SAFETY

 Freedom from unacceptable risk or

harm.
 Safety of a Process Can be Described
as the Ability Of the System To
Withstand Extreme Conditions.
GENERAL SAFETY RULES
 Always Use PPE’s.
 No Smoking or Carrying Matchbox.
 Good housekeeping.
 Safety Training for all employees and contract
workers.
 No Job without a Safety permit.
 All Chemicals should be labelled and kept in
secure containers.
GENERAL SAFETY RULES
 Pressurization/Depressurization of pressure
vessels at specified rate.
LEGAL REQUIREMENTS
 Atomic Energy Factories Rules, 1996
 Atomic Energy Act, 1962
 The Factories Act 1948
 Radiation Protection Rules, 1971
 The Indian Electricity Act, 2003.
 The Indian Boilers Act, 1923.
 The Petroleum Act, 1934 &The Petroleum Rules, 1976.
 Gas Cylinder Rules, 1981.
 Static& Mobile Pressure Vessels (Unfired) Rules, 1981.
 Water Prevention & Control of Pollution Act, 1974.
 Air Prevention & Control of Pollution Act , 1981.
 Environment (Protection)Act, 1986.
 Manufacture, Storage & Import of Hazardous Chemicals Rules,1989.
 Hazardous Waste Management and Handling Rules, 2002.
TECHNICAL SPECIFICATIONS
Define the limiting operating conditions so as to
ensure safety and health of plant and personnel
working in the plant and Public.
TECHNICAL SPECIFICATIONS
 LCO : Limiting values of the parameters not to be
exceeded during plant operation
 LSSS : Settings on safety valves/rupture
discs/instrumentation which initiate the automatic
protective action at a level such that the safety limits
will not be exceeded.
 SL : Limits of process variables within which the
operation of the plant has been designed to be safe.
TECHNICAL SPECIFICATIONS
NORMAL VALUE 14P05 Converter Cracker
loop pressure loop
pressure
LCO 26.0 Kg/cm2 210 Kg/cm2 142
Kg/cm2

LSSS 27.5 Kg/cm2 220 Kg/cm2 145

Kg/cm2

SL 30.0 Kg/cm2 230 Kg/cm2 148

Kg/cm2
 HAZARD

An existing or potential condition which may

lead to an accident causing damage to
property or health.
TYPE OF HAZARDS
 PHYSICAL : High Temp, Low Temp, High
Pressure, Height & Noise.
 CHEMICAL : Toxic leak, Fire, Explosion
 ELECTRICAL : Shock, Burn &Fire
 MECHANICAL: Rotating Equipment,
Structural Collapse, Vessel
Rupture/Disintegration.
 NATURAL : Earth quake, storm, Tsunami,
heavy rains & flooding
HAZARDOUS AREA CLASSIFICATION

 ZONE 0

 ZONE 1

 ZONE 2
 HAZARDOUS CHEMICALS IN HWP

 SYNTHESIS GAS: FIRE & EXPLOSION

 AMMONIA: TOXIC
 K METAL: FIRE & EXPLOSION
 POTASSIUM AMIDE: FIRE & EXPLOSION
 ASSOCIATED GAS: FIRE & EXPLOSION
 n HEXANE: FIRE & EXPLOSION
CHLORINE: TOXIC
PARAFFIN OIL: FIRE
HYDRAZINE HYDRATE: CORROSIVE
NITROGEN GAS: ASPHYXIATION
NITROGEN LIQUID: COLD BURNS
DIESEL: FIRE
 SYNTHESIS GAS
Major component : Hydrogen
Colorless gas
Explosive Limit: 4.1% to 74.2% by volume in
air.

Auto ignition temp. 400 C

O

To fight fire, use Carbon dioxide or Dry

Chemical Extinguisher. To fight fire, use Carbon
dioxide or Dry Chemical Extinguisher.

One who is under the effect of asphyxiation

should be removed to fresh air and given artificial
 AMMONIA
Formula: NH3
Explosive limit : 16% to 25% by volume in
air.
Auto iginition temperature: 651'C
T.L.V 25 ppm for 8 hours exposure.
Use appropriate type of Gas Mask or
Breathing Apparatus and required personal
protective clothing.
In case of exposure to Ammonia, remove
the affected person to fresh air in open area.
Administer artificial respiration if the breathing is
interrupted.
In case of burn, flood the affected area with
copious quantity of water.
K- METAL
POTASSIUM AMIDE
 CHLORINE
Formula: Cl 2

T.L.V of Chlorine is 0.5 ppm in air.

