing calcium oxide (such as limestone, chalk, marl) with a siliceous
material (such as clay, shale, sand) along with certain additives or corrective materials (such as
bauxite, laterite iron ore) and when burning the mixture at high temperatures in a kiln. The
resulting clinker is cooled and then ground with gypsum & fly ash to produce the finished
products.
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A. MINING UNIT:

Limestone is extracted through mining and then limestone is transported by dumper's to

stationary crushing plant. Limestone is crushed in a mobile crusher and crushed
limestone is transported to the plant.
B. CRUSHING UNIT:

Crushing is done by means of impact crushers. The purpose of crushing is to prepare the
material for grinding in raw mill
)

C. STACKER UNIT:
The crushed limestone is stacked in a multi layer fashion in two pre-blending stockpiles of
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35,000 MT capacity each. The quality of material is made uniform during reclaiming. The
reclaiming is done by a bridge type scraper reclaimer and the reclaimed limestone is transported
to the raw mill hopper by belt conveyors.

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 After testing the CaCO3 content in the raw material, the materials are divided in 3 grades
namely-

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1. High Grade
2. Normal Grade
3. Low Grade

D. RAW MILL UNIT:

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The conveyor belt carrying from the raw material passes through a magnet to remove any iron
particles present in the raw material. The raw material feeding belt is connected to the gravel
gate of raw mill so that hot air used for drying the material should not escape through the feed
point. The material are ground in a raw mill having vertical rollers.

E. PRE-CALCINATION UNIT:
The raw meal is extracted from the CB silo and fed to the top of the four-stage pre-heater with
the help of an air lift pump. The feed rate is accurately controlled by the 'POLDOS' system. As
raw meal flows downward from first stage to fourth stage it comes in contact with rising and
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progressively hotter gases from kiln and the raw meal gets heated from ambient temperature to
about 860C by utilising the sensitive heat of kiln waste gases.

During the pre-calcination, limestone (CaCO3) gets converted to lime (CaO) as per the following
reaction.

CaCO3 + Heat = CaO + CO2

As this reaction is highly endothermic, the heat is supplied for supporting the calcination
)

reaction by firing controlled quantity of pulverised coal in pre-calciner.

F. KILN UNIT :
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From the precalciner the precalcined raw meal enters the kiln. The kiln is rotary type and has a
capacity of 3000 MT/day. The kiln is fired with controlled quantity of finely ground coal and
maintained at a temperature of 1300 to 1400 0C at the firing end. Chemical reactions take place
and material melts to small pebbles (upto 25 mm) called clinker.

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 G. CLINKER-COOLER UNIT:

From the kiln the hot clinker flows to the reciprocating grate cooler, where it is

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effectively cooled to about 80 0C by cross current contact with cooling air blown by ten cooling
air fans. Hot clinker falls on cooler plates and is transported from one plate to another by the
reciprocating movement of plates. Beneath these plates the cooling air fans are fixed to cool the
clinker. The air which gets heated up during clinker cooling is put back in the kiln and
precalciner as secondary and tertiary air for coal combustion.

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H. COAL HANDLING UNIT:

Coal received from collieries by trucks is unloaded in the coal yard for obtaining a
uniform quality of coal. It is transferred to the coal stockpiles where it is stacked and then the
coal is crushed in the coal crusher and transported to raw coal hopper having a capacity of 300
MT in the coal mill plant by belt conveyors.

I. CEMENT MILL UNIT:

The clinker is extracted with the help of vibro-feeders installed below the clinker stock-
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pile and transported to the cement mill hopper by belt conveyors. Gypsum and Pozzolona are
also stored in cement mill hoppers. These materials are taken from the hopper in proportionate
quantity with the help of weigh feeders and fed to the cement mills by belt conveyors. Each
cement mill is a double compartment, horizontal ball mill filled with grinding media. The clinker
which is ground with gypsum to a very fine powder to yield a good quality of cement. Gypsum
is added to the clinker while grinding to the extent of 4 to 6% for dealing the commencement of
the setting time. The fined ground cement from ball mill is removed continuously by carrying
)

air and separated in high efficiency ESP. The cement collected in ESP is transported by air slide
and air lift, pump and stored in four cement silos .
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J. PACKING UNIT:

The cement is taken from the cement silos and transported to the packing plant with the help
of air slides and bucket elevators. The cement is fed to the automatic rotary packing
machines through rotary screens. Each packing machines packs 50 kg of cement in

78
 jute/HDPE bags. The filled bags are transported to trucks loading points with the help of belt
conveyors and loaded into the trucks with the help of shuttle and lifting conveyors.

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COMMON PERSONNEL RISK IN MANUFACTURING PLANT

Hazards in work place need to be eliminated, minimized or effectively controlled. Following are
some of the common methods of eliminating, minimizing, controlling hazards:

▪ Interlocks and trips.

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▪ Guards,
▪ Infra-red sensors with trip mechanism,
▪ Two handed operation to prevent entry of hand in the hazard zone,
Use of handled tools like chisels etc.,
▪ Use of PPE.
Following are some of the common hazards and means adopted for controlling
them:

MECHANICAL HAZARDS
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I. Trips: Pipelines crossing passages are a trip hazard. Such trip hazards of low lying
ground level pipe crossings of small size piping need to be covered with a ramp with
zebra markings. Higher level and bigger size piping need to be provided with step crossing.

