CHEA 512 Safety in Process-Hazard Classification

CHEA 512
HAZARD
CLASSIFICATION
Engr. Lina D. dela Cruz
Chemical Engineering Department
Technological Institute of the Philippines
Common Industrial Hazards

Chemical technology
technicians are exposed

to a variety of common
industrial hazards,
which can be
flammable, toxic and
radioactive.
When technicians may
come in contact with
these hazards, they
must follow several
steps to ensure their
safety.

The first step is the proper instruction in the
identification, handling and use of hazardous

substances.
The second critical step includes the use of
safety procedures in working with any of
these substances.

The National Fire Protection Association
has a standardized system used in chemical

hazard identification.

Toxic hazards include fuels, metal fumes,
solvents, products, and by products.

Flamable substances catch fire or explode
easily.
Radioactive substances include metallic
uranium, xray, and strotium 90.
These hazardous materials break down the
cells of exposed tissue.
Acute and chronic hazards have immediate or
delayed effect on workers.

Acute (immediate) poisons maybe ingested,
inhaled, injected or absorbed. Acute effects occur
when high concentrations of these chemical
compounds come in contact with the chemical
technician during a single exposure.
Examples of these chemicals are Chlorine, acids and
caustics. Chronic (delayed) hazards include
asbestos fibers, coal dust, and toxic metals such as
lead and manganese.
Chronic hazards are cumulative and frequently occur
over an extended period of time.
Physical, Chemical, Ergonomic, and

Biological hazards
Physical hazards- are
classified as electrical, noise,

radiation, or temperature.
Physical hazards associated
with chemicals are
categorized as a
combustible liquid, a
compressed gas, explosive,
a flammable gas, a
flammable liquid, organic
peroxide, oxidizer,
pyrophoric, unstable and
water reactive.
Chemical hazards
Chemical hazards are often referred to as
health hazard by process technicians and can

be categorized as carcinogens, mutagens,
teratogens, reproductive toxins, those that
cause asphyxiation, anesthetic, neurotoxic,
those that cause allergic response, irritants,
sensitizers, corrosive, toxic, highly toxic; and
those that target organ effects
Ergonomic hazards
They are activities that require chemical
technicians to work in an unusual or awkward

position for extended periods of time.
These may include repetitive motions,
monotony, work pressure, inability to match
the standard performance. Console
operations, or equipment and system
operation
Biological Hazards
Are described as any living organism capable
of causing disease in humans.

This includes insects, bacteria, fungi and
molds.
Electrical Hazards
Process technicians work with a variety of electrical
energized equipment and systems.

Electrical motors are used to drive pumps,
compressors, generators, mixers, conveyors, fans
and belts and a wide variety of other systems.
These substations have variety of voltages coming in
and out of local transformers.
The chemical processing industry has initiated
special procedure in isolating and safely tagging and
locking out process equipment and is part of process
technician's job.
Industrial Noise Hazards

Industrial noise is described as valueless or
unwanted sound that measured in decibels.

The trigger point for hearing protection is 85
decibels, and noise over 140 decibels can
cause permanent loss, and once hearing loss
occurs, it can never be recovered.
Industrial equipment produces noise at a
variety of decibel levels, and hearing
protection is provided and required in areas
where exposure will excess recommended
levels.
Radiation Hazards
Events that happened in places such as Chernobyl
have made the world aware of the hazards

associated with radiation. On April 26, 1986, a fire
explosion at the Chernobyl nuclear power plant sent
out invisible radioactive cloud that eventually circled
the globe.
Of the known elements on the periodic table, 50 are
known to be radioactive. Recent developments in
nuclear testing equipment, nuclear power, x-ray, and
other nuclear technologies have the ability to
seriously affect biological organisms.
Hazard Recognition
In a typical safety program, hazard
recognition is a considered to be a
management function.
Accidents are defined typically as an
unplanned disruption of normal activity
resulting in an injury or equipment damage.
The key to accident prevention is linked to
(1) determining the cause, (2) preventing its

recurrence.
By understanding the causes of accidents,
process technicians can more easily defend
against their occurrence.
Accidents can be broken down into four

1.
2.
3.
4.
parts:
Contributing causes poor instructions
Immediate causes did not use personal
process equipment (PPE)
The accident struck by truck
The consequence of the accident - fatality
Unsafe acts and unsafe conditions are responsible
for many accidents inside the plant.

