cbb2093 (2) standards regulations
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CHAPTER 2CHAPTER 2
Process SafetyProcess Safety--RelatedRelatedStandards & RegulationsStandards & Regulations
Instructional Learning ObjectivesInstructional Learning Objectives
After completing this chapter, students should be able toAfter completing this chapter, students should be able todo the followin :do the followin :
Brief understanding of safety regulations:Brief understanding of safety regulations:
•• OSHA (Occupational Safety and Health Act) Process SafetyOSHA (Occupational Safety and Health Act) Process SafetyManagement StandardManagement Standard
•• Factory and Machinery’s ActFactory and Machinery’s Act
•• Other International Safety Legislations: CIMAH, COMAH,Other International Safety Legislations: CIMAH, COMAH,COSHHCOSHH
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Relate the standards and regulations’ requirementsRelate the standards and regulations’ requirementswith the application of process safety fundamental towith the application of process safety fundamental toprevent lossesprevent losses
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PSM BackgroundPSM Background -- FlixboroughFlixborough 7474
Caprolactam Plant Explosion
Poorly engineered temporary
plant modifications
Control building collapsed,killing 28 operators
Outcomes
–Led to Advisory Committeeon Ma or Hazards
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–HSE champions Safety Report
concept –Led ultimately to CEC Seveso
Directive / Safety ReportConcept
PSM Background - Pasadena 1989
Plastics Manufacture PlantFire following vapour cloudexp os on
Poor Maintenance procedures,Contractor control andManagement of change
23 Fatalities132 InjuredUS$1,400 Million Damage
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Outcomes
–US OSHA PSM regulations
–CCPS established
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Impact of Standards and RegulationsImpact of Standards and Regulations
Laws and regulations are major tools for protecting peopleLaws and regulations are major tools for protecting peopleand the environmentand the environment
Government is responsible to create and enforceGovernment is responsible to create and enforceregulationsregulations
Major government agencies involved in creating andMajor government agencies involved in creating andenforcing safetyenforcing safety--related standards and regulations:related standards and regulations:•• Department of Safety and Health (DOSH)Department of Safety and Health (DOSH)
•• Department of Environment (DOE)Department of Environment (DOE)
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•• a ona ns ue o ccupa ona ae y an eaa ona ns u e o ccupa ona a e y an ea
Occupational Safety and Health Acts of 1970 (OSHA)Occupational Safety and Health Acts of 1970 (OSHA)
OSHA is used for Process Safety Management of HighlyOSHA is used for Process Safety Management of HighlyHazardous ChemicalsHazardous Chemicals
ObjectiveObjective: prevent unwanted releases of hazardous chemicals: prevent unwanted releases of hazardous chemicalsespecially into locations that could expose employees and others toespecially into locations that could expose employees and others toserious hazardsserious hazards
Makes employers responsible for providing safe and healthy workingMakes employers responsible for providing safe and healthy workingconditions for employeesconditions for employees
Highlights of OSHA’s enforcement rights:Highlights of OSHA’s enforcement rights:
•• Employers must admit OSHA compliance officers into their plant sites forEmployers must admit OSHA compliance officers into their plant sites for
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..
required to show probable causerequired to show probable cause•• OSHA’s right of inspection includes safety and health recordsOSHA’s right of inspection includes safety and health records
•• Criminal penalties can be invokedCriminal penalties can be invoked
•• OSHA officers finding conditions of imminent danger may request plantOSHA officers finding conditions of imminent danger may request plantshutdownsshutdowns
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Occupational Safety and Health Acts of 1970 (OSHA)Occupational Safety and Health Acts of 1970 (OSHA)
OSHA incidence rate is based on cases per 100 workers years.
A worker year is assumed to contain 2000 hours
(50 work weeks x 40 hours/week)
The OSHA incidence rate is based on 200,000 hours exposure
to a hazard
OSHA incidence rate Number of injuries and
(based on injuries = illnesses x 200000
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Total hours w orked by all
employees during period
covered.
