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Process Safety, Health and

Environment (CN3135)

Soh Guat Hiong


chesgh@nus.edu.sg

Outline of CN3135
Importance of process safety design and
operation
Identifying safety and health hazards eg.
HAZOP, Fault Tree
Predicting consequences
Design for sustainable processes eg. reliability
engineering, sustainable engineering

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Module Learning Outcomes


On successful completion of this module, students
will be able to:
Describe and identify chemical process hazards
Analyze and assess the potential impacts of
hazards on safety, health, and the environment
(SHE)
Develop methods for controlling process hazards
and minimizing their associated risks.
Describe the principles and aims of sustainable
development
Prepare for final year design project
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Lectures and Tutorials Schedule

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Lectures and Tutorials Schedule

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Tutorial Exercises

Will be assigned by individual


lecturers during each lecture

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Module Assessment
Mid term test (date, topics, duration) 10%
HAZOP/ Reliability Engineering project 30%
Final Examination 60%

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Textbook for CN3135


Chemical Process Safety:
Fundamentals with
Applications,
International Edition, 3/e

Author

: CROWL
LOUVAR

Publisher : Pearson
ISBN

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: 9780132782838

CN3135 Introduction to Occupational Health and Safety 1

Expectations
IVLE/CN3135
Lecture materials - download
Tutorial problems Attempt
Register your project teams
o Form team of 4 5 members
o Register: IVLE/Workspace/Groups/Sign-up

Bring textbook for lectures/tutorials

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Lecture 1
Introduction to Loss
Prevention

Learning Outcomes
Review major process safety accident cases
Assess loss prevention in process design and
operation
Analyse incident statistics

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Why Process Safety ?


Unexpected releases of toxic, reactive, or
flammable liquids and gases in processes
involving highly hazardous chemicals

May result in huge loss of


lives, property damage, impact
the environment and $$$

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Source : The 100 Largest Losses, 1974-2013

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Source : The 100 Largest Losses, 1974-2013


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Major Process Safety Accidents

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Video: Bhopal

http://www.youtube.com/watch?v=ELllSxnDS0g

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Taiwan Gas Blast


Kaohsiung
31st August 2014
At least 25 fatalities and
270 injured

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Major Process Safety Accidents

Fire at Shell Bukom


Fire had started in the course of open de-oiling of
naphtha from a pipeline that ran through a pump
house at the refinery
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Fire at Shell Bukom


Started 28th Sept 2011@ 1.15pm
Fire broke out in the pump room of Shell's halfa-million barrel per day Singapore plant
6 people suffered superficial wounds and 3 fire
engines were damaged from the fire
Damage was contained to the vicinity of the
pump-house, in an area 50m by 150m
Caused temporary shut down of refinery
Extinguished 29th Sept 2011 @9.18pm
Final handover by SCDF 2nd Oct 2011
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Shell was charged under Section 11(a) of the Workplace Safety and Health Act
(Chapter 354A) for having failed in its duty as an occupier to take reasonably
practicable measures to ensure the safety of persons at its workplace
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Source: www.wsh-institute.sg
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Source: www.wsh-institute.sg
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Workplace Injury Rate, 2006-2014

Source: WORKPLACE SAFETY AND HEALTH REPORT, 2014, WSH Institute

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Occupational Disease Incidence Rate, 2006-2014

Source: WORKPLACE SAFETY AND HEALTH REPORT, 2014, WSH Institute

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$10B costs
reported !

Source: Economic Cost of Work-related Injuries and Ill-health in Singapore, WSH Institute

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Process Safety Focus


Prevention of incidents involving leaks, spills,
fires or explosions
Facilities are well designed, safely operated
and properly maintained
Facilities are designed and engineered
properly with systems to monitor and control
hazards
Includes technical, management and
operational systems working together to
achieve desired outcome
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Process Safety Pyramid

Source: WSH Guidelines on Process Safety Performance Indicators, WSH Council


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Definitions
Safety: Strategy of accident prevention. Main
emphasis is on worker safety
Loss Prevention: Prevention of accidents through use
of appropriate technologies to identify and eliminate
hazards before an accident occurs. Includes
protection of people, equipment, production, property
and the environment
Hazard: An inherent physical or chemical characteristic
of a material, system, process or plant that has the
potential for causing harm or damage
Risk: A measure of the likelihood of occurrence and
consequence (severity) of an accident

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Definitions
Lower Risk Level

HAZARD:
Venom

RISK: Venom contacts


eyes may cause
blindness

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Spitting Cobra

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Definitions
Accident: Incident which results in consequent
losses
Incident: An unplanned or undesired event that
adversely affects a companys work operations
Include work-related fatalities, major injuries, minor
injuries, first aid cases, occupational illnesses,
property damage, spills, fires, dangerous
occurrences or near miss events

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Accident Pyramid
1
100
500
10 000

Disabling Injury
Minor Injury

Property Damage

No Damage

Source: Chemical Process Safety, Crowl & Louvar


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What is Acceptable
Risks?

