IN PLANT DESIGN

BY
VYSHAK KRISHNAN K
MAJOR HAZARDS IN PROCESS PLANT

• Physical hazards
• Chemical hazards
• Mechanical hazards
• Electrical hazards
• Hygienic
Safety in Process design
Process risk management method used during the design
phase can be put into 4 categories
– Inherent
– Passive
– Active
– Procedural
 Inherent Safety

• The basic philosophy of inherent safety is build safety into the

design rather than have add on systems.
• There fore inherent safety reduces the severity of the hazard and
the likelihood of a hazardous incident simultaneously.
• The safety of a process relies on multiple layers of protection.
• The first layer of protection is the process design features.
• Subsequent layers include control systems, interlocks, safety
shutdown systems, protective systems, alarms, and emergency
response plans.
Inherent safety is a part of all layers of protection; however, it is especially
directed toward process design features. The best approach to prevent
accidents is to add process design features to prevent hazardous situations. An
inherently safer plant is more tolerant of operator errors and abnormal
conditions.
The following four words are used to describe inherent safety:
1. Minimize (intensification)
2. Substitute (substitution)
3. Moderate (attenuation and limitation of effects)
4. Simplify (simplification and error tolerance)
ISD CATEGORY DETAILS

 Intensification minimizes inventories of hazardous materials.

 Substitution replaces hazardous materials with safer materials.

 Attenuation uses hazardous materials under the least hazardous conditions.

 Limitation changes designs or conditions to reduce potential effects.

 Simplification reduces complexity to reduce the opportunity for error.

Active Safety Systems
Which is also known as Engineered safety system or Add on safety
• Design of control systems
• Alarms, Trips
• Pressure relief devices
• Automatic Shutdown systems (ESD)
• Redundancy (duplication of key equipments)
• Fire detection and leak detection
• Fire fighting equipments
• Sprinkler systems
Passive Safety Systems
• Dike
• Underground drainage systems
• Fireproofing
• Fire wall
• Blast wall
• Flame arrester
• Refrigeration system
• Plant layout
• Equipment layout
• Hazard area classification
Procedural Safe Design
Procedural — Prevention or minimization of incident impacts using:
1. Safe operating procedures and operator training
2. Administrative safety checks
3. Management of Change
4. Planned emergency response
Design in overall safety
Plant Constructions
Project engineer should have some understanding of
1. Construction planning
2. Labour and labour relations
3. Actual construction operation
Construction Planning
• Design drawing and Specification give the detailed information to
construction department.
• Construction engineers should study the preliminary engineering data and
scale models of plants to be erected.
• Selection of derricks and hoisting equipments.
• Positioning of construction equipments.
• Planning of errection.
• Constructional labour distribution.
• Labour disputes.
• Labour rates.
Construction operations
• Site preparation
• Driving of pile
• Temporary buildings
• Temporary water supply
• Road ways and rail
• Excavation operations
• Installation of underground facilities
• Electrical conduit and underground piping
• Foundation construction
• Erection of derricks / cranes
• Erection of elevated reinforced concrete structure and structural steel.
• Erection of major equipments
• Installation of piping
• Pipe identification
• Insulation
• Buildings:- office buildings, ware houses, change houses, canteens, M/C shop, lab etc.
• Final stages of construction :-Instruments, electrical apparatus, small piping for
instrumentation,
• Cleaning of site
• Installation of safety equipments
THANK YOU