Process Safety - Managing Risks: Learning From.. Accidents and Incidents

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Process Safety - Managing Risks

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

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Physical Hazard/Damage
MIC ..Union Carbide - Bhopal, India 1984

1984 Bhopal – over 2000


immediate dead, plus many more
from the effects

Toxic Hazard
Minamata mercury pollution

Industry discharged effluent containing mercury compound which was used


as catalyst. After 5 to 7 years people started showing neurological symptoms.

ECO Tox Hazard


Accidental test of explosive properties on
production scale

Blaye Grain Storage


France
1997, 11 fatalities, caused by

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

Powder sugar can also lead to explosion under certain conditions


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Developing a Proactive Safety Program

• Too often, manufacturers implement safety programs and


technology as an afterthought in response to an accident or
customer requirement instead of in anticipation.

• In the past, the limitations of safety technology also contributed to


this reactive approach.

• Rigorous global safety standards, technology innovations and


thorough risk management techniques now make it possible to
develop a more proactive approach to safety programs.
• Conduct a thorough risk assessment
• Reduce potential hazards through design…..Implement PSM

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

Trevor Kletz, ICI, UK (1977)


– Named the concept
– Developed a set of specific design principles for the chemical
industry
– Later published - original paper referring to “Inherently Safer
Design”
• Kletz, T. A. “What You Don't Have, Can't Leak.”
Chemistry and Industry, 287-292, 6 May 1978.
VVB-IICHE-PSM2020
Learning From Accidents

It is important to build on the learning from


these accidents to develop good practice.
Inherent Safety
Collection Process Reactor Vent Layer Of
Of Basic Risk Venting System Protection
Data Analysis Strategy Design Analysis

Process Hazard Safety System


Analysis Specification
Key Questions

• Why do Accidents occur?

• How do Accidents occur?

• What must we do to keep them away from


happening?

• When?

VVB-IICHE-PSM2020
Working Towards Safety

Hazards ---- › Risk


severity x probability

 Know the risks


 Manage the risks
 Learn from accidents

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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
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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

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Thank You…

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