PLANT SAFETY & HEALTH DKK3423

DKK3423PLANT SAFETY & HEALTH

CHAPTER 6:PRACTICAL SH&E ASPECTS IN A CHEMICAL PLANT

By:Mr. Junaidi ZakariaLecturer, FKKSA, UMPjunaidibz@ump.edu.my

Edited by : Bijarimi

INTRODUCTIONSH&E aspects can be succeeded in chemical plant when the entire workers participate in the action.The plant normally organized SH&E committee and usually involves the highest ranking of management such as CEO or Plant Manager.SH&E committee consist of: SH&E/ safety officer, plant employee and manager or CEO.Every worker should get the proper training including the safety and health precaution prior to be assigned to the workplace.Some success plant hires plant emergency responder to overcome the emergency situation.The hired SH&E officer to conduct the periodic safety audit.

6.1: HAZARD IDENTIFICATIONDefinition:**refer to chapter 1Step: Laws and practice code Accident dataObservation MSDSInspection JSA ( Job Safety Analysis)

6.1: HAZARD IDENTIFICATIONHazard is classified into:physicalchemicalbiologicalergonomicpsychological

6.2: RISK ASSESSMENTCollect all the information of every identified hazard.The number of persons who were exposed to each hazard and the time of exposure.Use the above information to assess the possibility and the severity of every hazard.The possibility and the probability of hazard situation occur. Very likely oftenLikely sometime Unlikely seldom Very unlikely very seldom

6.2: RISK ASSESSMENTWhat is the effect of the hazard? FatalitySevere injury (cannot recover to normal)Slight injury (usually can recover)First Aid Use the risk table to evaluate the RISK involved in every hazard.

6.2: RISK ASSESSMENT

6.3: SH&E MANAGEMENT COMMITTEEBusiness survive when got profit and the profit is proportional to the production.Human productivity can increase due to the good quality performance. This good performance is due to the safety and health of the human.Systematic approach is used to manage OSH according to OSH Act 1994. The Act of OSH (OSHAct 94) put the responsible or compulsory on the employer to form and assure SAFE WORK SYSTEM which covers the workers exposed the occupational hazard

6.3: SH&E MANAGEMENT COMMITTEESH&E Management is the process of planning, organizing, and controlling to establish the integrity of safety and health in every single process and activity certain organizationThe Principles of Occupational Safety and Health (OSH) ManagementEffective managerial controlDelegation of responsibilityMonitoring of performanceIntegration of safety and healthEfficient safe working

6.3: SH&E MANAGEMENT COMMITTEEThe Essential Components and Element in OSH ManagementManagement LeadershipFull responsibility Declaration of Occupational Safety and Health PolicyPolicy implementationAssigning the responsibleSupervise and practice the safe workSafety inspection, safe work analysis, audit etcEngineering explanationProcurementThe role of supervisor

6.3: SH&E MANAGEMENT COMMITTEESafety training MotivationHazard identification, assessment and controlSafety inspectionStorage system of accident and incident recordEmergency Response Program (ERP) and first aidEmployee responsibility

6.3: SH&E MANAGEMENT COMMITTEEManager and Managing Director ResponsibilityThe management is responsible to control the hazard since it appears due to the occupational activities effect which is conducted and established by the management.The control : according to the Hierarchy of controlThe management is responsible to assure the workplace where is under its supervision and authority must be physically and mechanically safe.The management is responsible to occupy its authority and capability to prevent and avoid any unsafe action or activity done by the worker.

6.3: SH&E MANAGEMENT COMMITTEESupervisor ResponsibilityTo implement the procedure and regulation of OSH.To train all the worker about the OSH.To inspect the environment and safe work compliance.To report all the accident or incident.To establish Job Hazard Analysis for every assignment.To assure that the worker is capable to handle the equipment or the machine safely.To manage a department meeting of OSH.To discuss OSH with the workers including accepting the comment about OSH.

6.3: SH&E MANAGEMENT COMMITTEEThe Responsible of OSH Officer Share the management responsible.consult and advise the management about OSHPeriodically inspects the plant, machine, equipment and work operation.Contribute the new idea, train and instruct the worker in promoting the safe work system.

6.4: OFFICERS AND COMMITTEESH&E committee: Another way to promote safety.Functions: provide a formal structure where all can funnel concerns and suggestions about SH&E.Combination between executive level + technical level improves the communication and action.Chairperson can be SH&E officer or not (more ownership of the committee).Work identify hazards and take steps to eliminate them.SH&E officer functions: as an advisor, facilitator and catalyst - OSHA, 1994, section 29(2)

6.4: OFFICERS AND COMMITTEESH&E committee should:Suggest to improve SH&E.Train the committee member.Authorize the committee.Encourage employee involvement.Be patient and reasonable to time constraint.Reward progress, participation and partnership.Train management for SH&E awareness.Stagger committee memberships variety of levels.

6.4: OFFICERS AND COMMITTEESH&E committee should not: As safety cops because management deserve it.Discuss topics unrelated to SH&E. Stay away from labor and personnel issues.Rotate members too quickly. 1 year is norm.One way communication during the meeting. Encourage and maintain the equal participation.Just bring the problems. Have them bring the solution as well.Scapegoat seeking. Management is responsible.Punish. Do hold persons accountable for their responsibilities

6.5: PERSONAL PROTECTIVE EQUIPMENTLast line of defense.Have to adopt and wear discomfort. Respirator, coat/ jacket, goggles, gloves and shoes specified by the task.GlovesPVC abrasion and min cut resistance. Avoid high TLeather abrasion and min cut resistance Cotton min abrasion and min cut resistance.Stainless steel cord (wrapped in synthetic fiber) abrasion and optimal cut resistanceButyl rubber heat and some chemical resistanceChain link / metal mesh max abrasion and cut resistanceViton rubber heat and all chemical resistance

6.5: PERSONAL PROTECTIVE EQUIPMENTRespirator Mouth and nose dust maskO2>19.5%, single use, PEL > 0.05 mg/m3Mouth and nose with chemical cartridgeO2>19.5%, cartridge: [organic] < IDLH and GMC [Cl2, HCl and SO2] < IDLHFull face mask with chemical canisterO2>19.5%, N canister higher [gas] exposure. Self-contained breathing apparatus (SCBA)all condition. Capacity between 30 60 min per spec.

