WHAT IS SAFETY

&
WHY
 BACKGROUND

• TECHNOLOGICAL ADVANCEMENTS, GROWING POPULATION & DEVELOPMENTAL ACTIVITIES

IN ALL SPHERES OF LIFE
• CONTINUOUS GROWING ATTENTION TO SAFETY, QUALITY & ENVIRONMENT ISSUES
• STRONG NEED FELT FOR RELIABLE PROACTIVE CONTROL UNDER A STRUCTURED
MANAGEMENT SYSTEM
• TO ENSURE SAFETY OF LIFE PROPERTY & THE ENVIRONMENT
 Why safety-
• All resources in this world can be classified in two parts only- Dead and Live resources
• All elements, components, minerals, metals, non metals and matters that are not alive- dead
resources
• All living creatures including human being are live resources
• All dead resources are invented, produced and used by living resources
• If there is no live resource, no importance of any dead resource
• Haphazard generation and use of dead resources by live resource have created threat to the live
resources and therefore, question of safety have been arisen
• The human or live resources can be developed (refined) only when they are Protected from the dangers
of dead resources
• This protection is nothing but the concept of safety.
 Health Vs Wealth
• The most important live resource is a man. His wealth or health
important? We may say simply ‘both’ because men want both.
• But well known phrases like health is wealth, sound mind in a sound
body- health is more important.
 Process Safety Management (PSM)
Required by OSHA regulation, Process Safety Management of Highly Hazardous Chemicals is
designed to prevent and control an accidental release of highly hazardous chemicals.

PSM Program Elements consist of the following:

• Employee Participation
• Process Information
• Process Hazard Analysis
• Operating Procedures
• Employee Training
• Contractor Safety
• Pre-Startup Safety Review
• Mechanical Integrity
• Safe Work Practices
• Management of Change
• Incident Investigation
• Emergency Planning
• Compliance Audits
• Trade Secrets
 Process Safety Management (PSM)
• PSM is a corporate tool to improve decision-making by incorporating safety into a business function. More
specifically, it is a systematic approach to manage safety that includes the necessary organisational structure,
management accountabilities, safety policies and processes needed for successful identification of hazards
and management of safety risks. hazards are defined as “a real or potential condition that could lead to an
unplanned event or series of events (i.e. mishap) resulting in death, injury, occupational illness, damage to or
loss of equipment or property, or damage to the environment”, whereas risk is defined as “a combination of
the severity of the mishap and the probability that the mishap will occur”

• The key questions were meant to address through PSM

– What are safety management systems and why are they useful?
– What is the role of the regulator in the SMS?
– What are the obstacles to implementing an SMS and how do we overcome them?
– How can we measure the impact of the SMS and the role resilience engineering plays in safety
management systems?
– How can accident investigations help us improve the SMS?
 Process Safety Management (PSM)
• SMS represents a shift in the approach to safety management. The shift in emphasis places less reliance on a
prescriptive, or compliance-based regulatory approach, and focuses more on a performance-based strategy.

Some of the key features of this change in focus include:

• Management commitment to establishing safety policies and objectives;
• Inclusion of explicit safety (non-punitive) reporting procedures;
• Safety performance monitoring and measurement;
• Identification of accountable management employees;
• Appointment of key safety personnel responsible for safety oversight and promotion;
• Implementation of a risk management process to identify hazards and associated risks;
• Documentation of the SMS structure and safety assurance processes and procedures;
• Coordination of the SMS safety with emergency response planning;
• Safety training at management and employee levels; and
• Effective management of change.
 Process Safety Management (PSM)
• There are likely many reasons that some organisations do not embrace safety management
systems, such as:

– The SMS is perceived as an additional ‘regulatory burden’ that requires more

paperwork;
– Some service providers believe that they are already meeting the requirement and do
not need to bother incorporating yet another safety management initiative;
– There might be a shortage of personnel that have the knowledge and skills required to
successfully carry out implementation and management of the SMS; and
– There might be a shortfall in resources made available to enable successful SMS
implementation.
 Process Safety Management (PSM)
Four components and twelve elements of the ICAO SMS Framework