Chlorine is extremely irritating to the mucous
membrane of the eyes and respiratory tract.
When encountering chlorine, use chlorine
gas maskes or self contained breathing apparatus.
The affected individual should be removed to
fresh air and action should be taken immediately to
administer artificial respiration. Get the help of
Doctor / First Aid post.
In case of chlorine leakage use Chlorine Kit.
 HYDRAZINE HYDRATE
Formula: NH2 NH2
 Flash point: 52. 1' C
Auto ignition temperature: 247' C
T.L.V of Hydrazine is 1 ppm in air.
Hydrazine can be absorbed through the
intact skin.It may cause damage to the liver and
destruction of red blood cells.
Fire Hazard: Moderate, when exposed to
heat, flame or oxidizing agents.
Explosion Hazard: Severe, when exposed to
heat or flame or by chemical reaction with oxidizing
agents.
 NITROGEN
Formula: N2
Molecular Weight: 28.02
Melting Point: -210' C
Boiling Point: -195.811 c
It is simple asphyxiant. Liquid
form can cause cold burns.
 Counter Measures: The asphyxiated
person should be removed to fresh air and
give artificial respiration.
 HEXANE
 C6H14
 Low flash point -21.6 OC
 B.P. 69OC
 Auto ignition Temp  225OC
 Explosive limits 1.2% to 7.5% by
volume.
 ASSOCIATED GAS
 Major component : Methane

 Colorless

 Highly inflammable gas

 Explosive Limit 
 PROCESS SAFETY
SAFETY OF A PROCESS CAN BE DESCRIBED AS
THE ABILITY OF THE SYSTEM TO WITHSTAND
EXTREME CONDITIONS
PROCESS SAFETY CAN BE OF TWO TYPES
A) INTRINSIC
B) EXTRINSIC

SAFETY DURING START-UP

SAFETY DURING OPERATION
SAFETY DURING SHUT-DOWN
INTRINSIC SAFETY
SOFTWARE INTERLOCKS
 Sequence tables
Programmatrix actions
SYSTEM ALARMS & TRIPS
SAFETY VALVES
RUPTURE DISCS
FLAMEPROOF FITTINGS
WEATHER PROOF MOTORS
SAFETY MARGINS IN DESIGN
 INTRINSIC SAFETY
REMOTE OPERATED MOTORISED VALVES
PRIORITY HEADER FOR I.A. SYSTEM
 SAFETY WATER SYSTEM
 EXTRINSIC SAFETY
Area Monitoring
Surveillance
Personal Protective Equipments
Fire Fighting System
Communication System
Emergency Assembly Points
Emergency Plan
First Aid Centre
 EXTRINSIC SAFETY
 Standard Operating Procedure (SOP)
 Safety Committee
 Safety Audit
 Safety Work Permit System (SWP)
 Mutual Aid Scheme
 Mock Drills
 Occupational Health Check-up
Area Monitoring
 Leak check survey
 Routine Safety inspection of Plant area

 Portable gas detectors and Explosive

meters
 Online Detectors with Alarm

 Noise survey

 Glass seal LP junction box checking for

explosive mixture.
 PPE survey

 Housekeeping Survey
Area Monitoring
 Illumination survey
 Corrosion Survey

 Insulation Survey

 Inspection of Supports

 Hydro/Pneumatic testing

 NDT

 Vibration Monitoring

 Electrical inspection
 SURVEILLANCE
Log-sheet/Log Book Readings
Alarm In The Panel (Control
Room And Local Panels)
Historical Trends
Field Rounds
Observations by Others

T
WORK STATION MONITORING METHODS OF MONITORING

NOISE SURVEY
Noise TLV: 90 dbs
Sound Level Meters
Personal Finding For Abnormal Sound
Compulsory Use of Ear Muff in High
Noise Area

T
TESTING OF EQUIPMENTS
Hydro-Testing
- New: At 1.5 times of design pressure
- Old: At 1.25 times of design pressure
Pneumatic Testing
- At 1.1 times of design pressure

T
WORK STATION MONITORING METHODS OF MONITORING

TESTING OF EQUIPMENTS
NDT
Nondestructive testing (NDT), also called
nondestructive examination (NDE) and
nondestructive inspection (NDI), is testing that does
not destroy the test object.