II. HEAD BUMPERS: Any obstacle at the head height (less than 6 feet) in the passage,
stairway is a head bump hazard. Such head bumps need to be either removed or
prominent caution board with yellow background and black letters to be put up. Further it
is very useful to provide thick sponge padding on the head bump to absorb any impact
)

of a head bumping on the obstacle.

III. OBSTACLE ACROSS PASSAGES: THERE SHALL BE NO PROTRUDING

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obstacles across any passage. All such protruding obstacles must be removed.

IV. TOE GUARDS AND FIRST ' RAILING FOR PLATFORMS AND STAIRS'
LANDINGS: All platforms and stairs' landings are required to have toe guards to

79
 prevent the foot slipping out of the platform. All first railings of platforms must be low
enough to prevent leg slipping out of the platform.

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V. MACHINE GUARDING: MACHINE GUARDS SHOULD BE SUCH THAT
EVEN a small finger should not be able to penetrate inside. All machine guar ds to be
fixed properly after maintenance.

VI. VERTICAL LADDERS: All vertical ladders to have cat-rings for protection.

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VII. HAMMER AND CHISEL HAZARD: A frequent cause of workshop activity involves
hand and finger injuries due to use of chisel and hammer f or cutting gaskets and sheets.
Use of chisel with handle eliminates this hazard.

VIII. IN-RUNNING NIPS CUTTER MOVEMENTS: These are the oldest of hazards
and still persisting, Nip guards are useful. There are advanced systems where starting the
machine requires both hand operation so that no hand enters the in-running nip of
moving cutter. There are also infra red sensor trips, that trip the machine when a
hand enters the hazard zone. All machine operations should be free of in-running
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nip/cutter hazard.

CORROSION HAZARDS

(I) PREVENTING CORROSION OF STRUCTURES, LADDERS, RAILINGS ETC:

Use of GI structures and piping prevents corrosion without any painting. For other MS-
Structures use of effective sand blasting and 5-coats of Zinc primer has proved very
effective and is now used widely.
)

ELECTRICAL HAZARDS

(i) EFFECTIVE EARTHING: All electrical equipments to have earthing,

(c

(ii) SEALING OF CABLE ENTRY POINTS: All cable entry points in flame proof
areas need to be sealed by electrical water proofing compound,

(iii USE ELECTRICAL DUTY TOOLS AND PPE: Only approved ISI marked
electrical duty tools and PPE to be used.

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 STATIC CHARGE HAZARD

Static charge is the most ubiquitous hazard in flameproof areas. Prevention of static charge hazard

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in chemical industries is one of the most challenging tasks.

AIR EMISSIONS SOURCES

SOURCE EMISSION

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Raw material crushing, grinding PARTICULATES

Kiln operation and cooling PARTICULATES, CO,SO2,NOx,HC

Product grinding and packaging PARTICULATES

COMMON AIR POLLUTANTS AND THEIR EFFECTS:

1. SUSPENDED PARTICULATE MATTER:

Atmospheric particulate matter is defined to be any dispersed matter, solid or liquid smaller than
500um. Under various conditions of their generation, they are also called by other names such as
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dust, fume, smoke and mist. The common diseases caused by the these particulates are:
bronchitis, bronchopneumonia and asthma.

SULPHUR DIOXIDE:

Sulphur dioxide when released in the atmosphere can also convert to SO3, which leads to
production of sulphuric acid. When SO3 is inhaled it is likely to be absorbed in moist passages of
respiratory tract. When it is entrained in an aerosol, however it may reach to deeper into lungs.
)

NITROGEN OXIDE

Almost all NOx emissions are in the form of NO, which has no, known adverse health effects in
(c

the concentrations found in the atmosphere, which in turn may give rise to secondary pollutants,
which are injurious. NO2 may also lead to formation of HNO3, which is washed out of the
atmosphere as acid rain.

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 CARBON MONOXIDE:

Most of the CO emissions are from transportation sector. Peek concentrations occur at street

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level in busy urban centers particularly when there is no atmospheric mixing as it happens during
winter season. Carbon monoxide interferes with blood’s ability to carry oxygen. It also causes
headache and dizziness.

LEAD:

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Lead released from motor vehicle exhaust may affect human populations by direct inhalations ,
in which case people living nearest to highways are at greatest risk. Lead can be ingested also
after it is deposited on the foodstuffs. it may also cause behavioral changes, learning disabilities
and permanent brain damage.

