Chapter 1 Introduction to Process Safety

Process Safety The application of engineering, science, and human factors to the design and operation of chemical processes and systems. The primary purpose is to prevent injuries, fatalities, fires, explosions, or unexpected releases.

Figure 1-1 Operational Hazard

Labor and Safety Movement in U.S. During the early years organized labor was weak Strikes were broken up as the courts sided with the owners. Workers suffered from Phossy Jaw, Black Lung, lead poisoning, and typical work place injuries.

Pittsburgh Survey of 1907 Provided the first statistical data on how many people had been killed or injured as a result of hazardous working conditions in the U.S. Between 1906 and 1907, 526 people had lost their lives and 500 had been seriously injured or disabled in the Pittsburgh area alone.

Pittsburgh Survey Brings Change In 1913 the National Council of Industrial Safety was formed. By 1913 the Department of Labor was organized In 1935 the Social Security Act was approved.

Occupational Safety and Health Act of 1970 The primary purpose is to (1) remove hazards from the work place that could lead to serious injury or death and (2) ensure safe and healthful working conditions for American workers. Applies to four categories: agriculture, construction, general industry, and maritime.

There are three main branches to the Occupational Safety and Health Act NIOSH - This agency is responsible for safety and health research. OSHA – Investigates catastrophes and fatalities, inspects workplace, and sets new standards and penalties. OSHRC – Conducts hearings for noncompliance that are contested, can overturn OSHA findings, and functions independently.

Hazard Communication Standard Implemented in 1983 Also called worker’s Right to Know Law Increased plant worker awareness of chemical hazards.

Process Safety Management Designed to keep the process in the pipes. In response to this standard the CPI, government, business, and educational communities joined forces to better educate the technical workforce.

Administrative Controls Policies, procedures, plans and agreements, principles, rules, agreements, and systems used to control industrial hazards. Mutual Aid Agreements between industry and outside emergency response organizations.

Personal Protective Equipment PPE provides an effective means for protecting technicians from hazardous situations.

New Technology Number one advancement has been automation. By1998–1999, a standardized state curriculum was adopted in Texas and Louisiana Current responsibilities of process technicians, chemists, and engineers will begin to merge.

General Plant Safety Rules Do not go to a fire, explosion scene, accident, or vapor release unless you have a specific duty. Obey traffic rules. Drink from designated water fountains and potable water.

Job Hazard Analysis A process used to assess risk. Identification of unacceptable risk The process used to eliminate or control the risk.

Fire Classification System Class A – Burning of combustible materials such as wood, paper, plastic, cloth and rubber. Class B – Combustible and flammable gases, liquids, and grease. Class C – Electrical fires. Class D – Combustible metals.

Types of Permits Hot work Energy isolation Confined space entry Opening or Blinding Unplugging Routine maintenance