Group Exercise: Case study of Paint Production

Bangkok, 1 March 2012

Reinhard Joas, BiPRO

Beratungsgesellschaft für integrierte Problemlösungen

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Group Exercise:Case Study of Paint Producers

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Awareness raising video “Blast Wave in Danvers”

Source: US Chemical Safety Board (CSB) http://www.csb.gov/videoroom

Solvent vapour explodes at CAI/Arnel ink and paint manufacturing facility.

Destroyed a neighbourhood: homes and businesses were damaged beyond repairLink to the upcoming interactive case based exercise

While watching, please attend to the following question:

How could Responsible Production and its tools have contributed to the prevention of this accident?

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Introduction to integrative case based exercise

Formulation and application of paints

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Tools for the first step of Responsible Production

1. Identify responsible production issues

UNDERSTAND THE PROCESS FLOW

RISK ASSESSMENT AND PRIORISATION

STANDARDS, CODES, LAW AND REGULATIONS

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Tool 1.1Prepare process flow chart

Tool 1.2Chemical inventory and hazard classification

Tool 1.3Identify risks

Tool 1.4Hazard hotspots map

Tool 1.5Legal register

Tools for the first step of Responsible Production

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Tool 1.1 Prepare a process flow diagram

Step 1: Prepare your process flow diagram

Define boundaries of process

Decision on level of detail to be included in the diagram

Identify steps and activities in the process

Describe sequence of activities

Discussion and revision of flowchart with relevant stakeholders

e.g. Workers and supervisors

Suppliers

Transporters

Customers

Maintenance companies

Waste transporters

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You are invited to.....

Prepare a process flow diagram for formulation and application of paints

containing

Boundaries of process

Certain level of detail

Relevant steps and sequence of activities

Now it is your turn....

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Process flow - Definition of boundaries of the process

Production of solvents

Production of pigments

Production of varnishes

storage storage storage

Formulation Non hazardous waste

Hazardous waste

disposal

disposaltransport ofproducts

storage

Re-packaging

storage

Application

Painted products

storage

storagetransport of solvents

Non hazardous waste

Hazardous waste

disposal

disposal

storage

storage

System boundaries

Transport of raw materials

Transport of raw materials

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Storage pigments

Storage solvents

Storage varnishes

Chemicals

Solvents

Pigments

Varnishes

Level of detail to be included in the flow diagram - Formulation

Storage of final paint product

Formulation

Dosing and pre-mixing

Milling and dispersing (cooling)

Finishing and blending

Filling

Packaging

Transport of raw materials to company site

Transport

Transport of hazardous

wastes

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Storage paints

Storage solvents

Chemicals

Solvents

Paint

Varnishes

Level of detail to be included in the flow diagram - Application

Application

Diluting

Blending

Application

Drying

Storage of other raw material

Painted product

Continuation of manufacturing of final product

Cleaning of equipment

Transport

Transport of hazardous

wastes

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Identification of steps and sequence of activities in the process of formulation

Transport to company site

Off-loading and storage at company site

Steps during production process

Quality control, packaging

Dosing and pre-mixing

Milling and dispersing

Finishing and blending

Filling

Transport of final product,Transport of waste

Formulation

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Identification of steps and sequence of activities in the process of application

Transport to company site

Off-loading and storage at company site

Steps during production process

Continuation of manufacturing of final

product

Application

Diluting

Blending

Application

Drying

Cleaning of equipment

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Identification of chemicals and their quantities

Identification of hazards associated with activities such as potential for a fire or an explosion

This information is explained in Material Safety Data Sheets (MSDS); should be

made available by suppliers

Identification of hazards for all chemicals

Mark hazards on flow-chart

Repetition of this process through entire process flow-chart

Step 2: Identify the chemicals, their quantities and the hazards involved in the process

Tool 1.1 Prepare a process flow diagram

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Next step......

Identify chemicals and their quantities

Potential hazards

forformulation and application of paints

.........it is again your turn....

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Ap

plic

atio

nFo

rmu

lati

on

Identification of chemicals and quantities

Process steps at company site Chemicals involvedQuantity of chemicals,

e.g. t/a

Dosing and pre-mixing

Milling and dispersing

Finishing and blending

Filling

Diluting

Blending

Application

Drying

Cleaning of equipment

Varnishes, pigments

Varnishes, pigments, solvents

Paints

Paints

Solvents, paints

Solvents, paints

Solvents, paints

Solvents

Solvents

Transport

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Identification of hazards for chemicals

Potential hazards

Ap

plic

atio

nFo

rmu

lati

on

Flammable properties, irritating effects

Sensitizing properties

Explosive and highly flammable properties

Harmful

Flammable properties

Danger for the environment

Chemicals involved

Varnishes

Pigments

Solvents

Paints

Solvents

Paints

Classifications

e.g. F, Xi

e.g. Xi

e.g. F+, E

e.g. Xn

e.g. F

e.g. N

Tran

spo

rt

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Identification of hazards for processes

