This document discusses reducing process risks in the pharmaceutical industry. It outlines several driving forces for reducing risk, including plant existence, harm prevention, regulatory requirements, and public image concerns. Several case studies of accidents at pharmaceutical plants are presented to illustrate hazards like explosions and chemical releases. Common causes of accidents included lack of inherently safer design practices, insufficient safety controls, poor hazard awareness, and deficiencies in procedures and maintenance. Reducing risks requires understanding hazards, implementing proper controls, and focusing on priorities like process safety, ergonomics, and hygiene.
Exposure Risk Assessment Challenges : Occupational Hygiene in the Pharmaceutical and Chemical Industries, AIHA 2013, Asia Pacific OH Conference, Singapore
Exposure Risk Assessment Challenges : Occupational Hygiene in the Pharmaceutical and Chemical Industries, AIHA 2013, Asia Pacific OH Conference, Singapore
Air Based Hazards ...
This topic comes under Hazards and Safety Management.....
This is useful for M.Pharm (Pharaceutical Quality Assurance) Students who studying in First year sem II....
This Presentation Contain following...
#Definition of Air Pollution
#Classification of Air Pollutant
#Sources of Air Pollution
#Man made sources
#Industrial sources
#Classification of Pollutants
#Effects of air pollution on plants
#Air pollution controlling equipments
#Case study
#Conclusion
#References
Thanks For Help and Guidance of Mr. D. V. Mahuli Sir
Bhopal disaster could safe by Abid Nadeem khanguestda7ab4
Bhopal accident could safe if all the safety precautious could be taken PSRM Process safety Risk Management is a nice to stop any where. Safe the Humans, by ANK
Air Based Hazards ...
This topic comes under Hazards and Safety Management.....
This is useful for M.Pharm (Pharaceutical Quality Assurance) Students who studying in First year sem II....
This Presentation Contain following...
#Definition of Air Pollution
#Classification of Air Pollutant
#Sources of Air Pollution
#Man made sources
#Industrial sources
#Classification of Pollutants
#Effects of air pollution on plants
#Air pollution controlling equipments
#Case study
#Conclusion
#References
Thanks For Help and Guidance of Mr. D. V. Mahuli Sir
Bhopal disaster could safe by Abid Nadeem khanguestda7ab4
Bhopal accident could safe if all the safety precautious could be taken PSRM Process safety Risk Management is a nice to stop any where. Safe the Humans, by ANK
For the following research paper assignment, you have been asked to renatas0nie
For the following research paper assignment, you have been asked to perform an evaluation of employee exposures at a small automobile parts manufacturing facility. The manufacturing processes include two metal presses, two machining stations, three welding stations, a small paint booth, and a shipping/receiving area. There are two employees working at each press, one person working at each machining station, one person working at each welding station, two people working in the paint booth, and four employees working in the shipping/receiving area.
One of the presses is a 2,000-ton press, and the other press is a 200-ton press. The 2,000-ton press is the greatest noise source for the facility. The machining area uses a metal working fluid. The safety data sheet (SDS) for the metal working fluid is attached here. All welding is performed on stainless steel. The painting booth uses a powder coating operation, but the employees use xylene and methyl ethyl ketone (MEK) to clean the parts prior to the powder coating operation. At the end of the shift, one of the employees uses 1,3 butadiene to clean the nozzles for the paint booth. The facility uses two electric forklifts to move materials between the production area and the storage warehouse and between the warehouse and the shipping area. All employees work an 8-hour shift.
Part 1:
Using the information on anticipation and control we studied in the textbook, identify the hazards that are present in the facility. In your discussion, explain why you chose the hazards, and describe whether you believe the hazards to be actual hazards or potential hazards (which require further evaluation). Describe the specific location(s) at the facility where the hazards are located, and determine how many employees are potentially at risk in those areas.
Your response for Part 1 should be at least one page in length.
Part 2:
Using the information on evaluation that we studied in the textbook, summarize how you would measure the personal exposures to the hazards that you identified in Part 1. Use the Occupational Safety and Health Administration (OSHA) website (https://www.osha.gov/dts/sltc/methods/toc.html) or the National Institute for Occupational Safety and Health (NIOSH) website (http://www.cdc.gov/niosh/docs/2003-154/default.html) to select the specific sampling and analytical method that would work best to evaluate any chemical hazards you identified. Provide a summary of the sampling media you would use, include the sampling flow rate, discuss how long you would sample, and explain how you would calibrate the sampling train. Include a discussion about why you selected the specific sampling and analytical method.
Your response to Part 2 should be at least one page in length.
Part 3:
Access the attached sampling results here. For each set of results, perform the following actions:
Calculate the 8-hour time weighted average (TWA) exposure.
Compare the results to the appropriate OSHA permissible exp ...
Dr. Renée Anthony - Hazards and Prevention of Airborne Exposures and RisksJohn Blue
Hazards and Prevention of Airborne Exposures and Risks - Dr. Renée Anthony, Great Plains Center for Agricultural Health, from the 2016 Iowa Pork Congress, January 27-28, Des Moines, IA, USA.
More presentations at http://www.swinecast.com/2016-iowa-pork-congress
This research paper introduces the Bhopal plant gas tragedy disaster that happened in India, 1984:
- Major causes and errors leading to multiple failures of the chemical plant are elaborated.
- Main catastrophic consequences are discussed and classified in terms of casualties and fatalities, acute and chronic health effects, and toxic effects on soil and water.
- Rehabilitation procedures adopted after the incident.
- Preventive barriers that could have been adopted in order to reduce the likelihood of the disaster occurrence.
If accidents are to be reduced, this needs maximum attention and an optimum risk management system.