I. Safety Policy and Objectives III. Safety Assurance

• Management commitment and • Safety performance monitoring and

responsibility measurement
• Safety accountabilities • The management of change
• Appointment of key safety personnel • Continuous improvement of the SMS
• Coordination of emergency response
planning
• SMS documentation
II. Safety Risk Management IV. Safety Promotion
▪ Hazard identification • Training and education
▪ Safety risk assessment and mitigation • Safety communication
 Process Safety Management (PSM)
The ISM Code is made up of two parts and 16 elements as shown in the table below
PART A – Implementation
1 General
2 Safety and environmental protection policy PART B – – Certification and verification
3 Company responsibilities and authority 13 Certification and periodical verification
4 Designated Person(s) 14 Interim certification
5 Master‘s responsibility and authority 13 15 Verification
Certification and periodical verification 16 Forms of certificates
6 Resources and personnel
7 Shipboard operations
8 Emergency preparedness
9 Reports and analysis of non-conformities,
accidents and hazardous occurrences
10 Maintenance of the ship and equipment
11 Documentation
12 Company verification, review and evaluation
 Process Safety Management (PSM)

The integration of safety with quality, environment and productivity can be done at different
levels, according to Jorgensen et al (2006):

• Strategic and cultural integration in order to enhance learning, continuous performance

improvement, stakeholder involvement and participative management;
• Coordination of common business processes between safety, quality and environment (e.g.,
policy, planning, procedures, audits, control of non-compliance, preventive and corrective
actions and management reviews);
• Correspondence of different standards (e.g., ISO 9001, ISO 14000, OHSAS 18001) with cross-
references and possibly a common information system
Safety management system
Total Processes Safety Management
 Processes for understanding hazards and risks
➢ Hazard Identification. ISO31000 calls for methods/tools to identify risks under the direct or
indirect influence of organisational processes. The exact methods and tools depend on the
needs of the organization, which should be identified by a participatory approach including
practitioners, risk assessors and stakeholders. Workplace prototyping tools can be explored to
assist the visualisation of hazards and their early recognition.

➢ Risk Analysis. ISO31000 provides limited guidance on the actual process of risk assessment,
requiring only that a risk assessment is carried out that fully accounts for the hazards and their
likelihood. Risk registries and knowledge management tools can ensure that analysts have
adequate information to make a good assessment of the level of risk within an organisation.

➢ Risk Evaluation. This involves a comparison between the level of risk that has been calculated
in risk analysis and the criteria of risk acceptance as decided earlier in the ‘context’ of risk
assessment. Tools that support a common operational picture can assist in this process by
producing safety dashboards allowing management to quickly identify areas of risk that are
unacceptable to the organisation.
 Challenges in risk assessment
➢ Hazard Identification. ISO31000 calls for methods/tools to identify risks under the direct or
indirect influence of organisational processes. The exact methods and tools depend on the
needs of the organization, which should be identified by a participatory approach including
practitioners, risk assessors and stakeholders. Workplace prototyping tools can be explored to
assist the visualisation of hazards and their early recognition.

➢ Risk Analysis. ISO31000 provides limited guidance on the actual process of risk assessment,
requiring only that a risk assessment is carried out that fully accounts for the hazards and their
likelihood. Risk registries and knowledge management tools can ensure that analysts have
adequate information to make a good assessment of the level of risk within an organisation.

➢ Risk Evaluation. This involves a comparison between the level of risk that has been calculated
in risk analysis and the criteria of risk acceptance as decided earlier in the ‘context’ of risk
assessment. Tools that support a common operational picture can assist in this process by
producing safety dashboards allowing management to quickly identify areas of risk that are
unacceptable to the organisation.
 Process Safety Management (PSM)
Management of Change (MOC) Process
• MOC is the evaluation and approval of all changes specific to the PSM process.
• Required for anything that is not a “replacement in kind.”
• Requires evaluation and APPROVAL of temporary and permanent changes to covered
processes BEFORE changes are made.
• Ensures ongoing safety of the PSM covered processes.
• Example of MOCs:
– Change of material of construction (stainless vs. fiberglass, gasket material, etc.)
– Piping modification
– Pump size, pump style
– Valve style (ball vs. gate valve)
– Change in Fail Open/Fail Close
– Change in department SOP
• The MOC Form must be completed with input from Operations, Maintenance, Safety,
Engineering, etc. and should include the description of change, review of impacts,
approvals, documentation, and training.
• The “Notification of Change” Form must be posted in the area and shared with the team.
 Process Safety Management (PSM)
Emergency Response
• PSM requires the facility to have an Emergency Preparedness & Response Plan
• Everyone must follow existing emergency procedures:
– Call emergency extension xxxxxxx from an outside line to report all emergencies
– Describe the emergency in detail before hanging up
• Loss Prevention, the Emergency Response Team (ERT), and the Medical First Responders
(MFRs) handle all emergencies at the Escanaba Mill.
• All emergencies must be reported immediately.
 ACCIDENT STATISTICS

