Chapter 1_Introduction to industrialsafety.ppt

introduction to safety

1. 1.Introduction
2.Safety Programs
3.Engineering Ethics
4.Accident and Loss Statistics
5.Acceptable Risk
6.Public Perceptions
7.The Nature of the Accident Process
8.Inherent Safety
9.Four Significant Disasters
Flixborough, England
Bhopal, India
Seveso, Italy
Pasadena, Texas
10.Problems
11.Suggested Reading
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2. Economy Technology Industry
“More complex processes require more complex safety
technology.
"To know is to survive and to ignore fundamentals is to
court disaster.“
Since 1950, significant technological advances have
been made in chemical process safety
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3. the technology of safety include
hydrodynamic models representing two-phase
flow through a vessel relief,
dispersion models representing the spread of toxic
vapor through a plant after a release, and
mathematical techniques to determine the various
ways that processes can fail and the probability of
failure.
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4. A good safety program eliminates the
existing hazards as they are identified,
whereas an outstanding safety program
prevents the existence of a hazard in the
first place.
Management systems directed toward
eliminating the existence of hazards
include safety reviews, safety audits,
hazard identification techniques, checklists,
and proper application of technical
knowledge.
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5. Safety or loss prevention:the prevention
of accidents through the use of appropriate
technologies
Hazard:a chemical or physical condition that
has the potential to cause damage to people
Chemical hazard & Mechanical hazard
Risk
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6. Safety knowledge: includes fundamental law of nature,
dangerous properties of chemicals
Safety experience:
Technical competence
Safety management support
Commitment: improving & practicing safety
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Safety Programs

7. Engineers are responsible for minimizing
losses and providing a safe and secure
environment for the company's
employees. Engineers have a responsibility
to themselves, fellow workers, family,
community, and the engineering
profession.
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8. Fundamental principles
Engineers shall uphold and advance the integrity,
honor, and dignity of the engineering profession by
Use knowledge and skill for the enhancement of
human welfare;
being honest and impartial and serving with fidelity
the public, their employers, and clients;
striving to increase the competence and prestige of
the engineering profession.
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9. OSHA incidence rate,

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covered period during employees allby workedhours Total
200000 X dayslost work o No.
ays)lost workdon (based rateincident OSHA 
covered period during employees allby workedhours Total
200000 X dayslost work o No.
ays)lost workdon (based rateincident OSHA 
covered period during employees allby workedhours Total
200000 X dayslost work o No.
ays)lost workdon (based rateincident OSHA 
covered period during employees allby workedhours Total
200000 X dayslost work o No.
ays)lost workdon (based rateincident OSHA 
covered period during employees allby workedhours Total
200000 X dayslost work o No.
ays)lost workdon (based rateincident OSHA 
covered period during employees allby workedhours Total
200000 X dayslost work o No.
ays)lost workdon (based rateincident OSHA 
covered period during employees allby workedhours Total
200000 X dayslost work o No.
ays)lost workdon (based rateincident OSHA 

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Fatal accident rate (FAR):

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13. Acceptable Risk
Public Perceptions
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14. The Nature of the Accident Process
Type of
accident
Probability
of
occurrenc
e
Potential
for
fatalities
Potential
for
economic
loss
Fire High Low Intermediat
e
Explosio
n
Intermedia
te
Intermedia
te
High
Toxic
release
Low High Low
The Accident
process:
•Initiation
•Propagation
•Termination
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20. An inherently safe plant relies on chemistry and physics
to prevent accidents rather than on control systems,
interlocks, redundancy, and special operating procedures
to prevent accidents.
The safety of a process relies on multiple layers of
protection. The first layer of protection is the process
design features. Subsequent layers include control
systems, interlocks, safety shutdown systems, protective
systems, alarms, and emergency response plans. Inherent
safety is a part of all layers of protection.
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21. Flixborough, England: June of 1974
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Fatility:28
Injured:36
Damage: 1821 Houses
Shop & factories: 167
70,000 caprolactum tons/an
cyclohexanecyclohexanonecyclohexanol
155oC, 7.9 atm pr
Inventories of
330,000 ga cyclohexane
66,000 ga naphtha
11,000 ga toluene
26,400 ga benzene
450 ga gasoline

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Bhopal, India
HAZARD:HAZARD:
Highly ToxicHighly Toxic
Methyl Methyl
IsocyanateIsocyanate
The Rising Case for Change………..
• 1984 – Bhopal, India – Toxic Material
Released

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2000 people died in Bhopal disaster

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More than 20000 civilians were
injured.

25. 1-1. An employee works in a plant with a FAR of 4. If this employee works a
4-hr shift, 200 days per year, what is the expected deaths per person per
year?
1-5. A plant employs 1500 full-time workers in a process with a FAR of 5.
How many industrial related deaths are expected each year?
1-9. A university has 1200 full-time employees. In a particular year this
university had 38 reportable lost-time injuries with a resulting 274 lost
workdays. Compute the OSHA incidence rate based on injuries and lost
workdays.
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Thank you for kind attention
Safety Go hand in hand