Presented to: Kentucky Chemical Demilitarization Citizens’ Advisory Commission and Chemical Destruction Community Advisory Board
Secondary Waste Working Group
Presented by:
Dr. John Barton
Systems Contractor Chief Scientist
Presented to: Subgroup of the Kentucky Chemical Demilitarization Citizens’ Advisory Commission and
Chemical Destruction Community Advisory Board
Secondary Waste Working Group
Presented by:
Jeff Brubaker
ACWA Site Manager
Doug Omichinski
Systems Contractor Project Manager
Roger Thompson, CIH, CSP
Systems Contractor Safety & Health Manager
Charlie Satterwhite, CIH
Systems Contractor Senior Industrial Hygienist
Dr. John Barton
Systems Contractor Chief Scientist
Neil Frenzl
Systems Contractor Resident Engineering Manager
They are a form of industrial accident where great damage, injury or loss of life are caused. Other disasters can also be considered industrial disasters, if their causes are rooted in the products or processes of industry.
I am looking for stable job with long term relation ship. I am ready to relocate within Gujarat. At present, I ERP manager in one of the EOU Gujarat based company. I am able to coordinate the ERP related activities. I can evaluate the ERP product and implementation partner considering various factors like multi company, multi location, multi currency, company's processes, turnover, strength etc.
WRI’s brand new “Food Service Playbook for Promoting Sustainable Food Choices” gives food service operators the very latest strategies for creating dining environments that empower consumers to choose sustainable, plant-rich dishes. This research builds off our first guide for food service, now with industry experience and insights from nearly 350 academic trials.
UNDERSTANDING WHAT GREEN WASHING IS!.pdfJulietMogola
Many companies today use green washing to lure the public into thinking they are conserving the environment but in real sense they are doing more harm. There have been such several cases from very big companies here in Kenya and also globally. This ranges from various sectors from manufacturing and goes to consumer products. Educating people on greenwashing will enable people to make better choices based on their analysis and not on what they see on marketing sites.
"Understanding the Carbon Cycle: Processes, Human Impacts, and Strategies for...MMariSelvam4
The carbon cycle is a critical component of Earth's environmental system, governing the movement and transformation of carbon through various reservoirs, including the atmosphere, oceans, soil, and living organisms. This complex cycle involves several key processes such as photosynthesis, respiration, decomposition, and carbon sequestration, each contributing to the regulation of carbon levels on the planet.
Human activities, particularly fossil fuel combustion and deforestation, have significantly altered the natural carbon cycle, leading to increased atmospheric carbon dioxide concentrations and driving climate change. Understanding the intricacies of the carbon cycle is essential for assessing the impacts of these changes and developing effective mitigation strategies.
By studying the carbon cycle, scientists can identify carbon sources and sinks, measure carbon fluxes, and predict future trends. This knowledge is crucial for crafting policies aimed at reducing carbon emissions, enhancing carbon storage, and promoting sustainable practices. The carbon cycle's interplay with climate systems, ecosystems, and human activities underscores its importance in maintaining a stable and healthy planet.
In-depth exploration of the carbon cycle reveals the delicate balance required to sustain life and the urgent need to address anthropogenic influences. Through research, education, and policy, we can work towards restoring equilibrium in the carbon cycle and ensuring a sustainable future for generations to come.
Diabetes is a rapidly and serious health problem in Pakistan. This chronic condition is associated with serious long-term complications, including higher risk of heart disease and stroke. Aggressive treatment of hypertension and hyperlipideamia can result in a substantial reduction in cardiovascular events in patients with diabetes 1. Consequently pharmacist-led diabetes cardiovascular risk (DCVR) clinics have been established in both primary and secondary care sites in NHS Lothian during the past five years. An audit of the pharmaceutical care delivery at the clinics was conducted in order to evaluate practice and to standardize the pharmacists’ documentation of outcomes. Pharmaceutical care issues (PCI) and patient details were collected both prospectively and retrospectively from three DCVR clinics. The PCI`s were categorized according to a triangularised system consisting of multiple categories. These were ‘checks’, ‘changes’ (‘change in drug therapy process’ and ‘change in drug therapy’), ‘drug therapy problems’ and ‘quality assurance descriptors’ (‘timer perspective’ and ‘degree of change’). A verified medication assessment tool (MAT) for patients with chronic cardiovascular disease was applied to the patients from one of the clinics. The tool was used to quantify PCI`s and pharmacist actions that were centered on implementing or enforcing clinical guideline standards. A database was developed to be used as an assessment tool and to standardize the documentation of achievement of outcomes. Feedback on the audit of the pharmaceutical care delivery and the database was received from the DCVR clinic pharmacist at a focus group meeting.
Artificial Reefs by Kuddle Life Foundation - May 2024punit537210
Situated in Pondicherry, India, Kuddle Life Foundation is a charitable, non-profit and non-governmental organization (NGO) dedicated to improving the living standards of coastal communities and simultaneously placing a strong emphasis on the protection of marine ecosystems.
One of the key areas we work in is Artificial Reefs. This presentation captures our journey so far and our learnings. We hope you get as excited about marine conservation and artificial reefs as we are.
Please visit our website: https://kuddlelife.org
Our Instagram channel:
@kuddlelifefoundation
Our Linkedin Page:
https://www.linkedin.com/company/kuddlelifefoundation/
and write to us if you have any questions:
info@kuddlelife.org
Willie Nelson Net Worth: A Journey Through Music, Movies, and Business Venturesgreendigital
Willie Nelson is a name that resonates within the world of music and entertainment. Known for his unique voice, and masterful guitar skills. and an extraordinary career spanning several decades. Nelson has become a legend in the country music scene. But, his influence extends far beyond the realm of music. with ventures in acting, writing, activism, and business. This comprehensive article delves into Willie Nelson net worth. exploring the various facets of his career that have contributed to his large fortune.