• ACCIDENTS ARE ON RISE WORLDWIDE

• 98% OF ACCIDENTS IN INDIAN INDUSTRIES ARE CAUSED BY UNSAFE ACTS & UNSAFE CONDITIONS.
• OFFICIAL STATISTICS OF WORK RELATED ACCIDENTS AND ILL HEALTH EACH YEAR DO NOT
REPRESENT EXTENT OF PAIN & SUFFERINGS THAT EACH EVENT BRINGS TO ITS VICTIMS, THEIR
FAMILIES, COLLEAGUES AND FRIENDS.
• OCCUPATIONAL ACCIDENTS AND ILL HEALTH IMPOSE FINANCIAL COSTS TO INDIVIDUALS,
EMPLOYERS AND SOCIETY AT LARGE.
• OVERALL COST TO EMPLOYERS OF PERSONNEL INJURIES,ACCIDENTS, ILL HEALTH AND AVOIDABLE
NON INJURY ACCIDENTS IS TO AN EXTENT OF OVER 10% OR MORE OF THE GROSS PROFITS.
MAJOR ACCIDENTS IN THE WORLD.

• EXPLOSION OF HIGHLY TOXIC HEXANE AT FLIXOBROUGH IN UK.

• HIGHLY TOXIC CHEMICAL DIOXIN RELEASE FROM EMERGENCY VENT IN A
FACTORY IN ITALY IN 1976.
• PROPYLENE BLOW OFF DUE TO LEAK IN ROAD TANKER IN SPAIN IN 1978 –
200 PERSONS DIED.
• EARTH QUAKE , NATURAL GAS EXPLOSION IN MEXICO CITY IN 1984 – 450
PERSONS DIED
• METHYL ISOCYANATE RELEASE IN BHOPAL IN 1984 – OVER 3800 PERSONS
DIED AND SEVERAL THOUSANDS INJURED.
DISASTERS MADE TO REALISE THAT
THE LAW MUST BE ENACTED TO
MAKE THE MANUFACTURERS RESPONSIBLE
FOR ENSURING THE HEALTH AND SAFETY OF WORKERS
AND PUBLIC AT LARGE.
SAFETY LIFE
Employees
is the Control Contractors
Visitors/ customers
of Community

Accidental
PROPERTY
Losses Share holders
Insurance company
to Financial institution
People National wealth
Equipment Customer’s products
Materials
Environment
ENVIRONMENT
What we owe to our future
generation
 SAFETY IS ABOUT
MANAGING RISKS.
SAFETY IS ABOUT
CONTROLLING ACCIDENTAL LOSS.

DET NORSKE VERITAS

In almost all competitive sports a good defense is critical to a winning game.
The same is true to business.

The First Duty Of Business

is to Survive
And
Guiding Principle of Business Economics
Is
Not the Maximisation Of Profits
But
IT IS AVOIDANCE OF LOSS
- Peter Drucker
A penny saved is a penny earned - Benjamin Franklin

• Large earnings necessary to pay for losses.

• A penny saved may be much more than a penny earned.
• With 5 % profit margin of the company, Rs 1.0 lac. of avoidable
loss can only be made up with Rs. 20 lacs of added sales to cover
the loss.
• This is important when the tight markets and the tough
competition make it difficult to improve revenues and when the
operating expenses have been reduced as far as possible.
• Control of avoidable losses will improve competitive position of
the company, either by improving profit margin or by reducing
the price of its goods and services.
 KEY DEFINITIONS

SAFETY
FREEDOM OF UNACCEPTABLE RISK OF HARM

CONTROL OF ACCIDENTAL LOSSES

 KEY DEFINITIONS – CONTD.

ACCIDENT
Undesired event giving rise to death, ill health, injury, damage or other loss

INCIDENT
An event that give rise to an accident or had the potential to lead to an
Accident
 KEY DEFINITIONS : Continued

HAZARD
Source or Situation with a potential for harm in
terms of Human Injury, Ill health, Damage to
Property, Damage to the Workplace Environment or
a combination of these.
 KEY DEFINITIONS : Continued

RISK
Combination of the Likelihood and Consequences of a specified
hazardous event occurring
RISK ASSESSMENT
Overall Process of estimating the magnitude of risk and deciding
whether or not the risk is tolerable.
 HAZARD MANAGEMENT MATRIX

HAZARD INVOLVE
RISK CAUSES
ACCIDENT
LEADS TO
DANGER LEADS TO
DAMAGE IMPLIES
SAFETY
S

IS IS IS IS IS IS
POTTENTIAL LOSS TO CONTROL OF
FREQUENCY HAZARDS LIKELY
OF LIFE & HAZARDS,
HAS PROBALITY CAUSES EVENT CAUSES EXPOSURE LEADS TO HENCE RISKS &DANGERS
ACCIDENT PROPERTY

I.E. I.E. I.E. I.E. I.E. I.E.