6.5: PERSONAL PROTECTIVE EQUIPMENTShoes Steel-toed safety shoesPVC and nitrile knee bootsPuncture-resistant soles Slip-resistant solesElectrical resistant material

6.5: PERSONAL PROTECTIVE EQUIPMENTClothJacket Coverall suit work thats need to variety of position.Splash suit nonflammable chemical splashRain coat during rainPersonal fall arrest harnessVinyl apron resist most chemical

6.6: CHEMICAL SAFETYRefer back to industrial hygiene.**MSDS and CSDS**Ventilator**Fume hoodRefer back to chemical process safety**Release model**Relief system

6.7: APPLICATION OF PERMIT TO WORKWhat is the Permit to Work System?A Permit to Work System provides a systematic disciplined approach to assessing the risks of a job and specifying the precautions to be taken when performing hot work and/or working in a confined space.The permit to work system: Specifies the work to be done and the equipment to be used Specifies the precautions to be taken when performing the task

6.7: APPLICATION OF PERMIT TO WORKGives permission for work to start Advises occupants of plant building that work is being performed within their building/ part/ unit. Provides a check to ensure that all safety considerations have been taken into account, including the validity of permits and certificates and compliance to the policies and proceduresOn completion of work it provides a checking mechanism that all work has been completed up to the companys satisfaction.

6.7: APPLICATION OF PERMIT TO WORKActivities involving routine production and process operations including startup, changes in operational modes and shutdowns do not require a Permit to Work.Normally, the activities of inspectors, surveyors, engineers, draftspersons and visitors will not require a Permit to Work, provided their presence in the operational area is approved in advance by the Responsible Officer and their activity does not interfere with plant or equipment, nor are they carrying potential ignition sources.Work carried out in designated maintenance (e.g. University workshops) and construction areas do not require a Permit to Work.

6.7.1: SAFE WORK PERMITThe Safe Work Permit is issued as a written record by the person who is/ are in charge of a unit, equipment, building area, authorizes a worker and/or work crew to do a specific job at that work site. It identifies what precautions (safe work practices) were taken and/or will be taken to ensure that the working conditions are safe for the type of work to be performed, in a specific job location, during a specific time interval. It outlines the safety equipment required and to be used for that specific job location.

6.7.2: CONFINED SPACE PERMITAny area which, because of its location, contents and the activities performed within it, may be deficient in oxygen or contain flammable/toxic vapours and gases. Limited openings for entry and exit, and unfavourable natural ventilation and not designed for continuous worker occupancy.Confined spaces may include, but are not limited to: Storage tanks, boilers, pressure vessels, silos Open topped spaces of more than 1.5m depth, such as degreasers or pits that are not subject to good natural ventilation Pipes, sewers, shafts, ducts and similar structures.

6.7.3: HOT WORK PERMITAll work with the potential to create a source of ignition. This includes grinding, welding, thermal or oxygen cutting or heating, and other related heat producing or spark producing operations.

6.7.4: LOCK OUT TAG OUTAll other employees whosework operations are or may be in areas where energy control proceduresmay be utilized shall be instructed about the procedures and prohibited from attempts to restart to re-energize equipment that has beenlocked out or tagged out. Employee Safety and Health will assist in development of these programs.

6.7.4: LOCK OUT TAG OUTRetraining shall be provided for allaffected employeeswhenever there is a change in their job assignments, a change inmachines, equipment or processes that presents new hazards, when thereis a change in energy control procedures, or when there is reason tobelieve that there are deviations form or inadequacies in the knowledge or use of the energy control procedures.

6.7.5: LINE BREAKING PERMITThe intentional opening of a pipe, line, or duct that is or has been carrying flammable, corrosive, or toxic material, an inert gas, or any fluid at a volume, pressure, or temperature capable of causing injury.

6.8: BEHAVIORAL SAFETYGeller, professional psychologist, used behavioral safety for the application of behavioral theories from the field of psychology to the field occupational safety.

6.8: BEHAVIORAL SAFETYBehavior safety is the "application of science of behavior change to real world problems". BBS "focuses on what people do, analyzes why they do it, and then applies a research-supported intervention strategy to improve what people do. To be successful a BBS program must include all employees, from the CEO to the floor associates.

6.8: BEHAVIORAL SAFETYTo achieve changes in behavior, a change in policy, procedures and/or systems most assuredly will also need some change. Those changes cannot be done without buy-in and support from all involved in making those decisions.BBS is not based on assumptions, personal feeling, and/or common knowledge. To be successful, the BBS program used must be based on scientific knowledge

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6.8: BEHAVIORAL SAFETYA good BBS program will consist of:

Common goals Both employee and managerial involvement in the processDefinition of what is expected Specifications of target behaviors derived form safety assessmentsObservational data collectionDecisions about how best to proceed based on those dataFeedback to associates being observedReview

6.9: SAFETY AUDITRefer back to PSM **compliance audit