DKK3423

PLANT SAFETY & HEALTH

CHAPTER 1: INTRODUCTION
By: Mdm Malyanah Binti Mohd Taib

Lecturer, FKKSA, UMP

malyanah@ump.edu.my

SAFETY PROGRAMMES

S:system A:attitude F:fundamentals E:experience T:time Y:you

*To record what needs to be done to have an outstanding safety program *To do what needs to be done *To record that the required tasks are done

* willingness to do some of the thankless work that is required for success

* Understand the fundamentals of chemical process safety in the design, construction and operation of the plants

* Learn from the experience of history or be doomed to repeat it

* safety takes time (study, to do the work, to record results, to share experience, time to train/be trained)

* Everyone should take the responsibilites to contribute to the safety program

Loss prevention
appropriate technologies identify the hazards of a chemical plant eliminate before accident occurs

chemical or physical condition potential to cause a damage to people, property, or the environment.

Safety

Hazards

measure of human injury, environmental damage, or economis loss accident likelihood and the magnitude of the loss or injury Risk

The most effective means of implementing a safety program is to make everyone responsible in a chemical process plant.

IMPORTANCE OF SAFETY AND HEALTH IN CHEMICAL INDUSTRY

The importance are:

Prevents the valuable equipments from totally damaged and losing a large amount of investment. Assures the prolonged human resource contribution to profit the chemical plant. To avoid other indirect cost

HAZARD AND RISKS

Hazard is a chemical or physical condition that has the potential to cause damage to people, property or the environment.

Danger is arisen when one exposed with the hazard.

Risk is a measure of human injury, environmental damage or economic loss in terms of both the incident likelihood and the magnitude of the loss or injury, severity.
6

ACCIDENTS AND LOSS STATISTICS

Accident and loss statistic are important measures of the effectiveness of safety program. These statistics are valuable for determining whether a process is safe or whether a safety procedure is working effectively. There are three systems considered OSHA incidence rate. Fatal accident rate (FAR) Fatality rate or deaths per person per year
7

ACCIDENTS & LOSS STATISTICS (cont)

OSHA incidence rate (based on injuries and illness) Number of injuries and illness x 200000 Total hours worked by all empployeesduring period covered

OSHA incidence rate (based on lost workdays) Number of lost workdays x 200000 Total hours worked by all empployeesduring period covered

ACCIDENTS & LOSS STATISTICS (cont)

Number of fatalities x 108 FAR Total hours worked by all empployeesduring period covered

Fatalities rate

Number of fatalities per year Total number of peoplein applicable population

FAR = Fatal Accident Rate

10

Example
A process has reported FAR of 2. If an employee works a standard 8-hr shift 300 days per year, compute the deaths per person per year.

Solutions
Death per person per year = (8hr/day) x (300 day/yr) x (2 deaths/108 hr) = 4.8 x 10-5
11

Responsible Care
Responsible Care = a well- organized, pro- active approach to managing health, safety and environment aspect of our plants and business as that goes beyond legislative requirements CICM is the Malaysian steward for the Responsible Care Programme (RCP), which is a global initiative adopted by chemical companies to continuously improve all aspects of safety, health and environment (SHE) protection of their operations and products in manner responsible to the concerns of the public.

Source: www.responsiblecare.org

Codes of Management Practices

DISTRIBUTION CODE (Aug 3, 95)
to reduce the potential for harm posed by the distribution of chemicals to the general public, employees and the environment

COMMUNITY AWARENESS AND EMERGENCY RESPONSE CODE (Nov 2, 96)

to work with nearby communities to understand their concerns and to plan and practice for emergencies

POLLUTION PREVENTION CODE (Nov 25, 97)

to achieve ongoing reductions in the amount of all pollutants released into the environment

Codes of Management Practices

PROCESS SAFETY CODE (May 19, 99)
to prevent fires, explosions and accidental chemical releases

EMPLOYEE HEALTH AND SAFETY CODE (May 19, 99)

to protect and promote the health and safety of people working at or visiting company sites.

PRODUCT STEWARDSHIP CODE (Nov 17, 99)

to make health, safety and environmental protection a priority in all stages of a product's life, from design to disposal.

Case Studies
Flixborough, England Bhopal, India Saveso, Italy Pasadena, Texas Chirnobyl, ALgeria Minamata, Japan Tasks - Form 10 groups - Choose one of the accidents above. - Download 1 video related to it - Make conclusion from the accidents based on safety point of view (Where, When, How, Why, What) - Presentation on Thursday, 7 MAC 2013 15