SUMMARY

This chapter discussed the various personal hazards in manufacturing industry,

especially the cement manufacturing section and control measures for the same

KEYWORDS
U
Personal risks, manufacturing industry

REVIEW QUESTIONS

1. What personal risk?

2. List out the personal risks in cement manufacturing sector

3. How the personal risks in cement manufacturing industry can be controlled?

)

FURTHER READING

1. Accident Prevention Manual for Industrial Operations: National Safety

council
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 UNIT VIII - PERSONNEL RISK IN CHEMICAL PLANT

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Objectives:
After completing this unit, you will be aware of

• The personal risks in chemical plants and control measures

PE
INTRODUCTION

The chemical industry is intimately connected with all the basic needs of society such as food,
clothing, housing and health. Its development and performance depend on several factors
directly connected with demographic dynamics of the country and national policies. For
example, the adverse implications of monsoon failure on agricultural production and, in turn,
on the demand for fertilizers and pesticides; or the role of drugs and pharmaceuticals in
providing health care needs to a growing population. The petrochemical sector which caters to
clothing and polymeric consumer products depends on regular and adequate feedstock
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availability which, in turn, is determined by the hydrocarbon resources and government
policies. Notwithstanding these factors, the chemical industry is poised for an impressive
growth, aided by a strong scientific and industrial infrastructure, manpower resources and
favorable government policies.

New industry initiatives encouraged by government policies and incentives are generating a
vast range of industrial development programmes. Balanced dispersal of chemical industries is
an important consideration not only for distributing the opportunities but also to avoid
)

overcrowding which would place unduly heavy strain on social infrastructure and associated
facilities.
(c

Problems connected with environmental pollution call for care in the selection of
environmentally acceptable options for mass production of chemical products. Compared to
the situation during the initial phases of its development, the chemical industry is now
increasingly responsive to the hazards of pollution and is willing to bestow more care in the
selection of process technologies as well as plant sites. The infrastructure corporations of

83
 various State Governments and Union Territories have also started planning for functional
industrial estates exclusively meant for highly polluting chemical Industries. The concept of

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preliminary treatment at the individual unit level and a well-conceived collection system
followed by combined treatment and disposal of effluents is gradually getting accepted in
industrial area planning. However, keeping in view the heterogeneous nature of chemical
industry which consists of tiny, small, medium and large scale sectors, there is need for
developing appropriate strategies for treating effluents and gaseous emissions so that damage

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to environment is minimal.

GOVERNMENT'S CONCERN FOR CHEMICAL PLANT SAFETY

Chemical and petrochemical manufacturing activities involving hazardous chemicals have the
potential to give rise to serious injury or damage beyond the vicinity of the manufacturing
area. Some indicative data on accidents and losses are shown in Annexure I. Practical
guidelines are needed for the protection of the health and safety of plant personnel and
population living outside the concerned manufacturing plant boundary as well as the protection
of the environment. The chemical and petrochemical plants employing dangerous, explosive,
U
flammable and toxic substances have therefore, to convince the environmental protection
agencies and the Government that major accident hazards have been recognized and measures
have been taken to prevent accidents and to control and minimize the consequences of those that
do occur. Recent chemical disasters - particularly Seveso, Mexico and Bhopal - have
increased public awareness of potential hazards to the community. This has brought a greater
urgency to undertake scientific safety assessment of the existing chemical plant installations.

RISKS IN CHEMICAL PLANT

)

The types of risks in chemical and petrochemical manufacture can be broadly classified as
under:
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o Runaway reactions, explosion, fire or such disaster in a plant handling or producing

dangerous, inflammable or toxic substances;
o Design faults leading to accidental mixing of chemicals and consequent hazards;

84
 o Storage of large quantities of dangerous substances vulnerable to decomposition,
explosion or toxic emissions caused by variations in temperature, pressure or

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ingress of foreign substances;
o Contamination of products intended for human or animal consumption by toxic
products or substances in the same plant;
o Accidents during transportation;
o Improper waste disposal practices resulting in serious environmental pollution.
o Accidents due to human failure;

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9. The Department of Chemicals and Petrochemicals, Ministry of Industry, Government of
India, has been concerned about these risk aspects with particular reference to industrial
manufacture of chemicals, pesticides, drugs and petrochemicals. The following points have
been identified as crucial for the safety of these plants:

▪ Hazard identification
▪ Location of an installation in relation to its surroundings; subsequent additions and
expansions
▪ Assessment of likely damage
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For new chemical plants, safety will have to feature very prominently in process technology
selection and implementation. From purely technological consideration, safety has clearly a
higher priority than economics, but from techno-economic considerations, safety and
economics can be made compatible by adequate attention to design. By using the concept of
inherent or intrinsic safety, new plants can be so designed that they use relatively safer raw
materials and intermediates or use the hazardous chemicals at milder operating
conditions. Inherently safe design requires the approach of risk assessment. This is an area
)

wherein expertise available within the country is very limited and there is urgent
need to develop this capability.
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▪ To undertake the inspection and survey of the hazardous chemicals,

petrochemicals and drug units.

▪ To make specific recommendations to control the hazards in the plants and

suggest measures required to improve the overall safety.

85
 ▪ To prepare a check list of items requiring periodical inspection in such plants.

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SUMMARY

This chapter discussed the various personal hazards in chemical industry, and
control measures for the same

KEYWORDS

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Personal risks, chemical industry

REVIEW QUESTIONS

1. What personal risk?

2. List out the personal risks in chemical industry

3. How the personal risks in chemical industry can be controlled?

FURTHER READING

2. Accident Prevention Manual for Industrial Operations: National Safety

U
council
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