Follow us on: Pinterest
Introduction
Willie Nelson net worth is a testament to his enduring influence and success in many fields. Born on April 29, 1933, in Abbott, Texas. Nelson's journey from a humble beginning to becoming one of the most iconic figures in American music is nothing short of inspirational. His net worth, which estimated to be around $25 million as of 2024. reflects a career that is as diverse as it is prolific.
Early Life and Musical Beginnings
Humble Origins
Willie Hugh Nelson was born during the Great Depression. a time of significant economic hardship in the United States. Raised by his grandparents. Nelson found solace and inspiration in music from an early age. His grandmother taught him to play the guitar. setting the stage for what would become an illustrious career.
First Steps in Music
Nelson's initial foray into the music industry was fraught with challenges. He moved to Nashville, Tennessee, to pursue his dreams, but success did not come . Working as a songwriter, Nelson penned hits for other artists. which helped him gain a foothold in the competitive music scene. His songwriting skills contributed to his early earnings. laying the foundation for his net worth.
Rise to Stardom
Breakthrough Albums
The 1970s marked a turning point in Willie Nelson's career. His albums "Shotgun Willie" (1973), "Red Headed Stranger" (1975). and "Stardust" (1978) received critical acclaim and commercial success. These albums not only solidified his position in the country music genre. but also introduced his music to a broader audience. The success of these albums played a crucial role in boosting Willie Nelson net worth.
Iconic Songs
Willie Nelson net worth is also attributed to his extensive catalog of hit songs. Tracks like "Blue Eyes Crying in the Rain," "On the Road Again," and "Always on My Mind" have become timeless classics. These songs have not only earned Nelson large royalties but have also ensured his continued relevance in the music industry.
Acting and Film Career
Hollywood Ventures
In addition to his music career, Willie Nelson has also made a mark in Hollywood. His distinctive personality and on-screen presence have landed him roles in several films and television shows. Notable appearances include roles in "The Electric Horseman" (1979), "Honeysuckle Rose" (1980), and "Barbarosa" (1982). These acting gigs have added a significant amount to Willie Nelson net worth.
Television Appearances
Nelson's char
Micro RNA genes and their likely influence in rice (Oryza sativa L.) dynamic ...Open Access Research Paper
Micro RNAs (miRNAs) are small non-coding RNAs molecules having approximately 18-25 nucleotides, they are present in both plants and animals genomes. MiRNAs have diverse spatial expression patterns and regulate various developmental metabolisms, stress responses and other physiological processes. The dynamic gene expression playing major roles in phenotypic differences in organisms are believed to be controlled by miRNAs. Mutations in regions of regulatory factors, such as miRNA genes or transcription factors (TF) necessitated by dynamic environmental factors or pathogen infections, have tremendous effects on structure and expression of genes. The resultant novel gene products presents potential explanations for constant evolving desirable traits that have long been bred using conventional means, biotechnology or genetic engineering. Rice grain quality, yield, disease tolerance, climate-resilience and palatability properties are not exceptional to miRN Asmutations effects. There are new insights courtesy of high-throughput sequencing and improved proteomic techniques that organisms’ complexity and adaptations are highly contributed by miRNAs containing regulatory networks. This article aims to expound on how rice miRNAs could be driving evolution of traits and highlight the latest miRNA research progress. Moreover, the review accentuates miRNAs grey areas to be addressed and gives recommendations for further studies.
1. Reducing Process Risk in
Pharmaceutical Industries
Maharshi Mehta, CSP, CIH
International Safety Systems, Inc. Baroda, India and
Fairfield, CT, USA
Maharshi.mehta@issehs.com
www.issehs.com
Seminar on – Emerging Trends in Environment,
Health & Safety Management
ORGANISATION OF PHARMACEUTICAL PRODUCERS OF INDIA
April 2, 2004
2. Agenda
The Emerging Need for Process Safety
Hazard and Risk
Hazard and Hazard Identification
Process Controls that Reduces Risk
3. Driving Forces
Plant’s existence
Harm to people, process and environment
Process Interruptions
Regulatory and Corporate Requirements
Liability
Return on Investment
Recovery of resources
Savings from waste management
Pollution control at source
Share holder’s confidence
Pre-requisite to participate in Global Economy
Public Image
Press coverage
Court decisions
Major accidents
4. Public Image
Survivors of NC pharmaceutical plant
explosion work in Nebraska
……..” Jan. 29, 2003, blast that killed six
people… "There were a lot of injuries ...
a lot of bad burns, and so many people
in shock," Howard said. "We tried to
help, but most of us just prayed. It was a
miracle of God that so many people
actually walked out of there."
5. KINSTON, North Carolina
(CNN) -- A massive
explosion and fire
Wednesday gutted a
pharmaceutical supply
plant, killing at least three
people and injuring more
than two dozen others --
about 12 of them critically. Authorities
recommended
residents within a
mile radius around
the plant to
evacuate
A volatile mix of air and
suspended dust caused
the explosion The
explosion was so
powerful it blew doors
open on houses more
The stock of West
Pharmaceutical was halted on
the New York Stock Exchange
after the explosion, which is
typical following a calamity
North Carolina Governor
6. The Occupational Safety and Health
Administration said the plant was inspected in
October, cited for numerous safety violations,
including problems with the electrical systems
design and use, inaccessible fire
extinguishers and hazardous-waste
operations, and fined about $10,000, which
was reduced to about $9,000 early this
month.