An unsafe act is defined as any act that increase a
persons chance of having an accident. An unsafe
act can be eliminated by a no-tolerance policy,
because this is not the most effective way to do
business, other alternatives needs to be researched.
Unfortunately, the negative reinforcement theory
makes it very difficult to convince someone to stop
performing unsafe acts. Many of these people think
the shortcuts they take are worth or that it cant
happen to me
Unsafe conditions are easier to handle than
unsafe acts.
An unsafe condition is defined as a condition
in the working environment that increases a
technicians chance of having an accident.
Unsafe condition can be corrected by
encouraging process technicians to identify
and correct unsafe conditions.
Accident Prevention
The basic principles of accident prevention
include a safe working environment, safe

work practice, and effective management.
Plant managers are the central focus of
safety program management. Managers
design the companys safety policy, enhance
safety awareness, and facilitate safe and
healthful work conditions.
Accident Prevention
In the typical chain of command, a safety
coordinator is the designated specialist who

provides current safety supervision and
expertise on the program.
The safety coordinator takes much of the day
to day operation and receives training in
specialized areas and carefully analyzes and
compares existing and new governmental
rules and guidelines to current plant
operations.
Three parts of accident prevention

Effective management
-accept responsibility for safety
-write safety policy
-stimulate safety awareness
-use engineering, administrative and PPE controls
-teach department heads and give authority
-utilize first line supervisors
-hold stewardship interviews
-integrate safety department into corporate culture
1.

2. Safe work practices
-conduct job safety profile

-develop job standards
-develop standard operational procedures
-integrate HAZCOM, PSM, respiratory
protection, PPE, respiratory protection, prmit
system, environmental standards, and other
selected topics

3. Safe working environment
-develop corporate safety philosophy

-implement general plant safety program
-launch accident prevention program
-launch hazard recognition program
-implement plant training
Accident prevention
Process technicians ensure that th rules of
safety program are maintained by all of the

people entering the facility.
Technicians are the backbone of any safety
program because they are responsible for:
-good housekeeping
-hazard recognition
-safe work practices
-safe work environment
Accident investigation
Accident investigation is designed to identify
the point of failure and prevent recurrence.

The point of failure typically falls into one or
two groups: hazardous conditions or poor
work practice.
First line supervisors should:
-conduct accident and near-accident investigations

-visit accident site as soon after the accident as possible
-take photographs
-collect data and information from witnesses and those
involved in accident
-fill out accident report:
a) analyze what has happened
b) identify objectives

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CHEA 512

Common Industrial Hazards

technicians are exposed

Common Industrial Hazards

identification, handling and use of hazardous

Common Industrial Hazards

has a standardized system used in chemical

Common Industrial Hazards

solvents, products, and by products.

Acute and chronic hazards have immediate or

delayed effect on workers.

Physical, Chemical, Ergonomic, and

classified as electrical, noise,

health hazard by process technicians and can

technicians to work in an unusual or awkward

of causing disease in humans.

energized equipment and systems.

Industrial Noise Hazards

unwanted sound that measured in decibels.

have made the world aware of the hazards

The key to accident prevention is linked to

(1) determining the cause, (2) preventing its

Accidents can be broken down into four

Unsafe acts and unsafe conditions are responsible

for many accidents inside the plant.

Unsafe conditions are easier to handle than

include a safe working environment, safe

coordinator is the designated specialist who

Three parts of accident prevention

Three parts of accident prevention

-conduct job safety profile

Three parts of accident prevention

-develop corporate safety philosophy

safety program are maintained by all of the

the point of failure and prevent recurrence.

First line supervisors should:

-conduct accident and near-accident investigations

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