Process steps at company site Potential hazardsA

pp

licat

ion

Form

ula

tio

n

Dosing and pre-mixing

Milling and dispersing

Finishing and blending

Filling

Diluting

Blending

Application

Drying

Cleaning of equipment

Spills

Spills, exothermic reaction

Spills, exothermic reaction

Spills, leaking

Spills, leaking

Spills, exothermic reaction

Explosion

Explosion, burning

Spills

Tran

spo

rt

Spills, leaking

Tran

spo

rtTr

ansp

ort

Spill

sSp

ills

Spill

s

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Identification of hazards for all chemicals

e.g. Material safety data sheets for solvents, pigments, varnishes, final paint product

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Tool 1.3 Identify health, environmental, social and economic risks

Step 1: Create a risk assessment team Step 2: Review your hazard hotspots

Pay particular attention to areas or process steps where large quantities of hazardous chemicals may be stored or handled

Step 3: Identify risk-prone and vulnerable groups, areas and assets in case of an accident

Identification of threatened objects (people, environment and property) in case of accident

Step 4: Identify potential accident scenarios related to the hazard hotspots you have identified

Identification and analysis of past accidents in the sector

List potential accidents related to the Hazard Hotspots which have been already identified

Consider different accident scenarios

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Continue to.....

Identify accident scenarios with

threatened objects and stakeholders

forformulation and application of paints

..........it is your third turn....

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factory site (formulation)

Farmers, agricultural land

Other industrial

sites

Other factory

Road

CommunityProperties, citizens

Accident scenarios

Modelling of dispersion in case of accident

River

Storage pigments

Storage

solvents

Storage varnishes

Drinking water supply

Transport

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Step 5: Identify the severity of related health, environmental, social and economic impact in an accident situation

Assign a ‘severity’ (importance) factor

Discussion and agreement in risk assessment team

Tool 1.3 Identify health, environmental, social and economic risks

Consider impact on

• Health of community and workers• Agriculture and fisheries• Water resources and quality of air• Site facilities and transport infrastructure• Community and social infrastructures• Company image

Scale should be adapted to both the country and the local context

1. Negligible 2. Limited 3. Serious 4. Very Serious 5. Catastrophic

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Tool 1.3 Identify health, environmental, social and economic risks

Step 6: Estimate the likelihood of each of the identified accident situations actually taking place

1. Practically impossible2. Unlikely3. Rarely4. Regularly5. Frequently

Step 7: Assign a risk factor to each hazard hotspot

Assign each hazard hotspot a risk factor from 1/1 (lowest) to 5/5 (highest) Consider different possible hazard scenarios related to hot spots when

assigning risk factors Repeat this for each activity in the process Mark the risk factor on your flow chart

Step 8: Prioritise your hazards hotspots

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Tool 1.3 Identify health, environmental, social and economic risks

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Go on to......

Risk assessment and prioritisation

of

formulation and application

Assign risk factors (frequency/severity)

Prioritize the hazard hotspots

..........the final stretch is close......

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Storage pigments Storage solvents Storage varnishes

Risk assessment and prioritisation - formulation

Storage of final paint product

Dosing and pre-mixing

Milling and dispersing (cooling)

Finishing and blending

Filling

Packaging

Frequency/Severity

1/1 3/3 2/3

2/4

2/3

2/4

4/2

2/1

2/1

Severity

1 negligible2 limited3 serious4 very serious5

catastrophic

Frequency

1practically impossible2unlikely3rarely4regularly5frequently

Transport of raw materials to company site

Transport

3/3

3/2

WasteTransport

3/3

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Storage paintsStorage

solvents

Risk assessment and prioritisation - application

Diluting

Blending

Application

Drying

Storage of other raw material

Painted product

Continuation of manufacturing of final product

Cleaning of equipment

Frequency/Severity

Severity

1 negligible2 limited3 serious4 very serious5

catastrophic

Frequency

1practically impossible2unlikely3rarely4regularly5frequently

1/1 3/3

2/2

2/2

2/2

3/3

1/12/2

Transport 3/2

WasteTransport

3/3

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Prioritise your hazard hotspots

3/3Application

Dosing and pre-mixing

Finishing and blending

Filling

2/4

2/4

4/2

Frequency/Severity

All others

Storage solvents 3/3

Storage solvents

Transport of raw materials to company site

3/3

3/3

WasteTransport

3/3WasteTransport

3/3

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Tool 1.4 Map the hotspots

Step 1: Map your Hazard Hotspots

On-site

Ground plan of the company or existing company floor plan

Main areas and departments

Off-site

Plan of the region and mark your site

Identification of routes of your suppliers for delivering chemicals

Identify routes used to transport your chemical products

Locate external activity with its associated risk factor

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Hazard hotspot map (on-site)

Storage pigments Storage solvents Storage varnishes

Storage of final paint product

Dosing and pre-mixing

Milling and dispersing (cooling)

Finishing and blending

Filling

Packaging

1/1 3/3 2/3

2/4

2/3

2/4

4/2

2/1

2/1

Transport of raw materials to company site

Transport

3/3

3/2

WasteTransport

!

