chapter 6 process 19319

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Chapter #6 Process SafetySENG 321 & 670Fall 2013

Dr. .!. "et$er

"ary %ay 'Coor Process Safety CeterChe()cal E*)eer)* Depart(et+ ,e-as !&" )/ers)ty

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Four still hospitalized after East Rutherford ink factoryexplosionWEDNESDAY OCTOBER 10, 2012, 5:06 PM

BY MICHAEL COPLEY

STAFF WRITER

THE RECORD

PAGES:12>DSP! N NE P!GE| PN,| E"!

EAST RUTHERFORD Seven plant workers were injured when a caron co!poundused to !ake lack newspaper ink i"nited a little a#ter $%$& p'!'( causin" an e)plosion

and a #ire in ductwork at the plant' *orou"h Fire Chie# +evin Felten initiall, said the

injured workers sustained non-li#e-threatenin" #irst- or second-de"ree urns'

On .ednesda,( /,nn Ca!pell( a spokeswo!an #or Sun Che!ical( which owns US 0nk(

said three e!plo,ees are still hospitali1ed in the urn unit at St' *arnaas 2edical

Center in /ivin"ston( and that one other( ein" treated at HackensackUniversit,

2edical Center( are in 3#air condition'4 Two injured workers were released #ro!

Hackensack , the end o# the da, Tuesda, and one was released .ednesda,

a#ternoon'

The explosion and fire, which the company in a

statement said likely occurred in the plants pre-mix

room, were completely contained inside the plant

building itself There was no danger to anyone offsite,

nor any external contamination or en!ironmental

impact as a result
http://www.northjersey.com/authors/?name=MICHAEL%20COPLEYhttp://www.northjersey.com/eastrutherford/?c=y&page=2http://www.northjersey.com/eastrutherford/?page=allhttp://e/return(PTMouseOver())%3Bhttp://e/return(PTMouseOver())%3Bhttp://e/return(ETMouseOver())%3Bhttp://www.northjersey.com/eastrutherfordhttp://www.northjersey.com/hackensackhttp://www.northjersey.com/hackensackhttp://www.northjersey.com/eastrutherfordhttp://e/return(ETMouseOver())%3Bhttp://e/return(PTMouseOver())%3Bhttp://www.northjersey.com/eastrutherford/?page=allhttp://www.northjersey.com/eastrutherford/?c=y&page=2http://www.northjersey.com/authors/?name=MICHAEL%20COPLEY


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45est)os !resse

5 hat s)*)8cat o(est)c & )terat)oal)c)ets le to the creat)o of Process Safety

re*5lat)os95 hat are S:!'s PS" & EP!'s "P re;5)re(ets9

5 :o< oes the )tet of S:! PS" )=er fro(EP!'s "P9

5 hat steps ()*ht )terat)oal cos. ta>e toes5re cos)stet process safety )(ple(etat)o


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?hopal & ther c)ets e toProcess Safety e*5lat)os

5 h)le the 1@AB ?hopal )saster ha a (aor )(pact othe 8el of process safety


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Process Safety e*5lat)os

5 S5ch (aor


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Process Safety

L )s ot oly for che()cal plats apetrole5( re8er)es.

t appl)es to ay plat


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S:! PCESS S!FE, "!N!GE"EN, S,!ND!DHPS"I

5 E(ployee Part)c)pat)o

5 Process :a$ar !alys)s

5 ,ra))*

5 Prestart5p Safety e/)e Per()t

5 c)et /est)*at)oM

5 Co(pl)ace !5)t

M )sc5sse ) f5t5re lect5re

5 Process Safetyfor(at)o

5 perat)* Proce5res

5 Cotractors5 "echa)cal te*r)ty

5 "aa*e(et of Cha*e

5 E(er*ecy Pla)*M

5 ,rae Secrets '

5 (rocess )afety *gmt of +ighly +aardous hemicals .()*/, 1002 - general reuirements for managing haardous substances with

focus to protect on-site people

5 1# elements to manage chemicals, pre!ent ma3or incidents, and protect

the safety of the workplace


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1 Process Safety for(at)o5 ,he h)*hly ha$aro5s che()cals to e 5se or pro5ce y the

process. efereces+ ) a)t)o to "SDSs r/)* Sa-+ Dangerous Properties of Industrial Materials; oert E.

e*a+ Sigma-Aldrich Library of Chemical Safety Data; Gesser G.:a


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Case St5y 6.1 :a$aro5s Che()calfor(at)o for Process Safety !alys)s

5 Na(e ofChe()cal

5 ,o-)c)ty )fo.