- Radiographic (X-Rays, Gamma

Radiation)
- Ultrasonic Techniques
- Magnetic Particle Examination
- Liquid Penetrant Examination T
WORK STATION MONITORING METHODS OF MONITORING

TESTING OF EQUIPMENTS
DT
Destructive testing usually provides a more reliable
assessment of the state of the test object, destruction of the
test object usually makes this type of test more costly

- Residual Life Assessment

- Stress tests
- Crash tests
- Hardness tests
- Metallographic tests
T
EARLY WARNING SYSTEMS

Flame Detectors
Chlorine Detector
Ammonia Detector
Hydrogen Detector
Smoke Detector

T
OTHER MONITORING AREAS

First Aid Boxes

Safety Showers
Water Curtains
Fire Fighting Equipments
Fire Hydrant Operations
Communication Systems

T
SAFETY DOCUMENTS
 Approved Operating Manuals, Technical
Specifications, Design Basis Report & Safety
Manual.
 On-Site Emergency Plan.
 MSDS.
 P&I Diagrams.
 Plant Health Reports.
 OHSAS 18001
 In Service Inspection (ISI)
SAFETY RECORDS
 Safety Tag Register
 Trip Interlock status Register
 Blinds Register
 SWP Register
 Incidence Register
 Log sheets
 Section Registers
 Instructions Register
 Leak Survey Records
Fire fighting systems

DCP/ CO2 extinguishers

1. 10 Kg DCP CYLINDERS, 150 NUMBERS, ARE KEPT AT
EARMARKED LOCATIONS WITH PROPER NUMBERING
2. 50 KG DCP CYLINDERS, 20 NOS.
3. 6.8 KG CO2 CYLINDERS, 40 NOS.
4. 50 LTS. FOAM UNITS, 5 NOS.
5. SAND BUCKETS IN K-METAL HANDLING UNIT.
 Ten Numbers Automatic DCP Extinguishers are Installed to
Protect Electrical Transformers
Fire fighting systems

FIRE TENDERS
THREE FIRE ENGINES ARE AVAILABLE

1. CRASH TENDER WITH 3000 LTS WATER, 1000 LTS

FOAM AND 1000 KG DCP
2. WATER TENDER WITH 6000 LTS WATER WITH PUMP
CAPACITY 700 GALLONS/MINUTE
3. FOAM TENDER WITH 3000 LTS FOAM AND 4000 LTS
WATER

THE PUMPS ARE OF 10 KG/CM2 PRESSURE & 40 KG/CM2

PRESSURE
Fire Hydrant System
 Total 40 No. of Single Head Hydrants
Keeping Maximum Distance of 30 meter
between Two Hydrant.
 Six No. of Fixed Water Monitors to Facilitate
Unmanned Operation.
 Wet Risers for Effective Fire Fighting at
Heights.
 Dry Risers for Cooling Tower.
FIRE EXTINGUISING SYSTEM…

FIRE WATER SYSTEM

 THE FIRE WATER QUANTITY AVAILABLE AT ANY
POINT OF TIME IS 26200 CUBIC METER
 FOUR ELECTRICAL PUMPS OF 410 M3/HR EACH
 FOUR DIESEL ENGINE OPEARTED PUMPS
 ONE JOCKEY PUMP TO MAINTAIN THE HEADER
PRESSURE DURING NORMAL TIMES
 THE SYSTEM IS RING TYPE AND ISOLATION OF
ANY PORTION IS POSSIBLE WITHOUT AFFECTING
REST OF THE AREAS.
SAFETY

BA SETS
1. 51 BA SETS ARE AVAILABLE OUT OF WHICH 20 ARE
EXCLUSIVELY USED FOR HWP
2. 100 SPARE CYLINDERS ARE AVAILABLE OF WHICH 25 ARE
EXCLUSIVELY USED FOR HWP .
3 UNIVERSAL CANISTERS ARE AVAILABLE WHICH CAN BE USED
FOR ANY GAS ON THE SITE.
4 ONLINE BREATHING MASK ARE AVAILABLE.
MOCK DRILL & COMMUNICATION
EXERCISE