7. North Carolina is the site of one of the
nation's worst workplace disasters:
Twenty-four employees and a delivery
man died and 56 people were injured in
a 1991 fire sparked when hydraulic fluid
from a conveyor belt sprayed over a
gas-fired chicken fryer at Roe's Imperial
Food Products plant in Hamlet.
8. April 1, 2002 RTE News
Two men were taken to hospital following an
explosion and fire at a pharmaceutical
company in Rathdrum, County Wicklow this
afternoon.
The two are believed to have suffered facial
burns in the incident. An investigation is
underway at the ABC plant.
9. Economic Impact
The stock of ABC was halted on the New York Stock Exchange
after the explosion
resulted in an estimated $150 million in property damage
On June 30, 2003, two new European explosion protection
regulations take effect. The first, ATEX 95, Directive 94/9/EC
covers equipment and protective systems that may be used in
areas endangered by potentially explosive atmospheres created
by the presence of flammable gases, vapors, mists, or dusts.
The second, known as ATEX 137, lays down the minimum
requirements for improving worker health and safety in
hazardous areas throughout Europe.
“Ergonomic-related illnesses remain the most frequent illnesses
at ABC Pharma. In 2002, 43% of all illnesses and 65% of all lost
time illnesses were musculoskeletal in nature and resulted in
1,450 lost days.” Excerept from MNC’s annual report
In 2002, many of our occupational illnesses and injuries resulted
from chemical exposures. For example, the second most
10. Priority AReas
Driver Safety
Ergonomics
Hygiene
Process Safety
Safety Engineering
HIV/HBV exposure controls
11. Accident Occurred
Acetone bucket caught fire: 10 L
metal container-plastic shoes-
suspended bucket on valve
2” dia rubber hose used to fill
metal drum with vinyl acetate-
violent explosion (same operation
conducted number of times
without problems): External paints
prevented grounding of the drum
N2 Purging was not enough: Fire
in Centrifuge, Insufficient N2 flow-
rota-meter 0-60 l/min, what
needed was 150 l/min
12. Accidents Occurred-Contnd.
SAVASO, Italy-Dioxane
released due to exothermic
reaction. Critical Temp known
was 230C. However it occurred
at 180 C in absence of agitation
A runaway reaction occurred
when gradual addition of
material and observing
temperature rise was done by
operator in control room. Faulty
temp recorder did not show rise
in temp. Temp increase was
indicated on a six-point recorder
but it was not located at
eyesight level.
13. Accidents Occurred (contnd)
Instruction-add methanol in waste product after applying
vacuum and breaking it with N2. Instead, TO REDUCE
AMOUNT OF WORK methanol was added directly resulting in
to fire.
Not realizing that a vacuum/pressure of as little as 0.1 psi
(vacuum of 2.5” wg, same hydrostatic pressure at the bottom of
cup of tea) to 0.3 psi (Press of 8” wg) could collapse/burst a
storage tank. 100 psi (7bar) of compressed air applied to clean
choked line blew lid off.
Drain valve of dist. column. kept open for longer draining water
and benzene
14. Accidents Occurred (contnd)
Sucking In occurred in tank because all three flame
arrestors were choked.
After cleaning of a tank on hot day, vent was closed
with plastic bag to prevent dust coming in. When rain
cooled tank, it collapsed.
A tank being steamed, sudden rain cooled tank so
quickly that vent could not draw-in air fast enough. 10
to 20” of opening was needed.
Content was pumped out more than air could get in
quickly because of change in pump.
15. Why it Happened-Commonality
Because it has not happened in --years, it won’t happen
Concept of Inherently Safer Process Design was missing-
Sufficient redundancy not in place, redundancy design flaws or
not working
Administrative Controls
Concept of system safety missing-e.g., PHA
Hazard Realization and Communication
Consequences of deviation not realized
Safe Operating Procedures not available or not blended with
Operation Procedures
Preventive Maintenance often was Reactive Maintenance-
Specifications on what to inspect not known/followed
Contractors-Weakest link of chain
ORGANIZATIONAL CONCERNS-e.g., Line vs staff function
16. Good News
“Working conditions in pharmaceutical plants are better
than those in most other manufacturing plants” BLS
With the exception of work performed by material
handlers and maintenance workers, most jobs require
little physical effort. In 2002, the incidence of work-
related injury and illness was 3.0 cases per 100 full-
time workers, compared with 7.2 per 100 for all
manufacturing industries and 5.3 per 100 for the entire
private sector.
17. Occupational Health and Safety Hazards
(B2-3)
Chemical Hazards
Flammability
Reactivity
Toxicity
Dust Explosions
Compressed Gases and Cryogenic Liquids
Physical Hazards
Noise
Ionizing and non-ionizing radiation
Other Hazards
Cumulative Trauma Disorders (Ergonomics)
Mechanical Hazards
19. Ignition Sources
Electrical (23%), Smoking (18%)
Friction (10%), Hot Surfaces (7%),
Overheated Material (8%)
Cutting, Welding, Open Flames (4%)
Spontaneous ignition (4%)
Slow oxidation of low volatile compound
with accompanying evolution of heat in
non-ventilated area
Static Electricity (1%)
20. Ignition Sources-Static Electricity
Non-Polar materials like hydrocarbons accumulate static
charges readily as they have high insulating values
22 mJ of ignition energy from walking across a rug,
many hydrocarbons require only 0.25 mJ
Flow of liquid through pipe, strainers, filters. In one test
charge development with filter was 10 to 200 times high
than without filter
Settling of conductive phase to non-conductive phase e.g.,
water in oil.