DOMINO CONSEQUENCES MORAL
CHANGE OF HAZARD
ACCIDENT HAS BECOMING
THROUGH
EFFECT BRINGS EXPOSURE RESULTS IN
OF ACCIDENT DEMANDS
LEGAL &
POTTENTIAL MULTIPLE PROBALITY LOSS OF LIFE & ECONOMIC
ACCIDENT
CAUSES PROPERTY MOTIVES

EXIST IN ARISES FROM CAUSED BY EXISTS IN I.E.

A SERIES OF
MAN & THE MAN & THE FAILURES OF MAN & THE
TRAGEDY HAZARD
SYSTEM AGAIN SYSTEM LEADS TO MAN & THE THEN SYSTEM ENDS IN DEMANDS MANAGEMENT
AGAIN
SYSTEM
AN INJURY/LOSS INVARIABLY RESULTS FROM A
COMPLETE SEQUENCE OF FACTORS
THE LAST ONE IS INJURY ITSELF

The accident which caused the injury

is caused or permitted directly
by the unsafe act of a person
or unsafe condition
which can be a mechanical or physical
hazard.
 HAZARD
Source or Situation with Potential to cause harm
IN TERMS OF INJURY.
• DAMAGE TO ENVIRONMENT.
• DAMAGE TO ASSETS.
• ILL HEALTH. OR THEIR COMBINATION
A source or situation with a potential for harm in terms of human injury or ill-
health, damage to property, environment or a combination to these.

• RISK
• Combination of Likelihood and
• Consequence of a hazardous event occurring.
The combination of the likelihood and consequence of a specified hazardous event occurring.
Risk can also be expressed as probability and extent of damage or loss.
examples of ..................

HAZARDS RISKS
slips, falls Severity
⚫ Injuries
lifting and handling hazards – MINOR - cuts, bruises,irritation
operation hazards – M AJOR - burns, concussion
dismantling ,fractures , deafness, lung
disorders
maintenance, repair – SEVERE - poisoning, fatal injury,
commissioning cancer, multiple
fire and explosion fracture
vehicle
Likelihood
violence
⚫ number of personnel exposed
inhalation ⚫ frequency and duration of exposure
eye damage hazards ⚫ failure and shutdown
skin contact ⚫ unsafe acts being performed

electric shocks
contractor’s etc .......
Occupational Health hazards
Evaluation
Chemical concentration.
Route of exposure.
Length of exposure. Potential to cause sickness,
Frequency of exposure impaired health, discomfort.
Individual variation.
Drug/medicine reactions
Chemical formulations
Environment
Controls in use
Risk Assessment
Ask The question
What can go wrong?
How serious could it be?
How likely is it to happen?
What should we do about it?
 SEQUENCE OF LOSS

• SOCIAL ENVIRONMENT
• FAULT OF A PERSON
• UNSAFE ACT OR CONDITION
• ACCIDENT
• INJURY OR LOSS
It is easiest and most effective to remove the centre
domino UNSAFE ACT OR CONDITION
THE FIVE FACTORS IN ACCIDENT SEQUENCE
REMOVAL OF THE CENTRAL FACTOR
HAZARD
MAKES THE ACTION OF
PRECEEDING FACTORS
INEFFECTIVE
 ACCIDENT CAUSATION MODEL

Lack of Basic Immediate

causes Incident Loss
control causes

LOSS CONTROL MODEL

DET NORSKE VERITAS

 IMMEDIATE CAUSES
Substandard Acts/Practices Substandard Conditions
Operating Equipment Without Authority Inadequate Guards or barriers
Failure to warn Inadequate or Improper Protective Equipment
Failure to secure Defective tools, Equipment or Materials
Operating at improper speed Congestion or Restricted Action
Making Safety device inoperative Inadequate Warning System
Removing Safety Device Fire and Explosion Hazards
Using Defective Equipment Poor Housekeeping, Disaster
Failing to Use PPE properly Noise Exposure
Improper Loading Radiation Exposure
Improper Placement Temperature Extremes
Improper Position for Task Inadequate or Excess Illumination
Servicing Equipment in operation Inadequate Ventilation
Horseplay
Under Influence of Alcohol and/or Other Drugs
 BASIC CAUSES