 MOCK DRILL IS CARRIED OUT ONCE IN EVERY QUARTER. THE

SCENERIOS DECIDED ARE BASED ON THE RISK ASSESSMENT . ALL
THE RECOMMENDATIONS OF THE MOCK DRILL EXERCISE ARE
COMPLIED WITH

 COMMUNICATION EXERCISE IS CARRIEDOUT EVERY FORTNIGHTLY

TO CHECK HEALTH OF THE COMMUNICATION SYSTEM AND
ACCLIMATISE THE MANPOWER FOR COMMUNICATION DURING
EMERGENCIES.
Classification Of Fire
Class Materials Suitable
Extinguisher
A Ordinary Combustible Water
Material  Wood, Cloth,
Rubber, lastic etc.
B Flammable Liquid  Foam, CO2, DCP
Paints, Petrochemical,
Oils etc.
C Gases Under Pressure DCP, CO2

D Combustible Metal  K Sand, Special

Metal DCP
 Never Use Water in Case of Electrical Fire
 Never Use Water in Case of K metal Fire
 In Case of Fire due to Potassium Amide,
Continuous Flow of Large Amount May be
Used.
MUTUAL AID SCHEME

RCF HAS ENTERED IN AGREEMENT WITH GAIL,

VIKRAM ISPAT, ISPAT, NITCO BPCL ETC. FOR
MUTUAL AID DURING EMERGENCIES. ALL THE
RESOURCES SHALL BE MADE AVAILABLE TO EACH
OTHER DURING EMERGENCIES.
 OHSAS 18001
 Policy
 Objective and Target
 HIRA
 Risk Control  SMP, OCP, WI
 Review  Audits, Plant Meeting,
Management Review Meeting.
PERSONAL
PROTECTIVE
EQUIPMENTS
PPE

METHODS OF CONTROLLING HAZARDS

 ENGINEERING CONTROL – GUARDING

 BY CHANGING EQUIP.
 MATERIAL SUBSTITUTION – REPLACING WITH
LESS TOXIC MATERIAL
 PROCESS CHANGE
 ADMINISTRATION CONTROL – TRAINING, WORK
INSTRUCTIONS, SOP ETC
 PPE’s
PPE

WHAT IS PPE

HAZARDS EXIST IN THE WORK PLACE SO

TO PROTECT WORKERS ARE ESSENTIAL.

PPE IS A EQUIPMENT WORN BY WORKER

TO MINIMIZE EXPOSURE TO HAZARDS.
PPE

NEED OF PPE

 WHEN HAZARDS CAN NOT BE REMOVED

OR CONTROLLED ADEQUATELY.
 IT IS ALSO CALLED LAST LINE OF
DEFENSE.
 STATUTORY REQUIREMENT AS PER
FACTORIES ACT-1948
PPE

PPE divided in to

PPE

N on - R espirato ry R espiratory
E quipm e nt E quipm en t
PPE

Non Respiratory PPE

 Eye Protection
 Face Protection
 Ear Protection
 Head Protection
 Body Protection
 General PPE
PPE

EYE PROTECTION
 FOR THE PROTECTION OF FACE & EYES
FROM FLYING PARTICLES, CHEMICAL
SPLASHING, WELDING & CUTTING
OPERATIONS
PPE