Splashing of liquid jets
Ejection of droplets from nozzles
Stirring and Mixing
Solid handling-Sieving, pouring, grinding, micronizing,
pneumatic conveying
22. Specific Conductivity of Selected
Chemicals
Liquid Specific Conductivity
mho/cm
Toluene <1x10-14
Xylene <1x10-15
Heptane
Hexane
<1x10-18
Methanol 4.4x10-7
Isopropanol 3.5x10-6
Water 5.5x10-6
23. NFPA and Indian Petroleum Act
Classification of Flammable Chemicals
NPFA
Class I Flash Point < 100 F
Class IA Flash Point < 73 F (22.7C) and BP < 100 F
Class IB Flash Point < 73 F and BP >
100F
Class IC Flash Point > 73 F and BP > 100 F
Class II Flash Point > 100 F (37.7 C) but < 140 F
Class III A Flash Point > 140 F (60 C) <200 F
Class III B Flash Point >200 F (93.3 C)
Indian Petroleum Act
Class A: Flash Point < 23C, Class B: 23C-65C, Class C:
65 C- 93C
26. Reactive Chemicals-Characteristics
High reaction rate
Reaction rate increases with temperature. Rate of reaction
increases exponentially with increase in temperature. An
increase of 10C roughly doubles the reaction rate in many
cases.
If the reaction rate and resulting heat are not controlled , an
explosion could occur.
Heat initiated decomposition could result in explosion e.g.,
certain peroxides
Light could be initiator of an explosive reaction e.g.,
hydrogen and chlorine reacts explosively in the presence of
light.
Shock could initiate an explosion, e.g., acetylides, azides,
organic nitrates, nitro compounds and peroxides.
Picric acid becomes highly shock-sensitive when its normal
water content is allowed to evaporate.
28. Dust Explosions-What is required for Dust
Explosions
Presence of Combustible Dust
Min O2 Conc-3 to 15% v/v
Min Ign Energy (MIE) and Temperature (MIT)
Right Particle Size
<particle size, > the explosion pressure -<MIE and MIT
Rate of pressure rise of polythene dust explosion
increase from 150 to 400bars/s when part.size reduced
from 100 to 25 microns.
Minimum Explosible Concentrations (MEC)
MEC for most materials is 10 to 500 g/m3
10 g/m3 dust concentration looks like dense fog with
visibility of 1Meter.
Moisture Content of dust: > Moisture, >MIE, MIT and MEC
30. Dust Explosion Characteristic of Selected Dusts
Phthalic
Anhydride
Aluminum
Powder
Benzoic acid
Explosibility Index >10 >10 >10
Ignitian Sensitivity 13.8 1.4 5.4
Explosion Severity 1.6 7.7 2.1
Max Expl Press, psig 72 84 76
Rate of Pressure rise
psi/sec
4200 20000+ 5500
Ign Temp C 650 650 620
Ign Energey, J 0.015 0.05 0.02
Min Expl Conc oz/cuft 0.015 0.045 0.03
Limiting O2%, Inert Gas 14% CO2 2%CO2
31. Exposure Limits
Permissible Exposure Limit (PEL)
Threshold Limit Values (TLV)
Recommended Exposure Limit (REL)
Short Term Exposure Limit (STEL)
CEILING LIMIT
Conc. Immediately Dangerous to Life or
Health (IDLH)
Lethal Dose, Concentration (LD50, LC50)
32. ODOR AS AN AID TO
CHEMICAL SAFETY
CHEMICAL TLV (ppm) AOT (ppm)
Acetone 750 13
Ammonia 25 5.2
Arsine 0.05 0.5
Carbon monoxide 50 100.00
Chlorine 1 0.31
Chloroform 10 85
p-Dichlorobenzene 75 0.18
Ethyl alcohol 1000 84
Ethyl ether 400 8.9
33. ODOR AS AN AID TO
CONTD....
Hydrogen sulfide 10 0.008
Methyl alcohol 200 100
Methylene chloride 100 250
Naphthalene 10 0.084
Ozone 0.1 0.045
Phenol 5 0.04
Toluene 100 2,9
Vinyl chloride 5 3000
m-Xylene 100 1.1
34. Exposure Limits for Selected Compounds
Chemical TLV
ppm
STEL/C
ppm
AOT
ppm
IDLH
ppm
NFPA Rating
H F R
Styene 20 40 0.017-1.9 700 2 3 2
Toluene 50 skin 150 N 0.16-37 500 2 3 0
Xylene 100 150 1 900 2 3 0
Butyl
Cellosolve
25 skin NA 0.1-0.48 700 2 2 0
1-Butanol 50 C Skin 1400 1 3 0
Methanol 200 250 6000
MMA 100 NA .049-0.34 1000 2 3 2
Phenol 5 Skin NA .012-.057 250 4 2 0
MM
TLV- Threshold Limit Value AOT-Odour Threshold Value
NFPA Rating-Hazard Rating H-Health, F-Flammability, R -Reactivity
35. Exposure Limits for Selected Compounds
(Contnd)
TLV
mg/cum
STEL/C
mg/cum
IDLH
mg/cum
NFPA
Rating
H FR
Phthalic
Anhydride
6.1 NA 60 3 1 1
Lead 0.05 NA 100
Chromium
VI
0.05 0.1, 1 C 3 0 1
TiO2 10
Ref: 1998 ACGIH TLVs
N-NIOSH Limits, C-Ceiling Limits
36. Physical Hazard-Noise
Health Effects:
Noise Induced Hearing Loss
Temporary and Permanent
Increased pulse Rate, Blood Pressure
Nervousness, Sleeplessness and fatigue
Health Effects Depends on:
Sound Level
Extent of Exposure
Frequency of Sound (audible 20 to 20K, Hz:
Most Impact around 1000 Hz)
37. Noise -Allowable Levels
Exposure Time
(Hours)
Max Allowable Sound Level
(dBA)
8 90
6 92
4 95
3 97
2 100
1 105
1/2 110
Redusing Time by half will increase the allowable level by
5dB
38. Approximate Sound Levels
Area/Activity Sound Level (dBA)
Normal Conversation 65
Milling Machine 90-95
Tablet Press 80-90
Manual machining 80-85
Power Saw 100-110
Jet Plane 140-150
What will be Total Noise Level if two compressors-Each
Produces Sound Level of 95 dBA?
