8/9/2019 Loss Prevention slides.pdf

1/21

PreventPreventMaterial lossMaterial loss (plant, equipment, chemicals)(plant, equipment, chemicals)

Human lossHuman loss (injury, death)(injury, death)

Environmental lossEnvironmental loss (pollution, contamination)(pollution, contamination)

ByBy

Anticipating potential hazardsAnticipating potential hazards

Applying safety measuresApplying safety measures

8/9/2019 Loss Prevention slides.pdf

2/21

Increased plant size and complexityIncreased plant size and complexity More rigorous operating conditionsMore rigorous operating conditions

Increased potential for lossIncreased potential for loss

IncentivesIncentives

Moral, public perceptionsMoral, public perceptions

LegalLegal

EconomicEconomic

8/9/2019 Loss Prevention slides.pdf

3/21

FlixboroughFlixborough (UK) 1974(UK) 1974 -- 28 deaths, 400+28 deaths, 400+ injuriesinjuries Cyclohexane explosionCyclohexane explosion -- reactor startreactor start--upup

Flame 100m+ > 20 minFlame 100m+ > 20 min

90% site buildings damaged90% site buildings damaged

BhopalBhopal (India) 1984(India) 19843,800+ deaths, 200,000+ injuries3,800+ deaths, 200,000+ injuries

36 tonnes methyl36 tonnes methyl isocyanateisocyanate releasedreleased

Poor isolation of storage tanksPoor isolation of storage tanks

Large scale storage of hazardous materialLarge scale storage of hazardous material

8/9/2019 Loss Prevention slides.pdf

4/21

CoodeCoode IsIs (Vic) 1991(Vic) 1991 27/47 storage tanks destroyed / damaged27/47 storage tanks destroyed / damaged

11stst

explosion damaged tank drenchingexplosion damaged tank drenching

systemsystem

Explosions followed in a another 12 tanksExplosions followed in a another 12 tanks

Costs $2 million (fire fighting), $50 millCosts $2 million (fire fighting), $50 mill

Minimise stock holdingMinimise stock holding

8/9/2019 Loss Prevention slides.pdf

5/21

KurnellKurnell (NSW) 1995(NSW) 1995Power failure Boiler shutdownPower failure Boiler shutdown

Fires in cat cracker & crude distillationFires in cat cracker & crude distillation

7 days production lost7 days production lost

8/9/2019 Loss Prevention slides.pdf

6/21

Victoria 1998Victoria 1998 2 deaths2 deaths

8 injuries8 injuries

No gas supplies to industry and domesticNo gas supplies to industry and domestic

consumers in Victoria for 3consumers in Victoria for 3 -- 4 weeks4 weeks

Plant lossPlant loss

Downstream production lossDownstream production loss

8/9/2019 Loss Prevention slides.pdf

7/21

11stst

DegreeDegreeidentify potential for problemsidentify potential for problems Presence of hazardous materialsPresence of hazardous materials

HeatHeat

OxygenOxygen

Ignition sourcesIgnition sources

Human errorHuman error

Mechanical failureMechanical failure

Requires good engineering and designRequires good engineering and design

8/9/2019 Loss Prevention slides.pdf

8/21

2nd degree hazards2nd degree hazardspossible outcomespossible outcomesFireFire

ExplosionExplosion

ReleaseRelease

ImpactImpact

FallingFalling

Need to be minimizedNeed to be minimized

8/9/2019 Loss Prevention slides.pdf

9/21

ToxicityToxicity Lethal Dose (LD), Threshold Limit ValueLethal Dose (LD), Threshold Limit Value

(TLV)(TLV)

FlammabilityFlammability Flash point, auto ignition, flammability limitsFlash point, auto ignition, flammability limits

ExplosionExplosion

Detonation, deflagration, unconfinedDetonation, deflagration, unconfined vapourvapourcloud (cloud (UVCEsUVCEs), boiling liquid, expanding), boiling liquid, expandingvapourvapour ((BLEVEsBLEVEs))