5 PE

5 Phys)cal ata L

5 eact)/)ty ata

L a so o L

Phosphor5s chlor)e HPCl3I+ phosphor5s tr)chlor)e

Po)so y )halat)o. "oerately to-)c y )*est)o. !corros)/e )rr)tat to s>)+ eyes Hat 2 pp(I+ a(5co5s (e(raes

ethal ose Hfor 0 of pop5lat)oI ats HoralI 0(*>*

ethal cocetrat)os for )halat)o Hfor 0 ofpop5lat)oI ats 10B pp( for B hrs

G5)ea p)*s 0 pp( for B hrs

S:! PE Ahr t)(e


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2 Process :a$ars!alys)s

5 hat ca *o


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3 perat)* Proce5res

5 (portat that operators e tra)e ) reath of perat)*

Proce5res6 r)tte perat)* Proce5res ee to e spec)8c to the

perso or persos Hpos)t)osI for each of the fac)l)tyTsoperat)* areas

5 ,he capa)l)ty to reco*)$e


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B ,ra))* & Cert)8cat)o

Fo5r )*re)ets for a e=ect)/e tra))* pla

1. ))t)al tra))* for e< operators or e< processes

2. refresher tra))* at prescr)e )ter/als+ a at

least e/ery three years 3. /er)8cat)o or test)* to pro/e that e(ployees

5ersta the process a safe proce5resO a'ltra))* as eee

B. oc5(etat)o to co8r( that the tra))* atest)* ha/e ee carr)e o5t

1"


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Cotract Persoel5 Co(pa)es fre;5etly 5se o5ts)e cotractors .

5 ,he S:! process safety staar re;5)res that pr)(arye(ployers assess the safety recor of prospect)/ecotractor 8r(s efore cotract)* 5s)*.

5 espos))l)t)es

pr)(ary e(ployer 1I co((5)cate process ha$ars )for(at)o to

cotractors

2I perfor( per)o)c e/al5at)os

3I (a)ta) a )5ry a )lless lo* of cotract e(ployees

cotract e(ployer

1I pro/)e safe a healthf5l place+ )cl5)* tra))*

2I ass5re e(ployees follo< pr)(e e(ployer's safety r5les

3I (a)ta) )c)et lo* of e(ployees

1#


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cot'5"ay facets to th)s area

6es5r)* cos)stecy of e(ployer & cotractor safety (etr)cs

6


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6 "echa)cal te*r)ty

5 Estal)sh a )(ple(et


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7 "aa*e(et of Cha*e

Estal)sh a (ple(et r)tte "aa*e(et ofCha*e Proce5res L for cha*es ) process che()stry+e;5)p(et or operat)* proce5res. "C aresses

5 ,ech)cal ?as)s He-cept for )>) replace(etI5 (pact o Safety a :ealth

5 "o)8cat)os to perat)* Proce5res

5 ,ra))* a Prestart5p e/)e "aa*e(et Pro*ra( for Che()cal !cc)etelease Pre/et)o H"PI+ 1@@6

6 Foc5s to protect o=s)te people & e/)ro(et

6 e5ce the r)s> of releases of to-)c+ a((ale+a react)/e s5staces

6 )st of 140 re*5late che()cals


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(ple(etat)o of "P

1. :a$ar assess(et F)/e year acc)et h)story

orst case release scear)o )/ol/)* a((ale orto-)c o s)te (ater)alsO E.G.+ 10 ()5te release of

lar*est ;5at)ty of re*5late che()cal !lterat)/e release scear)os ... (ore l)>ely to occ5r tha


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"P & PS" Co(par)so

5 RMP 11 ele(ets

5 e*5lates o=s)tepeople &

e/)ro(et5 )s> !ssess(et

release

cose;5eces5 fo to co((5)ty

5 EP ot)8cat)o ofco((5)ty+

respoers

5 PSM 1Bco(prehes)/e

ele(ets5 e*5lates place

5 E(ployee

part)c)pat)o5 Cotractors

aresse

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Sa#et, 9 Environ!ental 2"!t S,ste!

5 SE2S re:uired #or all US O##shore Continental Shel#;OCS< operations , =ov( >?$$

5 Si!ilar ele!ents as OSHA 7S26 Focuses on process sa#et, with so!e occupational

sa#et,( and additional re:uire!ents added toA!erican 7etroleu! 0nstitute ;A70< R7 @&

6 Operators held responsile #or overall sa#et, o#

#acilit,( operation and contractors6 Applies to all o##shore drillin" 9 operatin" phases

5 SE2S 00B addresses workplace authorit, ;operator vs'

contractor


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5str)al Co(pl)ace


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:6a 5e ,h5rs+ ct 10

5 6.2

5 6.B

5 6.6

5 6.A

5 6.@

5 6.1@

5 6.21

chapter 6 process 19319

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