Transcript HIGH HAZARD INDUSTRIES VISA-A

HIGH HAZARD INDUSTRIES
VIS-A-VIS
MAJOR EMERGENCIES
By
V. C.Bhatt
CM (Fire & Safety)
GNFC LTD.
DEVASTATION BY FIRE
HIGH HAZARD INDUSTIRES:
Hazards in chemical industry has potential
for Fire, Explosion, Toxic release.
• Can cause injury, ill health, damage to property.
• Damage to environment.
• Serious disruption to people Onsite, Offsite,
premises and services.
• Short term effects and long term effects.
Potential Hazard In Chemical Industries Is
High Due To:
• Hazardous Materials / Chemicals / Inventories of
Materials
• Rigorous Operating Conditions/High Pressure/High
Temperature / Corrosive Combination
• Exothermic Reaction
• Incompatibility
• Varying Environmental Condition
• Human Factors
• Natural Disasters.
SOME POTENTIAL HAZARDS
A. ENERGY SOURCE
• Process Chemicals, Fuels, Nuclear Reactors,
Generators, Batteries Source of Ignition, Radio
Frequency Energy Sources, Activators, Radiation
Sources
• Rotating Machinery, Prime Movers, Pulverizes,
Grinders, Conveyors, Belts, Cranes
• Pressure Containers, Moving Objects, Falling
Objects.
SOME POTENTIAL HAZARDS
B. RELEASE OF MATERIAL
• Spillage, Leakage, Vented Material
• Exposure Effects, Toxicity, Burns, Bruises,
Biological Effects
• Flammability, Reactivity, Explosiveness,
Corrosively and Fire Promoting Properties of
Chemicals
• Wetted Surfaces, Reduced Visibility, Falls,
Noise, Damage
• Dust Formation, Mist Formation, Spray.
SOME POTENTIAL HAZARDS
C. FIRE HAZARD
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Fire, Fire Spread, Fireballs, Radiation
Explosion, Secondary Explosion, Domino Effects
Noise, Smoke, Toxic Fumes, Exposure, Effects
Collapse, Falling Objects, Fragmentation.
D. PROCESS STATE
• High/Low/Changing Temperature And Pressure
• Stress Concentrations, Stress Reversals, Vibration,
Noise
SOME POTENTIAL HAZARDS
• Structural Damage or Failure, Falling Objects,
Collapse.
• Electrical Shock and Thermal Effects, Inadvertent
Activation, Power Source, Failure.
• Radiation, Internal Fire, Overheated Vessel.
• Failure of Equipment / Utility Supply / Flame /
Instrument / Component.
• Start-up and Shutdown Condition.
• Maintenance, Construction And Inspection
Condition.
SOME POTENTIAL HAZARDS
E. ENVIRONMENTAL EFFECTS
• Effect Of Plant On Surroundings, Drainage, Pollution,
Transport, Wind and Light Change, Source Of Ignition /
Vibration / Noise / Radiation Interference / Fire
Spread/Explosion
• Effect Of Surroundings, On Plant(as Above)
• Climate, Sun, Wind, Rain, Snow, Ice, Grit, Contaminants,
Humidity, Ambient Conditions.
• Acts Of God, Earthquake, Arson, Flood, Typhoon, Force
Majeure.
• Site Layout Factors, Groups Of People, Transport Features,
Space Limitations, Geology, Geography
• Security
HIGH HAZARD INDUSTRIES CATEGARIZATION
• Scale Of Operation / Inventory / Process,
Integrations Obvious
• Legal Requirements – Legal Criteria to Classify /
Categorized Industries
• Hazardous Materials Inventories / Hazardous
Processes
• Risk Levels With Respect To Location, Surrounding
Neighborhood, Population Density, Environment
Sensitivity
• Acceptability Criteria For Risk
Acceptability Criteria for Risk
• Risk levels, risk to individuals, societal risk,
voluntary risk and involuntary risk, perception
of risk.
• Profound questions of Ethics and philosophy
of life.
• What risk is acceptable?
• Risk can be minimized at a cost even if can not
be completely eliminated.
• How far should one go along this road?
Acceptability Criteria for Risk
• If we express risk as a Fatal Accident
Frequency Rate (FAFR) – calculated as the
number of deaths per hours of exposure to
risk multiplied by 108.
• FAFR represents the number of deaths from
industrial injury in a group of people during
their working lives.
• Some recommended criteria of acceptable risk
in plant design. (always subjective and
debatable as it is a emotive area)
Acceptability Criteria for Risk
I. The value of life should not be coasted.
II. FAFR below 0.4 or 0.3 for any single risk.
III. For risk to general public such values are subject
to speculation and debate however the following
may be considered acceptable.
a.
b.
c.
d.
If it occurs less frequently then once in 100 years.
If it has a FAFR below about 0.001 or less.
If the risk of death caused by the plant is under 10-5
per year for an offsite individual with this value
determined at a higher statistical confidence limit.