EYE PROTECTION

 SAFETY GOGGLES - MADE UP OF

PLASTIC OR PVC WITH HEAD BAND
 SAFETY SPECTACLES - WITH ROBUST
METAL OR PVC FRAME WITH OR
WITHOUT SIDE SHIELDS.
PPE

EYE PROTECTION

 FACE SHIELDS - IT HAS TRANSPARENT

VISOR, SUPPORTED IN FRONT OF FACE
TO SHIELD THE EYES, FACE, FOREHEAD
AND FRONT OF NECK
 WELDERS HEAD SCREEN.
PPE

HEAD PROTECTION

 PROTECTION AGAINST FALLING

OBJECTS, FLYING PARTICLES, STRUCK
WITH, SPLASHING OF LIQUID ETC
PPE

HEAD PROTECTION

 SAFETY HELMET - MADE UP OF HDPE

MATERIAL TOUGH ROBUST
 3 IN 1 SAFETY HELMET
 HOOD - MADE UP OF PVC CHEMICAL
RESISTANCE MATERIAL
PPE

EAR PROTECTION

 PROTECTION FROM HIGH NOISE

GENERATING FROM INDUSTRIAL
OPERATIONS AND MACHINES.
PPE

EAR PROTECTION

 EAR PLUGS INSERT TYPE - REDUCE

NOISE UP TO 25 - 30 dB
 EAR MUFFS - REDUCES NOISE BY 30 - 35
dB
PPE

BODY PROTECTION

 PROTECTION AGAINST HEAT AND HOT

METAL
 PROTECTION AGAINST IMPACT AND CUTS
 PROTECTION AGAINST EXPOSURE TO
TOXIC MATERIAL
PPE

BODY PROTECTION

 PVC SUIT
 ASBESTOS SUIT
 BOILER SUIT
PPE

BODY PROTECTION

 PROTECTION AGAINST FALL FROM

HEIGHT
 SAFETY BELT
 SAFETY HARNESS
PPE

HAND PROTECTION

 PROTECTION AGAINST HEAT AND HOT

METAL
 PROTECTION AGAINST IMPACT AND CUTS
 PROTECTION AGAINST EXPOSURE TO
TOXIC MATERIAL
PPE

HAND PROTECTION

 COTTON HAND GLOVES

 ASBESTOS HAND GLOVES
 PVC HAND GLOVES
 NIT RILE HAND GLOVES
 ACID ALKALI PROOF HAND GLOVES
 ELECTRICAL HAND GLOVES
PPE

Respiratory PPE

Respiratory PPE

Suplied Air Type Air Purifying Type

PPE

Respiratory PPE

Supplied Air Type

Air Line Respirator

Self Contained BREATHING APPARATUS

PPE

Respiratory PPE

Air Purifying Type

Chemical Filters Mechanical Filters

PPE

Chemical Filters
 Canister Gas Mask
Useful only when O2 is Min.18% and
contaminant gas conc. is 2-3%.

Mechanical Filters
 Dust respirator
 Polyurethane Face Mask
SAFETY WORK PERMIT SYSTEM
 CLASS I
Hot jobs
Excavation
Work at Height
Online sealing
Work on fragile roof/ceiling

 CLASS II
 ENTRY INTO CONFINED SPACE
MAIN FEATURES OF SWP SYSTEM

 Issuing authority / Signatures

 Safety tagging
 Electrical isolation
 Validity
 Return of SWP
 Cancellation of Permit
 PROCESS SAFETY
SAFETY DURING START-UP
 Synthesis gas and ammonia are explosive in nature. Oxygen
content should be less than 0.5% before charging synthesis gas and
ammonia in to any vessel.
 While lining up one loop with the other loop, pressure between
the loops must be equal to avoid sudden pressurisation.
 Pressurisation rate must be 60 Kg/cm2 and it should be in forward
direction.
 Rate ofo heating of cracker and converter should be restricted
below 30 – 40 C/hr to avoid thermal shock to the catalyst beds.
 While charging steam header, traps should be in line to avoid
water hammering.
 While lining up cooling water, high vent point is to be kept
opened.
 PROCESS SAFETY
SAFETY DURING OPERATION
After transfer ammonia and amide, the lines should be
emptied before isolation to avoid over-pressurisation due to
very high volumetric expansion of liquid ammonia.
 Amide lines to be drained and washed with ammonia
before depressurisation to avoid choking. Before
depressurisation the liquid is to be drained completely.
 Converter skin temperature should be restricted below
180oC. Limiting temperature in cracker is to be strictly
adhered to.
 In potassium amide solution heaters, steam temperature
must be restricted below 80oC.
 PROCESS SAFETY
SAFETY DURING SHUT-DOWN
During shut down, vapour valves of ammonia coolers are to be kept
opened.
When towers are under shut down, liquid should not be allowed to go
in to gas inlet of T2 to avoid liquid entry into the compressor 19K3.
Starting of the compressor is to be done after draining discharge line
liquid completely.
When cracker is under shut down, it is to be ensured that ammonia is
not condensed in the tube. Pressure is to be reduced to 40 Kg/cm2.
The plant has been grouped into 3 pressure zones. During shut down,
isolation valve between these zones should be closed.
Boiler vent is to be kept opened to avoid buckling of steam drum due
to vacuum formation inside because of condensation.
Ensure cooling water circulation through all coolers to avoid
corrosion.
 PROCESS SAFETY
PROCESS EMERGENCY

Heavy leakages
Power failure
Fire accidents