39. Ergonomics-Cumulative Trauma
Disorders-Back Injuries
Back Injuries
50 to 80% of working population affected
Account for 33 to 41 % of all compensation
cost
Average Direct cost is about $10000/claim
Indirect Cost Could be eight times higher
Causes
Poor Equipment design Layout and Postures
Lifting-Turning around while lifting
Pushing/Pulling
Prolonged Sitting Standing
40. Why Hazard Identification
“ For every dollar it costs to fix a problem in the
early stage of design, it will cost $10 at flow
sheet stage, $100 at the detail design stage,
$1000 afte r the plant is build and $10,000 to
cleanup the mess after an accident”
KLETZ
41. Hazard Identification
Can the process/activity pose a threat to health,
safety, environment or property?
INPUT: Properties of materials, historical
experience, knowledge of process parameters,
management system, available safeguards,
application of analytical methods
Output: List of potential problem materials,
process conditions, and situations and
understanding of what can go wrong.
Conclusion: No known hazard exist, known
hazards that can be controlled, sound controls
may not control hazards
42. Hazard Identification (B1.32)
Accident and Incidence Investigation (B4)
Accident Analyses
Incidence Rate (#of lost time accidents x 20,000)/ Total
Manhours
Frequency Rate ( #of lost time accidents x 106 )/ Total
Manhours
Severity Rate (#of lost work days x 106)/ Total Man hours
Comparative analyses among employees, departments,
companies, preceding months and years, for time, nature of
accidents (e.g., burns, inhalation), cause of accidents and
body parts affected by accidents.
Employee exposure monitoring. Workplace air monitoring.
Pre-startup survey and scheduled plant audits
43. PROCESS HAZARD
ANALYSIS (B1.32)
Hazards of Process
Previous Incidents
Engineering and Administrative Controls
Consequence of Failure
Facility Sitting
Human Factors
Qualitative Factors
44. PROCESS SAFETY
INFORMATION
Hazards Technology Equipment
Toxicity Block Flow
Diagram
Construction
Materials
PELs Chemistry Piping &
Instrumention
Physical Inventory Electrical
Reactivity Operating
Ranges
Relief Vents
Corrosivity Hazards of
Deviations
Design Codes
Stability Material Balances
Compatibility Safety Systems
45. Elements of Hazard Analysis
Implementation Plan
Process Safety Information
(Hazards, Technology, and Equipment)
Prioritize the Process Hazard Analyses (PHA)
Conduct PHA According to Schedule in Standard
Schedule for Completing Actions Noted During the
PHA
Operating Procedures
(for each operating phase and for safety systems)
Certify Current Employees Sufficiently Trained
Document the Completion and Comprehension of
Training
Contractor Injury Log
46. Elements of Process Hazard
Analysis..Counted...
Procedures for Maintaining Mechanical Integrity
Document Process Equipment Inspections and Tests
Hotwork Permits
Management of Change Procedures
Incident Investigation
Emergency Action Plan
Process Safety Management Compliance Audits
47. Hazard Analysis - System Safety
Job Safety Analysis (JSA)
Preliminary Hazard Analysis (PHA)
What-if and What if -Check List
Hazard And Operability Analysis (HAZOP)
Failure Mode and Effect Analysis (FMEA)
Fault-Tree Analysis (FTA)
Management Oversight Risk Tree (MORT)
Human Reliability Analysis (HRA)
48. Time Estimate for Hazard Analyses
Analyses Prep Time Evaluation Documentation
Simple Comple
x
Simple Compl
ex
Simple Compl
ex
PHA 4-8 hr 1-3 d 1-3 d 4-7 d 1-2 d 4-7 d
What-if
Chklst
6-12 hr 1-3 d 6-12 hr 4-7 d 4-8 hr 1-3 wk
HAZOP 8-12 hr 2-4 d 1-3 d 1-3 wk 2-6 d 2-6 wk
FMEA 2-6 hr 1-3 d 1-3 d 1-3 wk 1-3 d 2-4 wk
FTA* 1-3 d 4-6 d 2-4 d 1-4 wk 3-5 d 3-5 wk
HRA* 4-8 hr 1-3 d 1-2 d 1-2 wk 3-5 d 1-3 wk
* Model construction requires additional 3-6 d for simple process
50. HAZOP EXAMPLE-Rasin Plant-Xylene Feed
Ite
m
No
Deviati
on
Causes Conseque
nces
Safe Guard Action
2.1 High
Flow
Rota Meter
Fails
Feed Valve
Fails-Open
?? Calibrated
quarterly
Inspected
quarterly
Provide excess
flow valve
Low
Flow
No Flow
Other
Than-
MT
Contaminati
n
Reverse
flow
52. Inherently Safer Process
Design
A design incapable of causing injury no matter what you do
Emphasis on selection of safer chemicals, reducing
inventory, vessels and machinery that can withstand
extreme conditions and not rely on interlocks, alarms and
procedures
Examples:
Using continuous process Vs batch process
Using fixed piping Vs hose connection
Replacing chlorine with ozone in water treatment
Use of dryshaft seals
53. Inherantly Safer Process
Design
Open structure for storage processing of hazardous materials-
Small quantity of flammable causes significant damage in
closed building-In an accidental discharge of butadine in an
enclosed process area of 133’x288’with flammable controls
provided, an explosion caused 46 fatality, 8 by flying debris,
80% of concrete slab blown off
Use of pallets of flammable solids in place of finaly devided
solids
Spring Loaded ballvale as drain valve in distillation column.