Acceptable Risks
Any risk that is currently tolerated is considered
to be acceptable (US EPA)
Tolerable risk: risk which is accepted in a given
context based on the current values of society
(ISO & IEC)
Level of potential losses that a society or
community considers acceptable given existing
social, economic, political, cultural, technical
and environmental conditions (UN)

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Acceptable Risks
Cannot eliminate risks totally
At design stage, need to decide if risks are
acceptable
< Normal day-to-day risks in non-industrial
environment
Risks from multiple exposures are additive

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Acceptable Risks
Risk acceptance is a function of many factors
and varies considerably across industries
Company culture and the culture of the country
in which a facility is located influence risk
acceptability
Risk acceptability is also time dependent what is acceptable today may not be
acceptable tomorrow, next year or next decade

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Workplace Safety and Health Act

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Legal Requirements WSH (Risk


Management) Regulations

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Risk Management using As Low as


Reasonably Practicable Principles (ALARP)

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Obtainable from Workplace


Safety and Health Council
website
www.wshc.sg

Latest Revision: 2015


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Safety and Health Hazards


Physical (eg. fire, explosion, noise, temperature, radiation)
Mechanical (eg. moving parts of machinery, sharp edges,
work at height)
Electrical (eg. electricity, static electricity)
Chemical (eg. corrosives, toxic chemicals)
Ergonomics (eg. back strain, repetitive strain injury)
Biological (eg. pathogens)
Psychosocial hazards (eg. human & cultural factors)

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Sources of Hazards
huMan
Machine
Method
Material
Physical
Environment
Organisation/
Work factors

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Severity of Hazard
Level

Score

Severity

Catastrophic Fatality, fatal diseases or multiple major injuries

Major
3

3
Moderate

Description

Minor
Negligible

Serious injuries or life-threatening occupational


disease (includes amputations, major fractures,
multiple injuries, occupational cancer, acute
poisoning, deafness, disabilities)
Injury requiring medical treatment or ill-health leading
to disability (includes lacerations, burns, sprains,
minor fractures, dermatitis, work-related upper limb
disorders)
Injury or ill-health requiring first-aid only (includes
minor cuts and bruises, irritation, ill-health with
temporary discomfort)
Not likely to cause injury or ill-health

Code of Practice on Risk Management by Workplace Safety and Health Council


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Likelihood of Occurrence
Level

Likelihood

Description

Rare

Not expected to occur but still


possible.

Remote

Not likely to occur under normal


circumstances.

Occasional

Frequent

Almost Certain

Possible or known to occur.


Common occurrence.
Continual or repeating experience.

Code of Practice on Risk Management by Workplace Safety and Health Council

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Risk Ranking and Risk Matrix


Likelihood Rare - Remote Occasional Frequent
Severity

Almost

-2

-3

-4

Certain - 5

10

15

20

25

Major - 4

12

16

20

Moderate - 3

12

15

Minor -2

10

Negligible - 1

Catastrophic 5

Code of Practice on Risk Management by Workplace safety and Health Council

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Acceptability of Risk Levels


Risk Level

Risk Acceptable

Low Risk (1 3)

Acceptable

Medium Risk (4 12)

Tolerable

High Risk (15-25)

Not acceptable

Code of Practice on Risk Management by Workplace safety and Health Council

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Hierarchy of Hazard Control

Source
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Path

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Chemical Plant Accident


Accident
Type

Toxic
Release

Explosion

Fire

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Scenario

Outcomes

Probability
of
Occurrence

Potential
for
Fatalities

Release +
Dispersion

Toxic exposure
to employees
and
community

Low

High

Intermediate

Intermediate

High

Low to
Intermediate

Ignition in
confined space

Extensive plant
damage

Release + Ignition Low to


l Pre-mix with air? intermediate
plant damage

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Nature of Accident Process


Most common consequence is fire
Highest percentage of large losses from vapour cloud
explosion
Toxic release can result in high human and
environmental impact
Most frequent cause is mechanical failure (>50%),
followed by operator error (18%) and design (10%) *
Most common hardware failure piping systems,
reactors and storage tanks*
* Data from Chemical Process Safety by Crowl & Louvar

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Sequence of Accidents
Initiation Event that starts the accident
Propagation Event(s) that maintain or
expand the accident
Termination Event(s) that stop the accident
or diminish it in size

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Defeating the Accident Process


Step

Desired Effect

Procedure

Initiation

Diminish

Process design
Inert atmosphere
Intrinsically safe equipment
Grounding, bonding
Procedures, permit to work
Risk assessment
Training

Propagation

Diminish

Construction materials
Plant layout
Reduce inventories of materials
Install check and emergency shutoff valves
Emergency material transfer

Termination

Increase

Install check and emergency shutoff valves


Fire fighting, sprinklers, equipment &
Procedure
Relief system

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CN3135 Introduction to Occupational Health and Safety 1

