HIGH HAZARD INDUSTRIES HIGH HAZARD INDUSTRIES

VIS-A-VIS VIS-A-VIS

MAJOR EMERGENCIESMAJOR EMERGENCIESBy

V. C.BhattCM (Fire & Safety)

GNFC LTD.

DEVASTATION BY FIRE

HIGH HAZARD INDUSTIRES:HIGH HAZARD INDUSTIRES:Hazards in chemical industry has potential for Fire, Explosion, Toxic release.

• Can cause injury, ill health, damage to property.• Damage to environment.• Serious disruption to people Onsite, Offsite, premises and services.• Short term effects and long term effects.

Potential Hazard In Chemical Industries Is High Due To:• Hazardous Materials / Chemicals / Inventories of

Materials• Rigorous Operating Conditions/High Pressure/High

Temperature / Corrosive Combination• Exothermic Reaction• Incompatibility• Varying Environmental Condition• Human Factors• Natural Disasters.

SOME POTENTIAL HAZARDS

A. ENERGY SOURCE• Process Chemicals, Fuels, Nuclear Reactors,

Generators, Batteries Source of Ignition, Radio Frequency Energy Sources, Activators, Radiation Sources

• Rotating Machinery, Prime Movers, Pulverizes, Grinders, Conveyors, Belts, Cranes

• Pressure Containers, Moving Objects, Falling Objects.

B. RELEASE OF MATERIAL• Spillage, Leakage, Vented Material• Exposure Effects, Toxicity, Burns, Bruises,

Biological Effects• Flammability, Reactivity, Explosiveness,

Corrosively and Fire Promoting Properties of Chemicals

• Wetted Surfaces, Reduced Visibility, Falls, Noise, Damage

• Dust Formation, Mist Formation, Spray.

SOME POTENTIAL HAZARDS

C. FIRE HAZARD• Fire, Fire Spread, Fireballs, Radiation• Explosion, Secondary Explosion, Domino Effects• Noise, Smoke, Toxic Fumes, Exposure, Effects• Collapse, Falling Objects, Fragmentation.

D.PROCESS STATE• High/Low/Changing Temperature And Pressure• Stress Concentrations, Stress Reversals, Vibration,

Noise

SOME POTENTIAL HAZARDS

• Structural Damage or Failure, Falling Objects, Collapse.

• Electrical Shock and Thermal Effects, Inadvertent Activation, Power Source, Failure.

• Radiation, Internal Fire, Overheated Vessel.• Failure of Equipment / Utility Supply / Flame /

Instrument / Component.• Start-up and Shutdown Condition.• Maintenance, Construction And Inspection

Condition.

SOME POTENTIAL HAZARDS

E. ENVIRONMENTAL EFFECTS

• Effect Of Plant On Surroundings, Drainage, Pollution, Transport, Wind and Light Change, Source Of Ignition / Vibration / Noise / Radiation Interference / Fire Spread/Explosion

• Effect Of Surroundings, On Plant(as Above)

• Climate, Sun, Wind, Rain, Snow, Ice, Grit, Contaminants, Humidity, Ambient Conditions.

• Acts Of God, Earthquake, Arson, Flood, Typhoon, Force Majeure.

• Site Layout Factors, Groups Of People, Transport Features, Space Limitations, Geology, Geography

• Security

SOME POTENTIAL HAZARDS

HIGH HAZARD INDUSTRIES CATEGARIZATION

• Scale Of Operation / Inventory / Process, Integrations Obvious

• Legal Requirements – Legal Criteria to Classify / Categorized Industries

• Hazardous Materials Inventories / Hazardous Processes

• Risk Levels With Respect To Location, Surrounding Neighborhood, Population Density, Environment Sensitivity

• Acceptability Criteria For Risk

Acceptability Criteria for Risk • Risk levels, risk to individuals, societal risk,

voluntary risk and involuntary risk, perception of risk.

• Profound questions of Ethics and philosophy of life.

• What risk is acceptable?• Risk can be minimized at a cost even if can not

be completely eliminated. • How far should one go along this road?

Acceptability Criteria for Risk • If we express risk as a Fatal Accident

Frequency Rate (FAFR) – calculated as the number of deaths per hours of exposure to risk multiplied by 108.

• FAFR represents the number of deaths from industrial injury in a group of people during their working lives.

• Some recommended criteria of acceptable risk in plant design. (always subjective and debatable as it is a emotive area)

Acceptability Criteria for Risk I. The value of life should not be coasted.II. FAFR below 0.4 or 0.3 for any single risk.III. For risk to general public such values are subject

to speculation and debate however the following may be considered acceptable.

a. If it occurs less frequently then once in 100 years.b. If it has a FAFR below about 0.001 or less.c. If the risk of death caused by the plant is under 10-5

per year for an offsite individual with this value determined at a higher statistical confidence limit.

d. If several people can be killed, it should be 10-7 per year per person or 10-8 per year per person.

