Environment Health & Safety Management Issues Environment Health & Safety Management Issues & Challenges: Safety Management& Challenges: Safety Management

Prof. I.D. MALLDePArtMent of CheMICAL engg.

InDIAn InstItute of teChnoLogy, roorkeeroorkee- 247667

Process safety, occupational health and environmental issues are ever increasing in importance in response to heightening public concerns, and the resultant t ightening of regulations. SHE management is a mult idisciplinary function and every person needs to keep vigi l against potential cause of f ire & accidents and draw lessons from Past Incidents. Safety Involves•Protection of personnel•Protection of plant &property•Production uninterrupted•Legal requirements•Welfare of community•Good reputation

Surroundings* in which an organization operates, including air, water, land, natural resources, flora, fauna, humans and their interrelation.

*Surroundings in this context extend from within an organization to the global system

Negatively : Absence of illness

Functionally : Ability to cope with everyday activities

Positively : Fitness and well-being.

Survival : Health also implies good prospects for

continued survival.

Biological : In any organism, health is a form of homeostasis. This is a state of balance, with inputs and outputs of energy and matter in equilibrium (allowing for growth).

Occupational Health

Occupational health includes

• Industrial hygiene,

• Industrial diseases,

• Industrial work physiology,

• Industrial accidents,

• Toxicology in relation to industrial hazards,

• Occupational rehabilitation,

• Occupational psychology etc.

Safety can be defined as prevention of accidents using appropriate technologies to identify hazards and to eliminate them before an accident occurs

Hazard can be referred to as a condition or activity that has the potential to cause adverse consequences on life, property and the environment.

Risk is the probability of the occurrence of an adverse consequence of a specified nature and magnitude resulting from a potential hazard.

ISO 14001 European Eco-Management and Audit

Scheme BS 7750 ( UK ) EPA ( USA)

• OHSAS 18001

• ILO Guidelines

Public Perception Of Unsafe And Polluting Industry

Accidents like Bhopal, Flixborough, Seveso Low Frequency But High Impact

The health and safety problem in chemical industry can

be reduced by maintaining safe working conditions,

preparation and implementation of safe operating

procedures, study of environment of safety procedure,

training of employees and periodic medical supervision

and use of personal protective equipment

• Defined & authorized by top management• Appropriate to the nature, scale, Envoi. Impacts

and OH&S Risks of the activities, products, services of the organization.

• Commitment to comply with legal requirements. • Commitment for continual improvement in HSE

performance .• Commitment for prevention of pollution, ill

health and injury.• Available to Interested parties .

Organizational Does It

RightIndividual

Operational Discipline

Every Time

Everyone

SHE & Operation Excellence; Individual Safety

Fig: DuPont OD Program

Sources: Chemical News

Individual OD Characteristics

Knowledge: I understand how to do a task correctly & safely

Commitment: I Commit to do tasks the right way every time

Awareness: I anticipate potential problem & recognize unusual situation

Twentieth century has brought with it the explosion in industrial activities. Industrialization has made human life style much easier by making many consumer products. In addition industrialization has attracted hazards have increased risks and turn accidents. Without adequate safety one’s survival is threatened. Safety has made its shape in industries from scratch to priorities in the changing world. The following are the major requirements for development of safety:

•Legal

•Economical

•Social

To encourage safety in India, 4th March is celebrated as the National Safety Day every year.

•To respect humanity

•To preserve the environment

•To make the workplace a place of worship

•To comply with statutory authorities

• Adequate protection against the hazards to which the

works will be exposed

• Maximum comfort and minimum weight compatible with

protective efficiency.

• No restriction of essential movement.

• Durability and susceptibility of maintenance on the

premise’s where it is used.

• Construction in accordance with the accepted standards

for performance and material.

Personal protective Equipment may be divided into two broad groups:•Respiratory protective equipment •Non respiratory protective equipment

Section of equipment to protect different part of the body will

depend upon the hazardous conditions like injurious

mechanical contact etc. The former includes those which are

used for protection of respiratory system or related hazards.

These provide protection from suffocation due to presence of

harmful vapors/absence of atmospheric oxygen . The non-

respiratory PPEs safe guards the other body parts.

Safety tag system is also in existence. The need for this system is that any equipment in any kind of job or activity other than its normal use needs to be identified ,hence tagged. This help minimizing misreading/misconception. This tags used for isolation cordoning , restricting entry, etc.

Tags available are, “ DO NOT OPERATE “ , “DANGER” ,” NO

ENTRY” , “ROAD BLOCKED” , “BLIND” “ELECTRICALLY

ISOLATED” .In order to maintain an international level of safe work environment and to maintain a zero accident level SAFETY needs the cooperation of one and all as SAFETY IS EVERYBODY’S BUSINESS.