!

!

!

!

3/3 !

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Farmers, agricultural land

Road

CommunityProperties, citizens

River

Drinking water supply

Hazard hotspots map (Offsite)

Other industrial sitesWaste transport

Relevant for risk analysis!

!!Raw materials

transport

factory site (formulation)

Storage pigments

Storage

solvents

Storage varnishes

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Tool 1.5 Legal Register

Step 1: Identify all legal, code, regulatory and other requirements that may be applicable to your products, processes and operations

Step 2: Identify all requirements present in your licenses and permits

Step 3: List all applicable requirements Step 4: Establish, schedule and assign responsibilities for updating the legal register

List of existing regulations that may be applicable to raw materials, processes and operations

National and international laws, regulations, codes of practice, customer requests and standards

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Tool 2.1 Identify Stakeholders

Step 1: Identify Stakeholders, their relevance and importance

Step 2: Evaluate their relevance and importance

List of all stakeholders (institutions, organisations...)

Prepare ranking system

Assess each stakeholder

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Tool 2.2 Profile Stakeholders

Step 1: Profile each stakeholder Step 2: Keep stakeholder profiles and update them after each engagement

Write down importance, current status, relationship, possible influence etc. of stakeholder

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Tool 2.1 Identification of stakeholders

factory site

Farmer Farmer

Other industrial sites

Other factory

Road

Community

Storage fuels

Storage lubricants

Storage solvents

Storage of technical

gases

Storage acid

Waste storage

Drinking water supply

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Involved stakeholder in the supply chain

Producer of solvents

Producer of pigments

Producer of varnishes

Producer of technical gases

Producer of fuels

Transporter (train)

Transporter (truck)

Retailer / storage

Waste disposal company

Waste storage company

Maintenance company

Community

Local authority

Insurance

companies

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Tool 2.1 Identification of stakeholders

Tool 2.2 Profiling stakeholders

What is their knowledge of the chemical hazards posed by your

products and operations?

How important is this group to you?

Can they exert influence on your

operations?

What is the status of your existing

relationship with this stakeholder

group?

Transporter (train)

Transporter (truck)

Retailer / storage

Waste disposal company

Waste storage company

Maintenance company

Importance of stakeholder:

1= limited influence on your operation

2= influence on what you do

3= influence how you run your business & success as a business

4= significant impact on how you run your business and success as a business

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The final stretch......

Prepare a legal register

for

formulation and application of paints including

Standards, Codes, Laws and Regulations

Schedule with responsibilities

And

Select Relevant Stakeholders

..........

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Legal register

Products / processes and operations

Standards, Codes, Laws and Regulations

Requirements present in licenses and permits

Next check Responsible

Diluting

Cleaning

Applying

.........

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Prioritisation of stakeholder issues

Stakeholders Relevant Why are they

important

How important

(1 to 4)Yes No

Suppliers of chemicalsSupplier of equipmentLocal authoritiesGovernmentCommunity groups (mayors of surrounding villages)NGOsEmployeesTransportersPartners/ joint venturesInvestorsTrade UnionsInsuranceRetailersIndustrial neighbours…

1 = they can only have

a very limited

influence on how

you run your

business

2 = they can influence

what you do and

how you do it in

certain areas of your

business

3 = they can have an

influence both on

how you run your

business and your

success as a

business

4 = they can have

significant impact on

how you run your

business and your

success as a

business

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Tool 3.1Identify actions for risk reduction

Tool 3.2Risk reduction cost analysis

Tool 3.3Set goals, objectives, targets and indicators

Tool 3.4Chemical control action plan

Tool 3.5Training plan

Tool 3.6Emergencies plan

Tool 3.7 to 3.11Prevent and reduce risk (per activity)

Tool 3.12Business case

Tools for the third step of Responsible Production

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Tool 3.2 Prevention and risk reduction cost analysis

Step 1: Identify costs and savings (related to chemical safety initiatives)

For each preventive or risk reduction action identified earlier, list the following costs and savings

One time capital cost

Ongoing operating cost (per year)

One time capital saving

Ongoing operating saving (per year)

Appropriate containments for spills

Temperature control in mixing vessel with automatic switch-off function

Overflow control

Locked storage for solvents

Smoking prohibited in all rooms with handling or storage of solvents

Appropriate containments for spills

Temperature control in mixing vessel with automatic switch-off function

......

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Practical example: Risk reduction cost analysis II

Possible maximum loss (severity):

Probability for annual accident

Cost of measure

Reduced probability

Added value

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For the brave......

Prepare a cost analysis for prevention and risk reduction

for

formulation and application of paints

including

Return on investment

Costs for various accident scenarios

..........

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