Personal Factors Job/System Factors

Inadequate Capability Inadequate Leadership or
Supervision
Physical/Physiological Inadequate Engineering
Mental/Psychological Inadequate Purchasing
Lack of Knowledge Inadequate Maintenance
Lack of Skill Inadequate Tools, Equipment,
Materials
Stress Inadequate Work Standards
Physical/Physiological Abuse or Misuse
Mental/Psychological Wear and Tear
Improper Motivation
 LACK OF CONTROL
Inadequate System/Standards/Compliance
FAILURE TO MAINTAIN COMPLIANCE WITH ADEQUATE STDS. FOR
Leadership and Administration Personal Protective Equipment
Leadership Training Health & Hygiene Control
Planned Inspections & Maintenance System Evaluation
Critical Task Analysis & Procedures Engineering & Change Management
Accident/Incident Investigation Personal Communications
Task Observations Group Communications
Emergency Preparedness General Promotion
Rules & Work Permits Hiring & Placement
Accident/Incident Analysis Materials & Service management
Knowledge & Skill Training Off-the-Job Safety
 Loss Control

When Factors Causing Losses Are Controlled

By Installing
A Coordinated Management System

One Controls
Factors Causing Waste Of Time, Effort & Resources

And This Enables

Maximisation Of Profits
ACCIDENTS DO NOT HAPPEN
THESE ARE CAUSED

H. W. Heinrich
pioneer in Safety informed that
PEOPLE CAUSE ACCIDENTS
NOT THINGS
 DR. W. EDWARDS DEMING AND OTHER MANAGEMENT
SPECISLISTS HAVE DISCOVERED

15% OF THE LOSS RELATED PROBLEMS OR MORE IS

CONTROLLED BY EMPLOYEES

85 % OR MORE IS CONTROLLED BY MANAGEMENT

IN OTHER WORDS
VAST MAJORITY OF OCCUPATIONAL HEALTH
AND SAFETY PROBLEMS AND OTHER LOSS
PRODUCING EVENTS ARE MANAGEMENT
PROBLEMS.
 SIGNIFICANT ACCIDENT STUDIES – 1969
By Frank E Bird Jr. – Then Director Of Engg. Services
For Insurance Company Of North America

• 1,753,498 Reported Accidents By • Revelation :

297 cooperating Companies • For Every Reported Serious Or
were Analysed. Major Injury there were there
• Companies Represented 21 were 9.8 Minor Injuries.
Different Industrial Groups. • But 95 Companies had 15 Minor
• Employed 1,750,000 Employees (Medical Treatment) Injuries.
• Who Worked 3 Billion Manhours • 30.2 Property Damages were
During the Exposure Period reported for each major Injury.
Analysed. • 600 No Loss Incidents for each
serious or major injury was
calculated.
 ACCIDENT RATIO

1 MAJOR INJURY

10 MINOR INJURY

PROPERTY DAMAGES
30

NEAR ACCIDENTS
600

Our efforts should be directed to the many significant opportunities of near misses for
control of accidental losses

DET NORSKE VERITAS

 SIGNIFICANT ACCIDENTS – CONTD.

• CONSIDER THE RATIO – 30 PROPERTY DAMAGE ACCIDENTS WERE

REPORTED FOR EACH SERIOUS OR DISABLING INJURY.
• PROPERTY DAMAGE ACCIDENTS COST BILLIONS OF RUPEES ANNUALLY.
• YET THEY ARE FREQUENTLY MISNAMED – AS NEAR MISSES.
• THE PROPERTY DAMAGE SITUATION COULD ALSO HAVE RESULTED IN
PERSONAL INJURY.
• THE MISCONCEPTIONS THAT LEAD SUPERVISORS TO RELATE THE TERM
ACCIDENT TO INJURY ONLY AND NOT THE PROPERTY DAMAGES.
 COST OF ACCIDENTS
• DIRECT COSTS :
Compensation And Accident costs.
Amount to 25% Of the Total Cost.
• INDIRECT COSTS :
Rest 75 % Of costs are Hidden or the Indirect Costs Pertinent
to the Victims, Management & Society Are invariably omitted.
SAFETY DEPENDS on ........

