Process
safety is defined as the operation of facilities that handle, use, process or
store hazardous materials in a manner free from episodic or catastrophic
incidents. Knowledge of chemicals, process and plants in one of the prime
assets and is required for developing other modules of the management system –
process hazard analysis, operating procedures, training emergency preparedness
plans etc.
Complete and
accurate written information is required to be compiled for the following three
categories:
Process Chemicals. Hazardous/non – Hazardous category of chemicals
shall be defined. Data for all process chemicals (raw materials, intermediates,
products and chemicals) pertaining to process chemicals shall help in assessing
fire and explosion characteristics, reactive hazards, safety and health hazards
to workers and the corrosion and erosion effects on the process equipment. For
each process chemical, information in respect of (Physical properties, Boiling
point, Vapour Pressure, Melting/ Freezing point, Vapour Density and Specific
Gravity) is required.
In addition
information on fire and explosion hazards: (Flash point, Auto-ignition
Temperature, Explosive limits and burning rate) ; reactive hazards [The
tendency of the material to react violently when subjected to heat or the
presence of other process chemicals, water, air (oxygen) other possible
contaminates] ; Hazardous combustion/decomposition products ; Health Hazard
Data, [Personal] exposure hazard properties (long term and short time),
Information on Term Exposure Limit (STEL), Permissible Exposure Limit (PEL),
Lethal Dose 50 (LD50) etc.] also need to be maintained.
Process
Technology: Process
technology information should include :
(a) Written process description,
( (b) Process chemistry,
(c) Process Flow Diagrams (PFD),
( (d) Safe operating limits of process
parameters like pressure, temperature, flow rate etc. and the consequences or
results of deviation that could occur if operating beyond the established
process limit,
(e) Maximum inventory level for process
chemicals, and (f) Material and energy balances.
A process
flow diagram (PFD) shows major process equipment, valve on pipeline. Flow
rates, pressures, temperature and stream composition may be indicated for better
clarity. Process flow diagram (PFD) are more elaborate then block diagrams.
Piping and
Instrument Diagrams (P & IDs) are the detailed representation of the plant.
Each and every piece of equipment, pipelines, valves and instrument along with
their interconnection are shown and are most appropriate to show relationship
between equipment and instrument.
Process
Equipment. Process equipment includes columns,
vessels, heat exchangers, reactors, pumps and compressors, valves, piping,
drilling rigs and work-over rigs, cross country pipelines, tanks, loading and
un-loading facilities and other equipment that contains process chemicals.
Design data of process equipment should be documented and should include the
following:
(a) Materials of construction,
(b) Design specifications,
( (c) Codes, standards and industry
accepted engineering practices used for design and fabrication,
( (d) Electrical classification.
Planning for Safety . First concern of any management in
industry is to do business profitably. It is important for management to
understand that safety, health programming and care for environment embrace
profitable ways of operating effectiveness to achieve corporate goals. All
these three aspects need to be integrated into total management programmer and
objectives. Safety, health and environment are valuable and efficient business
tools today.
Efficient
production is the aim of industries to maximize profits. Efficient production
requires facilities, equipment, materials, and personnel. It is the duty of
management to supply these but in the process certain support services are also
needed. All these into support services have safety, health and environment
aspects. Incorporating them into support services allows us to involve safety,
health and environment at a function level, as an integral part of the operation.
These three important functions thus need to be built into support services,
organizational and personnel functions and then these needs to be continually
audited to ensure adequacy of controls. The company’s involvement in safety,
health and environment is essential.
The impact
of industry on the environment comes in the form of noise, hazardous
resistances, oil spills, ionizing, non ionizing radiation or thermal energy,
polluting air, water or soil. These sources must be identified and controlled
and the various programs needed for this must be established and used.
Proper
planning and organization are essential for any effective safety, health and
environment programed. Planning aspect involves appropriateness of programme,
fixing responsibility and accountability of senior management, delegation of
duties, identification of key personnel to carry out plan job descriptions
prescribing relationships between management, staff and line personnel, means
of measuring responsibilities, support of management, plans for identifying/
controlling/ auditing hazards, monitoring, information system, training,
resources, and defining objectives.
Medical Services . Occupational health programme needs
to be provided by management to deal constructively with
the health of employees in relation to their work. Apart from curative
medicine, health programme should also include prevention and maintenance of
health.
With increasing
use of synthetic chemicals in industry, it has become essential to make use of
services of full time industrial hygienists.
Periodic
health examination to detect underlying, potentially correctible diseases for
early treatment is nowadays essential. All employees need to be trained,
educated and motivated to use good health and safety practices both on and off
the job.
Industrial
hygienist must carry out work site inspection and monitor to detect and
appraise health hazards, and make appropriate recommendations for corrective
measures.
To reduce
absenteeism during an epidemic, employees should be offered inoculations on
company premises.
Special
programme to tackle emotional problems, alcoholism, drug abuse, etc. should
also be organized.
A great
emphasis needs to be given on prevention and research programmes for keeping
people healthy. Preventive medicine starts with health education,
lectures/films, periodical examination, and health counseling services.
Companies can provide facilities for employee physical conditioning programmes
(gyms, tracks, athletic fields, swimming pools, yoga and meditation classes)
for improved health and morale of employees which result in lower absenteeism
and higher production. Wellness is not merely an absence of disease but the
active pursuit of good health through improvement in lifestyle. If people are
well, they are on the job and productive. Strategies directed to lifestyle
improvement have been found to be more advantageous then efficient health care
systems.
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