Factor Influencing Process HazardFactor Influencing Process Hazard

Many complex processes are adopted in manufacturing processes, which are not intrinsically safe. Some of the factors influencing process hazard are

• Reaction types (hydrolysis, oxidation, reduction, sulphonation, nitration, polymerization, isomerisation, alkylation)

• Reaction parameters(stability, reactivity, heat of reaction, pressure, temperature)

• Physical and chemical properties of substances, their toxicity, corrosiveness

• Quantities of substances used and stored• Storage characteristics( pressure, temperature )

Accidents: Accidents can be classified into

five groups:

• BLEVE (Boiling Liquid Expanding Vapour Explosion)

• Release of flammable gases, flash fire, &

UVCE (Unconfined Vapour Cloud Explosion)

• Toxic vapour release

• Pool fires

• Fragmentation

Indirect Causes(Symptoms)Unsafe Act &

Unsafe Condition

Indirect Causes(Symptoms)Unsafe Act &

Unsafe Condition

Basic CausesManagement Safety Policy & Decisions,Personal Factors,

Environmental Factors

Basic CausesManagement Safety Policy & Decisions,Personal Factors,

Environmental Factors

Direct causesUnplanned Release of

Energy and/orHazardous

Material

Direct causesUnplanned Release of

Energy and/orHazardous

Material

AccidentPersonal Injury, Property Damage

AccidentPersonal Injury, Property Damage

Causes of accidentsCauses of accidents

Pathway : Inhalation of gases, vapours and particulatesFood : Ingestion of meat, fish, dairy, products, grains and produceSurface water : Ingestion, inhalation, dermal contact,Ground water : Ingestion, dermal contact

Adverse exposure of the chemicals can be acute

exposure (acute poisoning), chronic exposure (chronic

poisoning), site of toxic effects of chemicals, local,

Systemic, cumulative, synergistic or potentiating effect.

Some of the commonly occupational exposure limits are

Threshold limit values (TLV), Permissible Exposure limit,

Maximum allowable concentrations.

Commonly three types of TLVs are prescribed: TLV-

TWA(time weighted average), STEL( short term exposure

limit), TLV-C(ceiling limit)

[ ISC,2008].

Safety management in an organization can be reactive or proactive. Safety management will be reactive, if safety measures are by implemented after an accident has occurred. However it will be proactive if safety management implies realization of actions ahead of accidents and incidents.

Proactive Actions to Prevent Incidents are•Process Safety through Hazard Identification • Develop safe operating procedure to minimize operational Risk. • Ensure Mechanical Integrity of Process Equipment & Facilities including Safety Instrumentations • Minimize Human error through training of Workforce • Develop Core competency with continuous focus on Safety • HSE Aspects to be included in the curriculum of Engineering Institute to minimize the Knowledge Gap of fresh engineers.

•Safety Policy :Specifying how safety will be achieved •Safety Procedures : What management wants people to do to execute the policy•Safety Practices : What really happens on the job

•Goals and objective of the safety programme•Risk analysis and management•Industrial process design and operation •Mechanical integrity of process equipment•Safety regulations, codes and standards•Project safety and health review•Personnel motivation and training•Process and plant modification and change•Good work practices•Incident investigation and safety audits

IS18001 provides the industry a systematic, structured

and documented frame work to address OH&S issues

effectively and in an auditable manner. The element of

OH&S management systems are as follows:

•OH&S Policy

•Planning

•Implementation and operation

•Measurement and Evaluation and

•Management review

Benefits of OH &S Management system

Reducing the number of personnel injuries through preventive and control of work place

•Reducing the risk of major accident

•Reducing the material loss caused by accident and in

production interruption

•Ensuring the appropriate legislation is addressed

•Meeting increasing importance of OH &S for public image

•Serving the possibility for an integrated management system

including quality, environment and OH &S

Hazards Activit ies Consequences

Chemical Hazard

Chemical handling/storage

Fire, acute/chronic toxicity, ecotoxic

Electr ical Hazard

Plant operation

Fire, shock, burns

Mechanical Hazard

Plant operation

Injury

Physical Hazard

DG operation

Accident

Main stages of r isk assessment process

Risk Ranking Matrix

Helps in ranking the severity of the identif ied hazards/risks.

Moderate Risk High Probabil i ty with Mild Consequences or Low probabil i ty wit Severe Consequences.

Low risk Low Probabil i ty with Mild Consequences.

High Risk High Probabil i ty and Severe Consequences.

Fault Tree Analysis

Evaluation of probabil i ty of occurrence

Consequence Analysis

Evaluation of Consequences (generally by use of Risk Analysis Software under dif ferent simulated situations).