“HARDWARE” “SOFTWARE”
the plant and upkeep The organisation

“HUMAN WARE”
The people

DET NORSKE VERITAS

 Recruitment and
SAFETY DEPENDS on ........ Critical task placement
and procedures
Planned Inspection Accident incident
reporting/analysis
Engineering and change
Rules and Work permit
Procurement

“HARDWARE” “SOFTWARE” Emergency

The organisation preparedness
Maintenance the plant and upkeep
System review

Materials and Services

management

“HUMAN WARE” Leadership

Health and Hygiene The people
Training
Personal and Group Communications •Leadership
•Knowledge
Task Observation •skill
PP
E

DET NORSKE VERITAS

 How a System Can Help

• To maintain current results

• For continuing improvement
• To get consistent results
• To protect against catastrophes
• To cope with emerging requirements
• To provide a standard for new acquisitions
• To streamline tracking and reporting
• To attain “World Class” performance

DET NORSKE VERITAS

Safety management activities
 Manufacturing process. (FAct)
Making, altering, repairing, ornamenting, finishing, packing,
Oiling,washing,cleaning, breaking up,demolishing, or otherwise treating or adopting
any article or substances with a view to its use, sale, transport, delivery or disposal,
or
Pumping oil,water, sewage or any other substance. Or
Generating, transforming or transmitting power, or
Composing types for printing, printing by the letter press, lithography, photogravure
or other similar process. Constructing, reconstructing, repairing, refitting, finishing
or breaking of Ships or vessels.Preserving or storing any article in cold storage.
 Hazardous process
Any process or activity in relation to an industry specified in
the first schedule, where, unless special care is taken, raw
materials used therein or the intermediate or finished
products, bye-products, wastes or effluents thereof would-
1. Cause material impairment to the health of the persons
engaged in or connected therewith, or
2. Result in the pollution of general environment.
 Major Process hazards
FIRE. Explosion. Toxic Release.
Factors which determines the scale of the hazard.
The Inventory.
The Energy factor.
The time factor.
The intensity-Distance factor.
Exposure factor.
 THE INVENTORY

– The Most fundamental factor which

determines the scale of the hazard.
– The larger the inventory of material
the greater the potential loss.
– Insufficient appreciation if there is
any increase in magnitude of the
inventory.
 THE ENERGY FACTOR

Hazardous material to explode inside the plant or disperse in

the form of a flammable or toxic vapour cloud, there must be
energy. In most cases this energy is stored in the material
itself, either of chemical reaction or of material state.
In practical, material held above its boiling point at high
pressure and temperature contains large quantities of energy,
which cause a maximum loss. Material which is held as
refrigerated liquid at atmospheric pressure contains much less
energy. Toxic substances is produced as by product as by
product in a chemical reaction or runaway exothermic
reactions are hazardous.
 THE TIME FACTOR
Fundamental factor is the development of the hazard time. The time factor affects
both the rate of release and the warning time. The nature and scale of the hazard is
often determined by the rate of release, rather than inventory. The escape of toxic
gas depends on the rate of release, there is considerable difference between an
instantaneous and a continuous release of toxic gas.
The warming time available to take emergency countermeasures and to reduce the
number of people exposed is also important. An explosion gives a warming time
which is usually measured only in seconds or zero. where as toxic release gives a
warning which is often measured in minutes.
 THE INTENSITY-DISTANCE
• An important characteristic of a hazard is the distance over
which may cause injury or damage. In general fire has a
relative short potential range, explosion a rather longer one
and a toxic release a very long one.

• For explosion the variations of the blast parameter peak over

pressure with the mass of explosive and the distance is given
approximately by the relations.
 THE EXPOSURE FACTOR
Factor which can greatly mitigate the potential effects
of an accident is the reduction of exposure of the
people who are in the effected area. This reduction of
exposure may be due to the futures which apply before
the hazard develops or to emergency measures taken
after the hazard is recognized
 GENERAL PROCESS HAZARDS
• Exothermic reactions.
• a. Hydrogenation. The addition of hydrogen atom to both sides
of double or triple bond.(Hydrogen under pressure)
• b.Hydrolysis: Reaction of compound with water.(manufacturing
of acids)
• c. Alkylation:-Addition of alkyl group to a compound.
• d.Isomerisation: rearrangement of the atoms in an organic
molecule such as a change from a straight chain to a branched
molecule or displacement of double bond.(stability of reactive
chemical)
 GENERAL PROCESS HAZARDS

• a. Sulfonation: introduction of SO3H (Sulfonic acid)

radical into organic molecule through reaction with H2SO4.
• b. Neutralisation : Reaction between an acid and a base, to
produce a salt and water.
• c. Esterification: Reaction between an acid and an alcohol,
except in case where acid is highly reactive or where the
reacting substances are unstable.
• d. Oxidation: Combination of oxygen with some substance in
which reaction is controlled and does not go to CO2 and H2O
as in the case of combustion. (vigorous oxidizing agents such
as chlorates, nitric acid, hypochloric acids and salts)
 GENERAL PROCESS HAZARDS
• Polymerisation:-Joining together of molecules to
form chains or other linkages, heat must be
dissipated to keep the reaction under control.

