Accident Process

and

Inherent Safety Techniques

Dr. Waheed Miran

SCME, NUST

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 Successful Safety Program

• A good safety program

identifies and eliminates
existing safety hazards

• An outstanding safety
program has management
systems that prevent the
existence of safety
hazards.

(Safety reviews, safety audits,

The ingredients of a successful safety hazard identification techniques,
program. checklists, and proper application
of technical knowledge).
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Successful Safety Program

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 Nature of the Accident Process
Three Types of Chemical Plant Accidents

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Defeating the Accident Process

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Defeating the Accident Process

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Defeating the Accident Process

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Defeating the Accident Process

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 Inherent Safety Techniques
The following four words are recommended to
describe inherent safety:

• Minimize (intensification)
• Substitute (substitution)
• Moderate (attenuation and limitation of effects)
• Simplify (simplification and error tolerance)

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 Inherent Safety Techniques
1. The minimize strategy entails

✓ Reducing the hazards by using smaller quantities of

hazardous materials in the process.

✓ When possible, hazardous materials should be produced and

consumed on site—this minimizes the storage and
transportation of hazardous raw materials and
intermediates.

2. The substitute strategy entails

✓ replacing hazardous materials with less hazardous

materials. For example, a nonflammable solvent could
replace a flammable solvent
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 Inherent Safety Techniques
3. The moderate strategy entails

• using hazardous materials under less hazardous conditions.

• using materials at lower temperatures and pressures.
• using larger particle-sized solids to reduce dust explosions, to
name a few

4. The simplify strategy is based on the fact that

• Simpler plants are friendlier than complex plants

• Provide fewer opportunities for error and because they
contain less equipment that can cause problems

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Inherent Safety Techniques

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Inherent Safety Techniques

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 Inherent Safety Techniques
• The inherently safer design strategies that eliminate the
hazard are called first-order strategies.

• The strategies that make the hazard less intense or less

likely to occur are called second-order strategies.

After we have applied inherently safer design as much as

possible, we can use a hierarchy of management systems to
control the remaining hazards.

Inherently safer design are followed by

• Passive,
• Active, and
• Procedural strategies
To control the hazards
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 Hierarchy of Process Risk Management
Strategies
The strategies at the top of the table are more robust

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Hierarchy of Process Risk Management
Strategies

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