Process Safety - Managing Risks: Learning From.. Accidents and Incidents
Process Safety - Managing Risks: Learning From.. Accidents and Incidents
Process Safety - Managing Risks: Learning From.. Accidents and Incidents
Introduction
Learning From..
Accidents And Incidents
Vijay Bhujle
23/05/2020
VVB-IICHE-PSM2020
Accidental test of explosive properties
on production scale
Ammonium
nitrate-
explosion,
21.09.1921
Oppau
-4500 t
-561 fatalities
-1997 injured
-damaged
buildings within
a radius of 6 km
VVB-IICHE-PSM2020
Physical Hazard/Damage
MIC ..Union Carbide - Bhopal, India 1984
Toxic Hazard
Minamata mercury pollution
friction or autoignition
VVB-IICHE-PSM2020
Grains can also lead to explosion under certain conditions
Imperial Sugar Factory Explosion(2008)
Initial
explosion in
conveyer
14 dead &36
injured
VVB-IICHE-PSM2020
History of PSM Catastrophes
A series of catastrophic
releases
A series of of chemicals
catastrophic releases
leading
of to fires,
chemicals leading to fires,
explosions
explosions and fatalities
and have
fatalities
occurred in chemical processing
have occurred in
plants around the world over the
chemical processing
years.
plants around the world
These incidents lead to the
over the years.
passage of the Process Safety
Management Rule inlead
These incidents 1992.
to
the of the Process
Safety Management Rule
in 1992.
VVB-IICHE-PSM2020
Major PSM related incidents
1974 - 2001
Source: Wharton Risk Management and Decision Processes Center of the University of Pennsylvania.
New paradigm for the Safety
•Traditional safety approach
– “Add on” safety features
• Prevent - alarms, safety interlocks, procedures, training
• Mitigate – sprinkler systems, water curtains, emergency
response systems and procedures
•Inherently safer design
– Eliminate or significantly reduce process hazards rather than
controlling them
• When?
VVB-IICHE-PSM2020
Working Towards Safety
VVB-IICHE-PSM2020
Chemical Hazards
Thermal
Fires
Explosion
Toxiological
Toxic Gases
Toxic Effluent
Ecological
Biodegradability of product or effluent
Long – term effect
Chemical manufacturing
Chemical reactions
Synthesis reaction
Unwanted decomposition reaction
Unit operations
drying, milling, mixing
VVB-IICHE-PSM2020
What is Process Safety?
• A management system to help prevent major incidents
• Essential for managing complex chemical operations
• Process Safety focuses on:
– Technology
– Facilities
– Personnel
VVB-IICHE-PSM2020
Main Topics to be covered
• MSDS
• PSM introduction
• Process hazard analysis
• Hazard identification
• Plant layout –safety
• SHE regulations overview
• Laboratory safety
• Behaviour based safety
VVB-IICHE-PSM2020
Thank You…