8/9/2019 Loss Prevention slides.pdf

10/21

Electrical equipmentElectrical equipment Static electricityStatic electricity

Process flamesProcess flames

MatchesMatches

FrictionFriction

8/9/2019 Loss Prevention slides.pdf

11/21

Ionizing radiationIonizing radiationNoiseNoise

Operating deviationsOperating deviations

VacuumVacuum

8/9/2019 Loss Prevention slides.pdf

12/21

IntrinsicIntrinsicA process in which safe operation isA process in which safe operation is

inherent in the nature of the processinherent in the nature of the process

FactorsFactors

ChemicalsChemicals

Process route and equipmentProcess route and equipment

8/9/2019 Loss Prevention slides.pdf

13/21

A process which is rendered safe by careful designA process which is rendered safe by careful designand the application of safety systemsand the application of safety systems

FactorsFactors -- engineered safetyengineered safety

Control systemsControl systems Relief devicesRelief devices

Automatic shutdownAutomatic shutdown

Fire fighting systemsFire fighting systems Blast protectionBlast protection

Plant layoutPlant layout

8/9/2019 Loss Prevention slides.pdf

14/21

Explosive reaction orExplosive reaction ordetonationdetonation

React energetically withReact energetically withwaterwater

SpontaneousSpontaneouspolymerization/heatingpolymerization/heating

Intrinsically unstableIntrinsically unstablecompoundscompounds

ExothermicExothermic Flammables at highFlammables at high

temperatures and/ortemperatures and/orpressurespressures

Flammable liquids aboveFlammable liquids aboveatmospheric boiling pointatmospheric boiling pointdue to pressure ordue to pressure or

Operating in or nearOperating in or near

explosive rangesexplosive ranges Toxic materials,Toxic materials,

dangerous bacteria,dangerous bacteria,radioactive chemicalsradioactive chemicals

Dust of mist explosionDust of mist explosionhazardshazards

Large inventory of storedLarge inventory of storedpressure energypressure energy

8/9/2019 Loss Prevention slides.pdf

15/21

Basic Process DesignBasic Process Design Choice of ProcessChoice of Process routeroute

Process materialsProcess materials

Operating conditionsOperating conditions

Reaction pathways and systemsReaction pathways and systems

Operational ModeOperational Mode

Continuous or batchContinuous or batch

8/9/2019 Loss Prevention slides.pdf

16/21

InventoryInventory -- IntensificationIntensification Emissions and EffluentsEmissions and Effluents

Type and mode of disposalType and mode of disposal

Applicable regulationsApplicable regulations

Transportation of materialsTransportation of materials

QuantitiesQuantities

Physical statePhysical state

8/9/2019 Loss Prevention slides.pdf

17/21

Mechanical designMechanical design Equipment within operating limitsEquipment within operating limits

To recognized standards (AS, BS, ANSI)To recognized standards (AS, BS, ANSI)

Reliability of equipmentReliability of equipment

Fail Safe DesignFail Safe Design

Control valvesControl valves

CutCut--off valvesoff valves

Pressure relief systemsPressure relief systems

8/9/2019 Loss Prevention slides.pdf

18/21

Recommended separation distancesRecommended separation distances AccessAccess

VentilationVentilation

Emergency routesEmergency routes

Building locations (control rooms)Building locations (control rooms)

Separation policySeparation policy

8/9/2019 Loss Prevention slides.pdf

19/21

Types of problemsTypes of problemsAir, water, noise pollutionAir, water, noise pollution

Questions to be answeredQuestions to be answered

Source & distribution of pollutant?Source & distribution of pollutant?

Toxicity levels?Toxicity levels?

Ecology of pollutant?Ecology of pollutant?

Elimination or control measures?Elimination or control measures?

8/9/2019 Loss Prevention slides.pdf

20/21

Elimination of operation (entire or part)Elimination of operation (entire or part) Modification of operationModification of operation

Intensification, substitution, attenuationIntensification, substitution, attenuation

RelocationRelocation

Application of appropriate controlApplication of appropriate control

technologytechnology Combinations of the aboveCombinations of the above

8/9/2019 Loss Prevention slides.pdf

21/21

Perrys Chemical Engineering Handbook,Perrys Chemical Engineering Handbook,McGraw Hill, 7McGraw Hill, 7thth edition, 1998, Section 26edition, 1998, Section 26

CoulsonCoulson & Richardsons Chemical& Richardsons Chemical

Engineering, Volume 6 ChemicalEngineering, Volume 6 ChemicalEngineering Design,Engineering Design, ButterworthButterworth

Heinemann, 3Heinemann, 3rdrd edition, 1999, Chapters 9edition, 1999, Chapters 9

and 14and 14