INTRODUCTION TO SAFETY

CH153

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THE REALITY OF THE CHEMICAL PROCESS INDUSTRY
Revenue SAFETY

equal in importance to production

has developed into a scientific

discipline that includes many
technical and complex theories and
practices
PROFITS

Profit
Leaks
Quality Safety
Security
Environment
2
THE REALITY OF THE CHEMICAL PROCESS INDUSTRY
Revenue
To know is to survive and to
ignore fundamentals is to
court disaster.
H.H. Fawcett

PROFITS

Profit
Leaks
Quality Safety
Security
Environment
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THE BOHPAL INDIA DISASTER
Documentary The Bhopal Disaster INDIA Nat Geo Full 2014 720p HD – YouTube

4
THE REALITY OF THE CHEMICAL PROCESS INDUSTRY
Revenue SAFETY

equal in importance to production

has developed into a scientific

discipline that includes many
technical and complex theories and
practices
PROFITS

Profit
Leaks
Quality Safety
Security
Environment
5
TECHNOLOGY OF SAFETY EXAMPLES

• Hydrodynamic models representing two-phase flow through a

vessel relief

• Dispersion models representing the spread of toxic vapor through a

plant after a release

• Mathematical techniques to determine the various ways that

processes can fail and the probability of failure

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TERMINOLOGIES

• a chemical or physical condition that has the potential to cause

Hazard
damage or people, property or the environment
• a measure of human injury, environmental damage or economic
Risk loss in terms of both the incident likelihood and the magnitude of
the loss or injury
• a measure of the expected probability or frequency of
Likelihood
occurrence of an event

Consequence • a measure of the expected effects of the results of an incident

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TERMINOLOGIES

• the occurrence of a sequence of events that produce unintended

Accident
injury, death or property damage

• the loss of containment of material or energy; not all events

Incident propagate into incidents; not all incidents propagate into
accidents

• a description of the events that result in an accident or an

Scenario
incident

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TERMINOLOGIES
• the development of a quantitative estimate of risk based on an
Risk Analysis engineering evaluation and mathematical techniques for
combining estimates of incident consequences and frequencies

• the process by which the results of a risk analysis are used to

Risk Assessment make decisions, either through a relative ranking of risk
reduction strategies or through comparison with risk targets

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WHAT IS SAFETY?

Old concept

• use of older strategy of accident prevention through the

• use of hard hats, safety shoes, and a variety of rules and regulations

New concept

• “loss prevention”

• includes hazards identification, technical evaluation, and design of

new engineering features to prevent loss
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WHAT IS SAFETY?
the prevention of accidents through the use of appropriate technologies to identify the hazards of a
chemical plant and eliminate them before an accident occurs (Crowl, Louvar, 2002)

Employees’
Well being
Business
Local
Continuity
Legislations

SAFETY
Engineering
Ethics

Competiveness Media

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WHAT IS SAFETY?
Engineering ethics
• Engineers must provide a service to the company by maintaining and improving profits.

• Engineers are responsible for minimizing losses and providing a safe and secure
environment for the company’s employees.

• Engineers have responsibility to

• themselves
• fellow workers
• family
• community
• engineering profession

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SAFETY PROGRAMS

Chemical plants contain a large variety of hazards:

• Mechanical hazards – cause worker injuries from tripping, falling, or
moving equipment
• Chemical hazards
• fire and explosion hazards
• reactivity hazards
• toxic hazards

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SAFETY PROGRAMS

A good safety program identifies and eliminates existing safety hazards.

An outstanding safety program has management systems that prevent

the existence of safety hazards.

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SAFETY PROGRAMS
Ingredients of a Successful Safety Program

System 1. to record what needs to be done

Attitude 2. to do what needs to be done
3. to record that the required tasks are
done
Fundamentals
Experience Positive attitude of the participants

Time
Understanding and use of the safety
You fundamentals in the design,
construction and operation of chemical
process plants (by the participants)

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SAFETY PROGRAMS
Ingredients of a Successful Safety Program

System Learning from the experience of

history ~ case histories of past
accidents
Attitude
Recognition that safety takes time ~
Fundamentals time to: study, do the work, record
results, share experiences, to train or
Experience be trained

Time Recognition that everyone should take

the responsibility to contribute to the
You safety program

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END OF THIS PART

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