• Condensation: Joining together of two or more

organic molecules with the splitting of H2O, HCl or
other compounds.

• Halogenation: Introduction of halogen atoms into

an organic molecule.(strongly corrosive &
exothermal)

• Nitration: Involving replacement of hydrogen

atom in a compound with nitro group.(possible of
Explosion)
 GENERAL PROCESS HAZARDS
• Endothermic reactions.
• Calcination: Heating of material to remove moisture of
other volatile material.
• Electrolysis: separation of ions by means of electric current,
there are hazards because of the presence of flammable or
highly reactive products.
• Pyrolysis: Thermal decomposition of large molecule by
high temperature.
 SPECIAL PROCESS HAZARDS
Process temperature.
Low pressure.
Operation in or near flammable range.
Operating pressures.
Low temperatures.
In-storage.
Loss of material through corrosion and erosion.
Leakage of joints and packing.
 FIRE, EXPLOSION & TOXICITY INDEX
F or E = MF X(1+ GPh tot ) X (1+ SPHh tot )
Where MF is material factor – a measure for the potential
energy of the dangerous substances present.
GPh is general process hazards equals ameasure for the hazards
inherent in the process.
SPHh is special process hazards- a measure for the hazards
originating from the specific installation.
 FIRE, EXPLOSION& TOXICITY INDEX
• Toxicity index.(T)

T= Th + Ts (1+ GPh tot + SPHh tot )

Th is Toxicity factor data (obtained from NFPA (National Fire

Protection Agency)
Ts Supplement for MAC (maximum accident credibility) value.
 CLASSIFICATION OF HAZARD
Category F&E Index(F) Toxicity index(T)
I Less than 65 Less than 6
II 65-95 6-10
III more than95 more than 10

Category I Lowest hazard potential.

Category II Hazard potential.
Category III Highest hazard potential.
 CLASSIFICATION OF HAZARDOUS AREA
1. “O” area-if inflammable gases are vapours are expected to
be continuously present in the area.
“1” area- if inflammable gases or vapours are likely to be
present in the area under normal operating condition.
3. “2” area- if inflammable gases or vapours are likely to be
present in the area only under abnormal operating conditions.
 CLASSIFICATION OF SUBSTANCES

Class A. Flash Point below 230c

Class B. Flash point. 230c to 650c
Class C. Flash point 650c to 930c
 EXPLOSION
• Characterized as shock waves which can heard as a bang and can cause damage to
buildings.
• Deflagaration:- When burning velocity of flame speed is relatively slow 1m/s.
• Detonation:-Flame speed is extremely high velocity 2000-3000 m/s.
• Gas & Dust explosions:- When considerable quantities of flammable material are
released and dispersed with air to form an explosive vapour cloud before ignition
takes place. Dust explosions occur when flammable solid material are intensively
mixed with air. The dispersed solid material is in the form of powder with very small
particle size.
 EXPLOSION
• Confined and unconfined explosions:-
confined explosions are those which occur within
some sort of containment such as vessel or pipe
work. Explosions which occur in the open air are
referred to as unconfined explosions.
 FIRE
• Is a rapid exothermic, oxidation chemical reaction which
generate heat & light. To start a fire following three elements
are essential in right proportion.1. Fuel 2. Air (Oxygen) 3.
Heat (Ignition)
 FIRE
SOURCES OF IGNITION :
1. Open Flame.
2. Heat from hot surfaces.
3. Smoking of cigarettes.
4. Welding & mechanical spark.
5. Static charge accumulation.
6. Spontaneous combustion.
7. Chemical energy.
 PREVENTION OF FIRE -Factors
– 1. Isolating open flames & hot processes.
– 2. Insulating hot process equipments
– 3. Strict enforcement of No smoking.
– 4. Use of non sparking tools wherever necessary.
– 5. Employing standard stack height precaution for preventing
spontaneous combustion.
– 6. Earthing and bonding for static charges.
– 7. Employing operations which reduce generation of static charge.
 PREVENTION OF FIRE
– 8. Periodic maintenance of machinery.
– 9. Use of flame arrestors.
– 10. Use of flame proof electrical fittings/equipments.
– 11. Use of intrinsically safe equipments.
– 12. Selection of fuel which is least flammable.
– 13. Limiting the inventory to minimum possible level.
 TYPES OF FIRES

Different forms of Fire:- Jet fire, Pool fire,

flash fires and BLEVE
BLEVE:- it is combination of fire and
explosion. Boiling liquid expanding vapour
explosion.
 INTRINSIC

