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UFAZ 2023 RP1 Intro Safety For Students
UFAZ 2023 RP1 Intro Safety For Students
© R.Pelletier 2023
pelandco@yahoo.fr
December 2023
Intro Safety 1
Introduction
Purpose of this ~20-hour lecture: provide students with a global
overview of the refining and petrochemical chain
© R.Pelletier 2023
• of the necessity of a rational approach to the critical environmental issues
Intro Safety 2
Introduction
A short “open book” exam will take place on Thursday September 14.
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It will be rather easy for those who listen carefully during the lecture.
Intro Safety 3
Short survey
among students
A warm-up before the core lectures: students are invited
to answer this short survey about different materials
used in food packaging. Please, be sincere in your answer.
In your opinion, which of these six materials is the « best
for environment », i.e. has the least ecological impact ?
© R.Pelletier 2023
Intro Safety 4
Introduction
Aluminum
Paper –
cardboard
Tin
Monolayer plastic
Glass
Multilayer
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plastic
Intro Safety 5
Introduction
© R.Pelletier 2023
entire lifetime : « from craddle to grave »
We shall come back on this issue when presenting “Polymers and Environment”
Intro Safety 6
Introduction to Risk Management
SAFETY FIRST !
"If you don't risk anything, you risk even more !"
© R.Pelletier 2023
Erica Jong
Intro Safety 7
Risk management
"SAFETY FIRST"
Well ! This lecture as well will abide to this simple rule.
Hopefully, this introduction will remind you that Safety will not be
obtained by working only on processes, equipment and
procedures.
It will be the result of a whole system. Everybody, from top to
bottom, should be involved; organization and mentalities should
really put "Safety First".
© R.Pelletier 2023
Intro Safety 8
Risk management
▪ Hazard vs Risk
• A hazard can be described as the inherent potential for damage
• Risk can be described as the possibility that the damage will occur
▪ Risk acceptance
• Accidents can never be acceptable
• In many cases however, it is worthwhile to take the risk because of the
benefit. Remember : risk also comprises the possibility that no accident
will happen.
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• Taking the risk does not mean that we accept the accident !
Intro Safety 9
Risk management
Example of toxicity
"All is poison, nothing is poison,
the dose makes the poison !"
Paracelsus (Theophrastus Philippus Aureolus Bombastus von Hohenheim)
The "father" of toxicology (1493-1541)
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doses, aspirin may be deadly. Yet, most of us "take
the risk" to have Aspirin at home !
Intro Safety 10
Risk management
Doing business
=
Being exposed to risks
© R.Pelletier 2023
Intro Safety 11
Risk management
Sustainable
Comfortable Possible
ENVIRONMENT
© R.Pelletier 2023
Intro Safety 12
Risk management
Marketing Political
Personal Technical
Change in consumer tastes Political unrest
Loss of market to competitor... Wars, embargos... Resignations Work accidents
Death... Fires / explosions
Production Financial Toxic emission
Transportation accident
Defective Process
Unexpected change in costs Currencies fluctuations
Faulty Product...
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Unavailibilty of raw materials... Change in interest rates...
Loss control 13
management
Intro Safety 13
Risk management
▪ In the plant, from shipping in, storage and acceptance of raw materials,
to packaging and delivery of finished goods to clients.
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▪ All engineers are key contributors to proper loss control management.
Intro Safety 14
Loss Control Management
▪ General methodology :
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Intro Safety 15
Loss Control Management
Example of world class ISRS* (Interntional Safety Rating System) audit system, helpings organizations
establish, develop and improve management systems. *from DNV, Det Norske Veritas http://www.dnv.com/
© R.Pelletier 2023
16
General Loss Control Concepts
Intro Safety 16
Loss Control Management
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** does not mean that other Risk Management components like Inspection Plan, Safety organization,
Transport rules, etc ... are not important as well !
Intro Safety 17
Safety at the workplace. Management of change
▪ For some polymer units (High Pressure Polyethylene for example), the
mean time between failure… and shut down of the
production is of the order of only a few days!
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*In petroleum refining, turnaround means a scheduled large-scale maintenance activity wherein an
entire process unit is taken off-stream during an extended period (~1 or 2 months) for complete check
of all equipment and for revamp.
Intro Safety 18
Safety at the workplace. Management of change
A lot of manual work in polymerization plants → higher risk for
workplace accidents. Unplugging pipes, changing knifes on the extruder,
washing silos, manipulating pallets, etc, are examples of daily activities
requiring constant attention from operators.