Inherent Safety Principles


Minimise eg. inventory, size of tanks/reactors
Substitute eg. less toxic, less flammable
materials
Moderate eg. lower temperature, lower pressure,
dilution, particle size
Simplify eg. Design for Safety, less maintenance,
housekeeping, easy to follow. Reduce
opportunities for error

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Bhopal Accident
Methyl isocyanate used in pesticide
manufacturing
Heavier than air
Reacts exothermically with water
Substitute with less hazardous chemical that
produce a less toxic chloroformate
intermediate (Substitute)
Decrease inventory of MIC on site (Minimise)

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Video: Sugar Dust Explosion

Port Wentworth, Georgia


http://www.youtube.com/watch?v=Jg7mLSG-Yws

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Port Wentworth Accident


Conveying equipment not designed to
minimise release of sugar dust and eliminate
all ignition sources (Minimise)
Poor housekeeping (Minimise, Simplify)
Company knows but fail to correct unsafe
condition (Company leadership issue)

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Combustible Dust Explosion


Automobile Metal Parts Polishing Supplier, Kunshan

2nd August 2014


68 fatalities, about 190 injured

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Taipei
Formosa
Water Park
Fire

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Major Process Safety Accidents

Fire at Shell Bukom


Fire had started in the course of open de-oiling of
naphtha from a pipeline that ran through a pump
house at the refinery
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Shell Bukom Fire - 3 Main Lapses


1) Contractors drain naphtha from two open
valves and an open flange joint of the pipeline
into trays.
Naphtha vapour to escape into the atmosphere
resulting in an accumulation of flammable
vapour, which would in turn pose a danger of
ignition

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Shell Bukom Fire - 3 Main Lapses


2) Use of a plastic tray, which was a nonconductive container, as a receptacle for
collection of naphtha
Free fall of naphtha onto the plastic tray allowed
accumulation of static charges
A spark could be caused and be sufficient to
ignite the naphtha vapour which is within
flammable range in the atmosphere

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Shell Bukom Fire - 3 Main Lapses


3) Failed to deploy portable gas monitors
sufficiently close to the open de-oiling area to
give the warning when the build-up of the
flammable vapour reached an undesirable level

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Performance Monitoring
Provide assurance that process safety risks are adequately
controlled
Leading Indicators - monitor proactively the effectiveness
of risk control systems and provide feedback on safety
performance before an incident or accident happens
Evaluate present state of workplace through routine and
systematic inspections
Lagging Indicators when desired safety outcome has
failed. Monitor reactively the effectiveness of risk control
systems, identify gaps and weaknesses in these systems,
and report on incidents or accidents

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Source: WSH Guidelines on Process Safety Performance Indicators, WSH Council


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Examples of Leading Indicators

Source: WSH Guidelines on Process Safety Performance Indicators, WSH Council


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Examples of Leading Indicators

Source: WSH Guidelines on Process Safety Performance Indicators, WSH Council


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Accident Statistics
Ministry of Manpower

Fatality Rate: per 100 000 employed persons

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Accident Statistics
OSHA (Occupational Safety & Health
Administration)
# of injuries & Illness*200,000
Total hrs worked by all employees
Incidence rate per 100 worker years
40hrs 50wk
hr
WorkYear

2000

yr
wk yr

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Accident Statistics
FAR (Fatal Accident Rate): Fatalities per
1000 employees over 50 years ( = 108 working hours)

Depends on no. of exposed hours


FAR = No. of Fatalities x 108
Total hrs worked by ALL
employees during period covered
[NB. 1 worker - 40 hr/wk, 50 wk/yr, and 50 exposed- yr/lifetime = 105 exposed-hr/lifetime]

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Assessing Risks
Target FAR
For planning, design to meet national or
company requirements
Sum of risks for most exposed person on site
< 2 deaths/108 exposed-hr
Single risk < 0.4 deaths/108 exposed-hr

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Accident Statistics
FR (Fatality Rate): per person per year
Independent of hours actually worked
FR = No. of fatalities per year
Total no. of people in
applicable population

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Fatality Rate:
FR = no. of deaths x
total population
Assessing
Risks
frequency
Acceptability Criteria
10-3/yr
unacceptable
10-4/yr
public money spent to control
10-5/yr
some degree of inconvenience
10-6/yr
no great concern

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Engineering Ethics
Use knowledge and skill for enhancement of
human welfare
Be honest and impartial
Strive to increase competence and prestige of
engineering profession
Hold paramount the safety, health and welfare
of public
(Extracted from American Institute of Chemical Engineers Code of
Professional Ethics)
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Your Role in Loss Prevention


Eliminate, design out the hazard
Mitigate the risk by reducing the severity
and probability of occurrence of the
incident

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VISION
ZERO

Zero Harm
Achievable?
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Tutorial Questions 19th Aug


Attempt problems 1-1, 1-2, 1-4, 1-6(a), 1-22
and 1-23 from textbook

3rd Edition

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