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Process

Know the potential hazards and appropriate safety precautions. Ask and be able to answer the following questions:What are the hazards?What are the worst things that could happen?What do I need to be prepared?What work practices, facilities or personal protective equipment (PPE) are needed to min

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Process

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    1. Process / Plant Safety Refresher M. Saban 4W4Poly2011 1

    2. Know the potential hazards and appropriate safety precautions. Ask and be able to answer the following questions: What are the hazards? What are the worst things that could happen? What do I need to be prepared? What work practices, facilities or personal protective equipment (PPE) are needed to minimize the risk? Know the location and how to use emergency equipment including safety showers, and eyewash stations. Familiarize yourself with the emergency response procedures, facility alarms and building evacuation routes. Know the types of PPE available and how to use them for each procedure Lab Safety (XRCC Refresher) 2

    3. In the labs Lab coat and safety glasses Gloves, hearing protection and dust masks/respirators if required In the Pilot Plant Coveralls, safety glasses, hard hats, static dissipating shoes Gloves, hearing protection and dust masks/respirators if required In the Manufacturing Plant Plant dependant; eg. in a petrochemical refinery fire retardant coveralls are a must, etc. Lab and Pilot Plant PPE (Personal Protective Equipment) 3

    4. The Flip Side of PPE: The ‘Hurt Locker’ Approach to Safety 4

    5. Thermal Process Safety Understand reaction hazards (reaction calorimetry, criticality assessment, DSC) Consider semi-batch vs. batch reactions Consider operation at reflux (but be aware of vapor buildup and explosion hazard) Useful Link: http://www.harsnet.net/harsbook/harsbook_02.htm Electrical Safety Eg. XRCC Pilot Plant is designated to handle Class I, Div 2, Groups C and D materials Explosion proof equipment Intrinsically safe equipment Link: http://en.wikipedia.org/wiki/Electrical_equipment_in_hazardous_areas Operational Safety (XRCC PP Example) Run only scheduled experiments Equipment SOPs in place/Process SOPs in place Haz-Op review completed ahead of each new experiment Books: Kletz, Trevor (2006). Hazop and Hazan (4th Edition). Taylor & Francis. Link: http://en.wikipedia.org/wiki/Hazard_and_operability_study Thermal Process, Electrical and Operational Safety 5

    6. Hazardous Location Classification for Electrical Equipment 6

    7. Deepwater Horizon Oil Spill, Gulf of Mexico, Apr 20-July 15, 2010 (Death Toll=11) Sunrise Propane, Toronto, ON, Aug 10, 2008 (DT=2) Imperial Sugar Refinery, Port Wenworth, Georgia, Feb 7, 2008 (DT=14) CAI Inc., Danvers, Massachusets, Nov 22, 2006 (DT=0) BP Refinery, Texas City, Texas, March 23, 2005 (DT=15) Azote Fertilizant (AZF), Toulouse, France, Sept 21, 2001 (DT=31) ----- ----- Union Carbide, Bhopal, India, December 3, 1984 (DT=3,800) http://www.bhopal.com/ Recent Examples of Industrial Accidents 7

    8. “A Matter of Time” article, Canadian Chemical News, Jan 2010, p.13 F. Stoesel, Thermal Safety of Chemical Processes, Willey-VCH, 2009. Guidelines for Hazard Evaluation Procedures, Center for Chemical Process Safety (CCPS), New York, 2008 L. G. Britton, Avoiding Static Ignition Hazards in Chemical Operations, AIChE, CCPS, 1999 G. Norval, Engaging Academia in Teaching of Process Safety via the Summer Institute, paper#1384, WCCHE#8, Montreal 2009. (G. Norval is U of T Prof. of ChemE) Consultants: Chilworth Technology Inc. Fauske and Associates, LLC Mettler Toledo RC1 Further Reading 8

    9. Plant/process safety is a job #1 for plant designers There are three important faucets of plant/process safety: 1. thermal process safety, 2. electrical safety and 3. operational safety It is up to you, as a plant designer, to pick the safest possible process chemistry, plant location, equipment, manufacturing process, operating procedures, and PPE for process scale-up It is a duty of every P. Eng. to keep public safety as the top priority (eg. http://en.wikipedia.org/wiki/Engineering_ethics) Although detailed safety assessment of our Specialty Polyester Resin plant is outside the scope of this course, safety process assessment should be incorporated in the final report… Take Home Messages 9

    10. Safety considerations should be incorporated in the final report Raws classification MSDS review HAZOP test Eg. of raws classification 10 How?

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