Acceptability Criteria for Risk e. Action should be taken regardless of the criteria to

minimize the number of deaths from any single events.

• Consider the question – whether an accident that can kill 1000 people should be required to occur 1000 times less frequently than one that can kill a single person?

• Hence acceptability is highly subjective.• Limitation of number of deaths from any

incidents. It must be the goal. • Loss prevention and loss control can help to

achieve this.

Loss Prevention And Total Loss Control A major hazard materializes due to loss of containmentLoss prevention is characterized by 1.A concern with depth of technology and associated hazards.2.An emphasis on Management.3.A system rather than trial and error approach.4.A concern to avoid loss of containment resulting in major fire, Explosion, Toxic release.

5. The development of techniques for identification of hazards.

6. The principle of risk criteria and quantification of hazards.

7. The development of techniques for the quantification of hazards.

8. The use of the techniques of reliability engineering.

9. The principle of independence in critical assessments and inspections.

10. The planning for emergencies.11. Strengthening of practices, codes, standards,

statutory regulation with technological change.

Total Loss Control areas are :1.Injuries health hygiene.2.Business interruption3.Property damage4.Fire / Explosion / Toxic Release5.Environmental pollution6.Security7.Product liability

This can be avoided by:• Identification of loss producing situations.• Measurement of such loses.• Selection of methods to minimize such loses.• Implementation of methods.

In spite of all these you can have incidentsturning into emergency as : • Human behaviour is unpredictable.• Chance, complacency, false sense of security,

lullness• Low probability events• Low predictability events• High probability but consequences mis calculated• Wrong priorities

Preparedness for Emergency and Response :Preparedness for emergency starts from drawing board stage itself. It is integral part of design, construction, operation, Maintenance.(As per the chart shown)

Safe Place of Work Assessment

Safe Place of Work Assessment

Residual Accident Event

Residual Accident Event

ConsequencesConsequencesConsequence Reducing Measures

Consequence Reducing Measures

Probability of Success Acceptable

Probability of Success Acceptable

Probability of Success Acceptable

Probability of Success Acceptable

Consequences of FailureAcceptable

Consequences of FailureAcceptable

Review Based on Safe Place of Work

Review Based on Safe Place of Work

Contingency Plan

Contingency Plan

Change ConceptChange Concept

Yes

No

Yes No

No

Definitions:Incident : An unplanned event causes or could cause under different circumstances injury, ill-health or damage to property or the environment.

Emergency : A dynamic incident in which there is a continuing potential for major injury, ill-health or damage to property, the process or environment.

Evacuation : the planned and controlled removal of personnel from an emergency area.

Escape : The uncontrolled departure of personnel from an emergency area.

Rescue : The recovery of personnel from an area of danger to safe location.

At any time emergency develops due to; Change in process parametersFailure of a piece of equipment or instrument.Failure of control system.Error by human being.Natural Disaster like Flood, Wind, lightening, Earthquake.Civil disorderMalicious damage - sabotage

Sequence of Events in an Emergency:

Phase Status Activity

Prevention

Normal Operation

Correct Upset

Abnormal Operation

Controlled Plant S/D

Containment

State of Alert

Emergency S/D, Venting, Dumping, Inventory

Emergency

Fire Prevention, Fighting, Emergency

Containment Activities

Evacuation

Mitigation

Evacuation

Orderly Evacuation Under Direction of supervisor

EscapeEscape groups and

IndividualsRescue

Recuperation

Emergency Teams in Action

Safety

Medical and Trauma Treatment of Personnel,

Recovery

Rehabilitation of Facilities

Normal Operation

Sequence of Events in an Emergency:

Elements of Emergency Preparedness

1. Identification of the FACTORY.2. Map of the AREA3. Factory Lay - Out.4. Storage Hazards & Controls.5. Material Safety Data Sheets (MSDS).6. Process Vessel Hazards & Control.7. Other Hazards & Controls.8. Trade-Waste Disposal.9. Records of Past Accidents/Incidents.10.Gas Dispersion Concentration.11.Evacuation Table.12.Environmental Impact Assessment.13.Weather Conditions.14.Incident Controllers (Ics).15.Deputy Incident Controllers (Dy.Ics).16.Site Main Controllers (SMCs).

Elements of Emergency Preparedness17.Key Personnel.18.Essential Workers.19.Assembly Points.20.Emergency Control Center (ECC).21.Fire & Toxicity Control Arrangements.22.Medical Arrangements.23.Transport & Evacuation Arrangements.24.Pollution Control Arrangements.25.Other Arrangements.26.Alarms & Sirens.27.Internal Phones.28.External Phones.29.Nominated Persons to declare Major Emergency.30.A Form to record emergency telephone calls.31.Statutory Communication.32.Separation Distances.33.Emergency Instruction Booklets.

Thank YouThank You