© R.Pelletier 2023
Intro Safety 19
Safety at the workplace. Management of change
Real case example of safety indicators in a particular petrochemical entity
(10 sites, ~1500 own employees + ~ 1000 contractors F.T.E.).
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TRIF = Total Recordable Incident Frequency " "
F.T.E. = Full Time Equivalent
Intro Safety 20
Safety at the workplace. Management of change
No ! Never be sure and satisfied in this domain ! Always stay modest!
Guesses about most fruitful actions, within the frame of global management system:
• Step change in the involvement for safety of all levels of management.
• More proactive attitude versus contractors.
• Improved reporting and sharing between entities of all mishaps.
• Trainings and re-training, ... and many other actions !
Lost-time Accidents History
Month Site Detail
dec-04 Site P
A contractor working in congested area injured his elbow when the wrench slipped This list of LTI and TRI in a
causing him to strike nearby equipment.
polymerization plant shows
janv-05 Site U Employee re-aggravated a non-work related back injury when making a sudden mostly bruises, cuts, falls,
movement, requiring prescription medications and 1 day of lost time
Contractor suffered severe cuts to 2 fingers when they became trapped due to hits, dust in the eyes, ...
févr-05 Site S
slippage of the ladder. Surgery required for nerve and tendon damage.
mars-05
avr-05
NONE
NONE Aren't we neglecting
mai-05 Site C Slipped and fell on wet stairs resulting in broken coccyx
mai-05 Site A
Slipped from curb and trapped foot between curb and scaffold. Fall resulted in twisted some more important
knee and upper leg
juin-05 Site C
safety issues by giving
Employee fell from height of 1,3m resulting in a broken wrist and one broken vertebra
juil-05 NONE too much attention to
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Maintenance tech suffered 2 broken fingers when a 30 kg piece of equipment fell on
août-05 Site A
his hand these petty problems?
sept-05 NONE
oct-05 NONE
nov-05 NONE
dec-05 NONE
Intro Safety 21
Safety at the workplace. Management of change
Aren't we neglecting some more important safety issues by
giving too much attention to these petty problems?
Most major accidents are actually
Fatality or major injury due to catastrophic combination of
relatively minor deviations.
Minor injury
Chasing for minor incidents
Property damage reduces the basis of the accident
pyramid.
Incident with no visible
consequences
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not a waste of time at all!
Intro Safety 22
Safety at the workplace. Management of change
Near miss (or « near accident » or “close call,” a “narrow escape, …”):
any event which had the potential to cause injury
and/or damage and/or loss but which was avoided by
circumstances (definition IAGC 1993)
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Near misses are valuable sources of information, which can be studied
and published, without the emotion linked to a real accident
Intro Safety 23
Safety at the workplace. Management of change
Of course, broad information (always), and action (if
necessary**), are required after each near-miss report
Same philosophy holds true for Environment and Product Quality. Many
companies have integrated Safety, Environment Protection and Quality
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Insurance into a single global Management System
**Beware of too fast decisions taken in the emotion following an incident. Take time to think.
Intro Safety 24
Safety at the workplace. Management of change
© R.Pelletier 2023
polymerization plants.
Intro Safety 25
Safety at the workplace. Management of change
One large sailboat manufacturer nearly
bankrupted after blisters developed on
hull of thousands boats. Problem linked
to the change of supplier for the
flegmatizer (for peroxide ) of the epoxy resin.
© R.Pelletier 2023
after a few days. Long sequence of successive
failures, initiating with use of new rail car tankers,
with un-symmetrical hatch position. 26
Intro Safety
Safety at the workplace. Management of change
For grass-root projects just as for minor or major revampings
▪ "Engineering and Change Management" objective is to
eliminate hazards before plant is actually started or modified,
thus minimizing the chance of accidents
© R.Pelletier 2023
Intro Safety 27 27
Project management - Staging the project
The decisions you take, or fail to
take, in the early stages of the
project will determine the future of Scope, process, lay out, principles of No return
your operation. operation, are frozen decision
At Gate 3, project objectives, process definition, plant lay-out, all safety and
environment protection principles are frozen. Any later change would be
extremely costly in money and delay. In subsequent phases of project (basic studies,
detailed engineering, project execution), the heavy engineering machine is running full
speed. Needless to say, changes are worse after plant start-up !!!
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We shall come back on these aspects of project management during the
2nd day of this petrochemical lecture
Intro Safety 28
Safety at the workplace. Management of change
© R.Pelletier 2023
Video: « The Mom’s Song »
Intro Safety 29