Operator has to hold the valve open.
Installation of remotely operated emergency isolation valves
54. Hazard Prevention and
Control-Principles (B2-3)
Substitute
Process Modification
Engineering Controls
Ventilation
Administrative Controls
Site Safety and Health Plan/Site Controls
Housekeeping
Safe Operating Procedures
Confined Space/Hot Work Entry Permit System
Lockout/tagout
Personal Protective Equipment
55. Substituted Chemicals
From Product To Working Function
Chlorinated solvents Aquious solution Tablet Coating
Formaldehyde/Glutara
ldehyde
Phenol, Peroxide Disinfectant
10% benzene in
isopropanol
10% toluene in
isopropanol.
Analysis of the intermediate
para-nitrophenol.
Carbon tetrachloride
& chloroform
Replaced by esters and
ketones
Many different analysis
A TLC running fluid-
chloroform 40,
methanol 25, formic
acid 7-has low
threshold limit values.
Changed to a TLC
running fluid, toluene
40, acetone 5, 100%
acetic acid 4.
Chemical analyses.
56. Flammable/Combustible Liquids-
Controls
Instrumentation used in Determining Explosive Limits
Keep in covered containers when not in use
Flammable concentrations to be kept below 10% of LEL
when an ignition source is present
Grounding and bonding for static electricity protection
Use of non sparking tools/ intrinsically safe electrical
apparatus and lighting
Flammable gas supply to include a non-return valve
Avoid using flexible hoses for transfer. If it has to be used
use one with male female coupling
Seal-less pumps or mechanical seals
57. FLAMMABLE AND COMBUSTIBLE
MATERIALS : STORAGE ROOMS
Allowable quantity per Table e.g., 5 gal/sq feet of floor
area when fire protection is not provided and room
fire resistance is 2 hrs
Intrinsically safe electrical wiring (Class I Div 2)
Liquid tight room
Ventilation to provide six air exchange rate per hour
Provide clear aisle of 3' wide
Stacking of containers one upon the other over 30 gal
prohibited
Dispensing by approved pumps or self closing faucet
58. Tank Storage(B3.19)
Not to overfill-Consider expansion of liquid when heated,
Gasoline expand about .06 F in volume for each 10 F
increase in T
Measure metal thickness, weep holes, ultrasonic indicators.
Minimum Thickness (API 650) t=0.0001456*D*(H-1)*S
Maximum thickness 1/2”Smaller than 50’ dia nominal
thickness 3/16”, >50<120 1/4”.
API Standard 2000 for venting of storage tanks
Wire Screen of 40 Mesh, parallel metal plates or tubes are
also used and preferred
dikes provided with drain pipe with valve closed outside
dikes Dikes > 6’ high not preferred,
loading rack to be located at least 25 feet away
Steel support to be protected by 2 hrs fire resistance
covering
NFPA 11 for Foam system
60. Tank Storage
Leave about 1M depth of liquid when
emptied to reuce fatigue of the
base/wall weld.
Design vent for ---M3/hr of vapour and
liquid to prevent overpresuring in
overflow situation
61. Unloading of Tank Cars/Trucks of
flammable liquids
Metallic gauging rod prohibited when ele power line is
within 20’ of tank opening
DO not locate under power-line, if feasible. Special rules
apply if loading/unloading has to be done under power-line
Setting of brakes, “STOP....”signs 25’ in front,
Bottom loading is preferred
Continuous present of the operator throughout unloading
No smoking, grounding/bonding connection
Truck loading rack be kept 25’ of tank, property (for Class I)
Grounding and bonding
Applying chocks on wheels
62. Static Electricity Controls
Bonding and grounding-Ground Resistance
of < 1Mohms adequate
Min size No 8 or 10 AWG wire ohms
Metal to metal contact essential (painted
surface)
Significance of relative humidity: 60-70% is
required.
Testing conductivity of wire and connections
Avoid using clothes and shoes made of
certain synthetic materials.
63. Static Electricity Controls
Avoid free fall of liq by bottom entry or extend fill pipe. Fill
pipe to terminate within 6” from the bottom of tank
Flow of liquid less than 1 m/s, not to exceed 7 m/s
Antistatic additives. e.g., Addition of 0.3 to 1 mg/L of Stadis
450 (DuPont)
Plastics are available with antistatic additives such as
carbon black
Grounding and Bonding During Charging of solids
Filters and other ristrictions, followed by long lenghth of
satraght pipe line
Pipe diameter to be increased after significant
accumulation of charge
REF: Control of Undesirable Static Electricity - BS 5958, 1991
64. Designs to Prevent Fires and
Explosions - Controlling Static
Electricity
Bonding and grounding (see diagrams on page 224-
228 of yellow book)
Dip pipes (or deflector tubes)
anti-siphon holes
Relaxation time
consider letting vessels “rest” after transferring low
conductivity solvents
Avoid open solids charging to vessels containing
solvents (e.g., use of “flapper valves”)
65. Inerting/Purging
In general O2 concentration to be kept below <8% to
prevent a dust explosion
Pressure Purging , Vacuum Purging, and Flow Through
Purging
Pressure Purging-Fast, uses more N2
Vacuum Purging-Slow Used for small vessel
Flow thru- when vessel is not designed for
pressure/vacuum
Condenced HC vapors in vertical N2 purging line from a
tank to reducing N2 valve
Inspect that N2 supply infact is ocuuring weekly basis by
testing O2 concentration in blanketed area.