Probabil ity

→

Severity↓

Likely Unlikely Highly unlikely

Serious Intolerable Signif ican

t

Moderate

Moderate Signif icant Moderate Tolerable

Minor Moderate Tolerable Insignif icant

DISASTER

Notify state PCB/local authorities / hospitals the nature and extent of disasterUndertake measures for control and containment of disaster situationAssist state PCB in monitoring relevant toxic/hazardous chemicalsFinance offsite medical aid to affected population

Monitor relevant toxic / hazardous chemicalsPredict likely hazard area and target population and notify local authorities about the same

Notify public about precautions to be taken to protect themselves and their propertyTake measures for the protection of the public / evacuationAssist in control / containment of disaster situation

Provide medical aid to affected population

Notify state PCB/local authorities (police fire, civil defence, collector, guard) /hospital about potential hazards and precautions to be taken by the public to protect themselves and their properties.Formulate plan for control and containment of disaster situationDevelop monitoring capacity for relevant toxic /hazardous chemicals.

INDUSTRY

Develop monitoring capacity for relevant toxic/hazardous chemicalsDevelop capability to predict likely hazard area and ta…rget population

STATE PCB

Local Authorities

Safety does not happen by itself or by external enforcement. I t has to be inbred, developed, nurtured and encouraged by management and every member of the organization Five Important key organization cultures that need to be taken into account are

•Maintain sense of vulnerabil i ty•Establish and imperative for safety•Perform valid/t imely hazard/risk assessments•Ensure open and frank communications•Learn and advance the culture

Eight global dimensions of safety culture: safety commitment and support, safety, att itude and behavior, safety communication , and involvement, safety training and competence, safety supervision, and audit, safety management organization, accident investigation, and emergency planning and reward benefit .

Safety commitment and support,

Safety, att itude and behavior,

Safety communication , and involvement,

Safety training and competence,

Safety supervision, and audit,

Safety management organization,

Accident investigation,

Emergency planning and

Reward benefit.

1. The Factories Act, 1948 and the states Rules notified thereunder .

2. The Dock Workers (Safety, Health & Welfare) Act, 1986 and the Regulations framed thereunder.

3. The Mines Act, 1952 and the Rules framed thereunder.

4. The Explosives Act, 1884 and the Rules framed thereunder.

5. The Petroleum Act, 1934 and the Rules framed thereunder.

6. The Indian Electricity Act, 1910 and the Indian Electricity Rules, 1956.

The Indian Boilers Act, 1923 and the Indian Boiler Regulations .

The Dangerous Machines (Regulation) Act, 1983. The Manufacture, Storage & Import of Hazardous

Chemical Rules1989 and the Rules framed there under

Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 and Rules framed there under

Beedi and Cigar Workers’ (Conditions of Employment) Act, 1966

Employers’ Liability Act, 1938 Public Liability Insurance Act, 1991 and Rules framed

there under

“Recognition, evaluation & control of those environmental factors or stresses arising in or from the workplace , which may cause sickness, impaired health and well being or significant discomfort among workers”

Recognition

Evaluation

Control

Chemical Hazards Chemicals are released in the form of dust , fumes,

gases, vapors etc in the work environment Physical Hazards

Noise , Heat , Illumination Vibrations etc

Management of Health, Safety and Environmental issues and requirements throughout project execution through the issue and maintenance of a project specific Health Safety and Environmental (HSE) plan. The HSE Plan to address all client requirements, national and local legislation.

HSE plan shall be the principal means by which all HSE related issues shall be managed, including risk management.

Components of HSE plan

Scope and ResponsibilitiesHealth and Design SafetyEnvironmentConstruction

Exposure to Chemical & Physical

Agents

Occupational Diseases

Degree of Hazards Depends upon:

Nature of Chemical Concentration & Length of Exposure Method of Handling Individual Susceptibility

Details of Processes / Operations Carried Out

Chemicals or Substances Used / Produced as a Raw Materials, Intermediates or By Product etc

Toxicity of Raw Materials, and

Products etc

Sources of Air Contaminants

New Stresses: Change on

Processesetc.

Job Activities Review

Existing Control Measures

NEGATIVE ASPECTSINJURY TO PERSONSLOSS to organizationDAMAGE TO EQUIPMENT &

PROPERTYLITIGATION COSTSLOST PRODUCTIVITY

Safety = freedom from accidents Protection of personnel Protection of plant &property Production uninterrupted Legal requirements Welfare of community Good reputation

With increasing focus on worker safety and loss prevention by both government and industries themselves safety is no longer confined to just hard hats, goggles and gloves.

For complying with the regulations and long term benefits an effective and optimal safety system is a must and with results so far the plant in question seems to have got the right balance.

Continue…..Continue….. Health, Safety and environmental aspects are

incorporated into all aspects of pre-FEED, FEED, engineering and construction and are given the highest priority.

All employees contribute towards Health, Safety and Environmental (HSE) Policy implementation to achieve safe working environment, safety designed and constructed plants conducting activities to safeguard the environment.

Target objectives Protection from risk of injury/danger to health Protection from property damage or loss Protection of the environment

MUMBAI HIGH INCIDENT

Fire in an Oil Depot in UK