Any sparking may occur in

normal working is incapable of
causing explosion of gas or
vapour.
 SAFETY VALVE
These are spring loaded pressure relief devices designed to
provide full opening with minimum over pressure. Static
pressure retained in the vessel and kinetic energy of the
gas/vapour are utilized to overcome the spring force on the
disc as it lifts, resulting pop action. The closing pressure will
be at a point below the set pressure and will be reached
after the blow phase is completed.
 RELIEF VALVE & RUPTURE DISC
– Spring loaded pressure relief devices designed for use in the
liquid service, the inlet pressure force overcomes the spring
force and the disc begins to lift off the seat.(10-25 % over
pressure)
– Prevent pressure from building too high in a vessel, which
would result in damage or destruction to that vessel. it is self
destruct
 HAZOP
• The hazard and operability study known as HAZOP. It is a
predictive approach that involves structural brain storming to
look for deviations from design intent.
HISTORY
• Developed by Imperial chemical Industries[ICI] in England at
1960.
• In 1970, method was speeded up by carrying out this design
check at the P & I Diagram.
 HAZOP
• In 1980, General acceptance of the methodology.
• It is better way of identification of the problem, used in
Flixbrough-1974, Three-mile-island-1979, Bhopal-1984, Mexico
city-1984, Chernobyl-1986 accidents.
 HAZOP
• A Multi disciplinary team is normally nominated to visualise the ways in which a
plant can malfunction or can be mal-operated and determine whether the existing
safe guards are adequate.
• PROCEDURES.
• Define objective and scope.
• Select the team.
• Prepare for the study.
• Carryout the examination.
• Follow up & record the results.
 HAZOP
• Team Composition.
• Hazop study team will be of chemical and Mechanical,
Production Managers, Instrumentation and Electrical Engg.
• PREPARATIVE WORK.
• Process flow diagram, Material and Energy Balance.
• P & I diagram.
• Process equipment Layout plan & Elevation.
 HAZOP
• Operating manual.
• Safety Manual.
• Equipment Specification.
• Piping Specification.
• Plot Plan.
• MSDS.
• Any report on safety reviews.
 HAZOP-Principle of examination
• Intention: The intention defines how the part is expected to operate
• Deviations: These are departures from the intention which are discovered by
systematically applying guide words.
• Causes: These are the reasons why deviations might occur.
• Consequences: These are the results of the deviations should they occur.
• Hazards: These are consequences which can cause damage.
• Guide words: These are simple words which are used to qualify the intention. Guide
words are:- NO or NOT, MORE, LESS, AS WELL AS, PART OF, REVERSE and OTHER
THAN.
 HAZOP
– Consider a process

a+b

PUMP
 HAZOP
Guide Deviation Possible Causes
word meaning
NO No Flow Wrong route, Line Blockage, Check v/v
wrong way round,v/v shut,large leak,Gas
lock,Supply tank empty, Joint leakage.
MORE More Pump Over speed,down stream leak/low
flow pressure up stream high pressure, control
failure, restriction oriffice omitted,2 pump
operation, density increase, wrong v/v
installed
LESS Less Flow Pump failure, Cavitations, line fouling, part
blockage,Control failure,Equpt
leakage,Sticking v/v, Viscosity increase,
ensity decrease.
 HAZOP
Guide Deviation Possible causes
word meaning
Reverse Reverse PP Failure,Wrong wired,High receiver pressure, Surging,Gas
flow locking,Siphoning, Check v/v passing,In correct operation,
Emergency venting.
As well An impurity Air, Process leak by pressure difference, spray, Mist,
as Corrosion pdt.

Part of A component or Incorrect specification material entering or activity is

design impurity is
missing, material ineffective or too effective.
is extra pure.
 HAZOP

Guide Deviation Possible causes

word meaning
Other An Similar containers or Off loading connections.
than entirely
different
material
used
 NOISE & ITS HAZARDS
• Noise is Wrong sound in the wrong place at wrong time
• Loudness: Measured in decibels – dB 90dB for 8 hours is the limit.
• Frequency: Denoted as Hertz – Hz or cycles/sec. Human Ear can hear sounds in the range of 20-20,000Hz.
• Auditory Effects: Hearing loss – Temporary or Permanent or Both
• Non-Auditory Effects
1. Interference with communication, disrupted speech, interference in hearing desired sounds.
2. Physical & Mental Disturbances: High B.P., Lack of sleep, Fatigue etc.
NOISE & ITS HAZARDS
Thank you