Low pressure N2 alarm to warn about loss of N2 blanketing
66. Designs to Prevent Fires and
Explosions - Inerting Example
Equation for sweep-through purging:
Qvt = V ln [(C1-C0)/(C2-C0)]
where Qv = volumetric flow rate of nitrogen (e.g., ft3/min or L/min.)
t = total sweep time (e.g., min.)
V = volume of vessel (e.g., ft3,, L, m3)
C0 = oxygen conc. of nitrogen (usually assume 0%)
C1 = initial oxygen conc. in vessel (usually 20.9%)
C2 = final desired oxygen conc. in vessel (typically 5%)
67. Designs to Prevent Fires and
Explosions - Inerting Example
Example: Given a 1000 U.S. gallon vessel (V = 133.7 ft3 or 3,786
L), a nitrogen purge flow rate (Qv) of 10 ft3 per minute (or 283
L/min.), a desired oxygen concentration (C2) of 5%, an initial
oxygen concentration (C1) of 20.9%, and assuming that the
oxygen concentration in the nitrogen (C0) is essentially 0% --
how many minutes of purging time are theoretically required?
t = {V ln [(C1-C0)/(C2-C0)]} / Qv
t = {133.7 * ln (20.9 / 5.0)} / 10
t = 19.1 minutes
68. Dust Explosion - Prevention
and Controls
Inerting, Purging, to keep O2 Conc
below MOC
Suppression
Explosion Venting
Process Isolation
Pressure Vessel Design
Control of Ignition Sources
69. Fire Protection (B3.15)
Minimum number of exits
The average recommended travel distance distance not
to exceed 100’, in Storage area 200’
Exits not locked - Doors opening outwards-Free/unobstructed
way to exit - Width of exit 30”-Width of an access to exit 36”
Illuminated Exit signs in place - Emergency lighting (NFPA
101)
Exits discharging outside building
“Not An Exit” sign for Doorways not used for exit i.e., closet
Fire Alarm system
70. Fixed Foam System for Storage
Tanks(B3.12)
Foam Application Rate: For air foam system, at least 0.1
gpm/sq feet of liquid surface area of tank to be protected
Duration of discharge vary depending on Foam Discharge
outlet (type 1 or 2) and flesh point of tank content. For
xylene with FP<100F, duration of discharge is 30 to 55
minutes.
Minimum number of supplementary foam hose stream of 50
gpm required for up to 65’ dia tank is 1. Minimum operating
time is 10 to 30 minutes.
One discharge outlet required for tank upto 80’ diameter.To
be provided with effective and durable seal, frangible under
low pressure.
Piping within dike buried or supported for mechanical
damage.
Foam Control Valves at a minimum distance of 50’, outside
dikes, for tank <50’ dia, one diameter for tank >50’diameter.
71. Peroxide forming agents
Dating on receipt, testing every 3 Mo to 1
year
Store in Opaque containers and exclusion of
air preferably by N2 , except Class C agents
provided with inhibitors that need limited
access of air
Disposal upon peroxide formation, or within
one month of opening or within 1 year after
receipt whichever is earlier.
72. Peroxide Detection Tests
Add 1 to 3 mL of the liquid to be tested to an equal volume
of acetic acid, add a few drops of 5% aq. potassium iodide
soln., & shake. The appearance of a yellow to brown color
indicates the presence of peroxides
Addition of 1 mL of a freshly prepared 10% soln. of
potassium iodide to 10 mL of an organic liquid in a 25-mL
glass cylinder should produce a yellow color if peroxides
are present.
Add 0.5 mL of the liquid to be tested to a mixture of 1 mL of
10% aq. potassium iodide soln. & 0.5 mL of dilute
hydrochloric acid to which Few drops of Starch soln. is
added just prior to the test. If blue or dark-blue color
appears within a minute shows the presence of peroxides.
73. Designs to Prevent Incidents -
Pressure Relief Devices
Location of Relief Devices:
consider need for pressure relief on all vessels,
including reactors, storage tanks, towers, etc.
blocked-in sections of liquid filled piping need
thermal relief
PD pumps and compressors need relief on
discharge side
storage vessels need pressure and vacuum reliefs
vessel jackets may need relief
74. References
NFPA 654-Standard for the prevention of Dust Explosions in Plastic Industry
NFPA 63- Standard for the prevention of Dust Explosions in Industrial Plants
NFPA-Fire Protection Handbook, 5th Edition
NFPA-101-Life Safety Codes
NFPA-69 Standard For Explosion Prevention Systems
The Human Factors Society, Santa Monica California, USA, American National
Standard for Human Factors Engineering of Video Display Terminal Work
Stations
HMSO, UK, Health and Safety at Work Dust Explosions In Factories, #22.
Bodurtha Frank, Industrial Explosion Prevention and ProtectionMcGraw Hill,
New York
Royal Society for Prevention of Accident, UK, (ROSPA) Engineering Codes and
Regulations for Lifting Appliances
ROSPA, UK Construction Regulation Handbook
AiCHE, Center for Chemical Process Safety, Hazard Evaluation Procedures,
New York, USA
75. References (Contnd)
Wood, Fawcett, Safety and Accident Prevention in
Chemical Operations, John Wiley and Sons, New
York
Hammer W., Occupational Safety Management and
Engineering, Prentice Hall, Englewood Cliffs, NJ,
USA.
Construction Safety Council, Fall Protection Field
Guide, Hillside, IL, USA.
ACGIH, Industrial ventilation, Cincinnati, OH, USA.
Fthenakis, Prevention and Control of Accidental
Releases of Hazardous Gases, Van Nostrand
Reinhold, New Yor, 10003