Occupational Safety and Health Acts of 1970 (OSHA)Occupational Safety and Health Acts of 1970 (OSHA)
OSHA incidence rate Number of Los t
(based on lost = workdays x 200,000
workdays)
Total hours worked by all
employees during period
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covered.
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Factories and Machinery Act (FMA), 1967Factories and Machinery Act (FMA), 1967
Provides equal protection for all workers working inProvides equal protection for all workers working infactories in terms of health and safety regardless of sexfactories in terms of health and safety regardless of sex
Examples of FMA’s enforcement rights:Examples of FMA’s enforcement rights:•• specify duty of occupier to provide rest rooms for womenspecify duty of occupier to provide rest rooms for women•• only a male person of at least 20 years of age may carry outonly a male person of at least 20 years of age may carry out
examination, lubrication or adjustment of unfenced machineryexamination, lubrication or adjustment of unfenced machinerywhile it is in motionwhile it is in motion
•• pregnant or breastfeeding workers must be temporarily removedpregnant or breastfeeding workers must be temporarily removedfrom leadfrom lead--processing areasprocessing areas
•• details for the reinstatement of the worker once she is no longerdetails for the reinstatement of the worker once she is no longer
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pregnan or reas ee ngpregnan or reas ee ng
Other International Safety Legislations:Other International Safety Legislations:
CIMAH, COMAH, COSHHCIMAH, COMAH, COSHH
Control of Industrial Major Accident Hazards (CIMAH)Re ulations 1984 UK has been re laced b Control of Major Accident Hazards Regulations 1999 (COMAH)
Control of Substances Hazardous to Health (COSSH)
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Control of Industrial Major Accident HazardsControl of Industrial Major Accident Hazards
(CIMAH) Regulations, 1984(CIMAH) Regulations, 1984
CIMAH was prompted by a number of serious accidents• Flixborou h, UK (1974) – c clohexane release
• Beek, Holland (1975) – petroleum refinery fire
• Seveso, Italy (1976) – toxic release
Aimed to control major accidents by:
• identification (of hazardous installations)
• prevention (of hazards)
• mitigation (of effects of hazards)
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3 elements of controlling major industrial accidents:
• identification (e.g., through NIHHS Regulations in UK)• control of location of hazardous installations
• assessment of hazards
Control of Major Accident Hazards Regulations1999 (COMAH)
Aim: to improve effectiveness of CIMAH
• CIMAH emphasized technical safety but management error isresponsible for 90% of major accidents
• COMAH emphasizes management errors
Changes implemented in COMAH:
• Major Accident Prevention Plan (MAPP) introduced inCOMAH—must include:
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aims of processing activities
principles of hazard control
description safety management systems (SMS)
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Control of Major Accident Hazards Regulations1999 (COMAH)
Changes implemented in COMAH (continued):
•
Must fully address potential hazards
Must be submitted to “competent authority (i.e., HSE in UK)
Management and organizational issues must be considered
• Site and installation: provisions apply to whole site as well asindividual installations (plants)
• Domino effects: effects of an incident on surrounding plants must
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• Emergency plans must be included
Control of Substances Hazardous to Health(COSHH) Regulations, 2002
Main piece of legislation covering control of the risks toem lo ees and other eo le arisin fromex osure to harmful substances generated out of or in connection withany work activity under the employer's control
Main objective: to reduce occupational ill health bysettingout a simple framework for controlling hazardoussubstances in the workplace
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Control of Substances Hazardous to Health(COSHH) Regulations, 2002
Many of the chemicals found in the process industries are
Examples of harmful effects:
• skin contact→ dermatitis
• allergic reactions→ asthma
• toxic fumes→ losing consciousness
• chemical exposure→ cancer
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substances
COSHH provides hierarchy of measures to controlexposure
COSHHCOSHH (continued
)Hierarchy of Measures to Control Exposure
1. Assess risks to health
.
3. Where prevention is not reasonably practicable, decidewhat steps will achieve adequate control of exposure
4. Ensure control measures are used and maintainedproperly
5. Monitor exposure of employees if necessary
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6. Carry out health surveillance where assessment hasshown this to be necessary
7. Ensure employees are properly informed, trained, andsupervised
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