If several people can be killed, it should be 10-7 per
year per person or 10-8 per year per person.
Acceptability Criteria for Risk
e.
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Action should be taken regardless of the criteria to
minimize the number of deaths from any single
events.
Consider the question – whether an accident
that can kill 1000 people should be required to
occur 1000 times less frequently than one that
can kill a single person?
Hence acceptability is highly subjective.
Limitation of number of deaths from any
incidents. It must be the goal.
Loss prevention and loss control can help to
achieve this.
Loss Prevention And Total Loss Control
A major hazard materializes due to loss of
containment
Loss prevention is characterized by
1. A concern with depth of technology and
associated hazards.
2. An emphasis on Management.
3. A system rather than trial and error approach.
4. A concern to avoid loss of containment resulting
in major fire, Explosion, Toxic release.
5. The development of techniques for identification
of hazards.
6. The principle of risk criteria and quantification
of hazards.
7. The development of techniques for the
quantification of hazards.
8. The use of the techniques of reliability
engineering.
9. The principle of independence in critical
assessments and inspections.
10. The planning for emergencies.
11. Strengthening of practices, codes, standards,
statutory regulation with technological change.
Total Loss Control areas are :
1. Injuries health hygiene.
2. Business interruption
3. Property damage
4. Fire / Explosion / Toxic Release
5. Environmental pollution
6. Security
7. Product liability
This can be avoided by:
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Identification of loss producing situations.
Measurement of such loses.
Selection of methods to minimize such loses.
Implementation of methods.
In spite of all these you can have incidents
turning into emergency as :
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Human behaviour is unpredictable.
Chance, complacency, false sense of security, lullness
Low probability events
Low predictability events
High probability but consequences mis calculated
Wrong priorities
Preparedness for Emergency and Response :
Preparedness for emergency starts from drawing board
stage itself. It is integral part of design, construction,
operation, Maintenance.
(As per the chart shown)
Safe Place of Work
Assessment
Residual Accident
Event
Consequence Reducing
Measures
Consequences
Probability of Success
Acceptable
No
Contingency
Plan
Yes
Yes
Probability of Success
Acceptable
No
Consequences of Failure
Acceptable
No
Change
Concept
Review Based on Safe Place
of Work
Definitions:
Incident : An unplanned event causes or could cause under
different circumstances injury, ill-health or damage to property or
the environment.
Emergency : A dynamic incident in which there is a continuing
potential for major injury, ill-health or damage to property, the
process or environment.
Evacuation : the planned and controlled removal of personnel
from an emergency area.
Escape : The uncontrolled departure of personnel from an
emergency area.
Rescue : The recovery of personnel from an area of danger to
safe location.
At any time emergency develops due to;
Change in process parameters
Failure of a piece of equipment or instrument.
Failure of control system.
Error by human being.
Natural Disaster like Flood, Wind, lightening,
Earthquake.
Civil disorder
Malicious damage - sabotage
Sequence of Events in an Emergency:
Phase
Status
Activity
Normal Operation
Prevention
Correct Upset
Abnormal Operation
Controlled Plant S/D
State of Alert
Emergency S/D, Venting,
Dumping, Inventory
Containment
Emergency
Fire Prevention, Fighting,
Emergency Containment
Activities
Evacuation
Sequence of Events in an Emergency:
Evacuation
Orderly Evacuation Under
Direction of supervisor
Mitigation
Escape
Escape groups and
Individuals
Rescue
Emergency Teams in
Action
Safety
Recuperation
Medical and Trauma
Treatment of Personnel,
Recovery
Rehabilitation of Facilities
Normal Operation
Elements of Emergency Preparedness
1. Identification of the FACTORY.
2. Map of the AREA
3. Factory Lay - Out.
4. Storage Hazards & Controls.
5. Material Safety Data Sheets (MSDS).
6. Process Vessel Hazards & Control.
7. Other Hazards & Controls.
8. Trade-Waste Disposal.
9. Records of Past Accidents/Incidents.
10.Gas Dispersion Concentration.
11.Evacuation Table.
12.Environmental Impact Assessment.
13.Weather Conditions.
14.Incident Controllers (Ics).
15.Deputy Incident Controllers (Dy.Ics).
16.Site Main Controllers (SMCs).
Elements of Emergency Preparedness
17.Key Personnel.
18.Essential Workers.
19.Assembly Points.
20.Emergency Control Center (ECC).
21.Fire & Toxicity Control Arrangements.
22.Medical Arrangements.
23.Transport & Evacuation Arrangements.
24.Pollution Control Arrangements.
25.Other Arrangements.
26.Alarms & Sirens.
27.Internal Phones.
28.External Phones.
29.Nominated Persons to declare Major Emergency.
30.A Form to record emergency telephone calls.
31.Statutory Communication.
32.Separation Distances.
33.Emergency Instruction Booklets.
Thank You