Process Safety, PSM in process industries

PSM

1. SAFETY AND ITS IMPORTANCE IN PROCESS INDUSTRIES PRESENTATION BY M . SRI HARSHA M.TECH - CHEMICAL ENGG ( O. U) PROFESSION : ASST. MANAGER (CEHS) SUVEN PHARMACEUTICALS LIMITED Certified as PROCESS SAFETY ENGINEER from DuPONT PROCESS SAFETY CONSULTANT

2. WHAT IS SAFETY ? IN YOUR WORDS

3. DEFINITIONS : SAFETY : Safety is a procedure or condition to prevent a consequences causes from hazards and to mitigate the severity of risk HAZARD : A source , situation or act which has the potential to cause personal injury, property damage, damage to Environment or both RISK : Risk is the combination of likelihood and consequence of an event that can cause harm Risk is associated with Hazard . There is no risk without Hazard

4. ROLE OF CHEMICAL ENGINEER IN SAFETY : HAZARD IDENTIFICATION:- Systematic procedure for understanding the conditions under which various hazards rise & to understand what things can go wrong & how

5. SAFETY & PROCESS SAFETY :

6. DEVELOPING A SAFE PROCESS by PROCESS SAFETY Process safety and engineering Process safety evolution steps Desktop screening Reaction / Thermal Evolution Powder safety evolution Powder safety sequence Application of process safety Process safety management

7. What is process safety and engineering? Process safety is a engineering and management procedure to identify the Hazards / risks involved within the well developed process and to implement / recommend certain measurements to prevent catastrophic events like explosions, toxic release, fires and fatality / facility damages. Process Safety engineering is a methodology / technology to get a knowledge on process parameters limitations, safe operating conditions and to make safe scale-up procedure in commercial scale. PROCESS SAFETY AND ENGINEERING

8. PROCESS SAFETY EVOLUTION STEPS: Desktop screening : MSDS / SDS of individual chemicals involved, approx. thermodynamic kinetics from CHETAH 2.0 , Oxygen balance. Primary or initial level of screening : Identification of CPP and its risks levels within the process. Preliminary DSC study of individual chemicals, reaction mass mixtures, residues and final powders. TGA for thermal stability.

9. Reaction / Thermal Evolution: Reaction calorimetry / Heat flow study for Heat of reaction, addition rate, ∆T ad in case of cooling failure scenario and maximum heat removal rate. ARC / 20 ltr Sphere study for TMR ad for temperature w.r.t maximum pressure. Maximum pressure in case of run away reaction scenario to control beyond the MAWP. Reaction calorimetry Acceleration rate calorimetry Heat flow Heat flow calorimetry 20 Ltr. Sphere study

10. Powder safety Study: Is important for safe handling of fine powders / dusts in large scale Mitigate the certain risks involved with required safety measurements and controls. Powder safety tools: Combustible test Dust Explosion test Bam-fall hammer test Minimum ignition energy (MIE) Minimum ignition temperature Layer ignition test (LIT) Bulk powder resistivity Charge decay Bam-fall ha m m er MIE test Charge decay test Combustible test Dust Explosion test Bulk powder resistivity

11. APPLICTION OF PROCESS SAFETY INDUSTRIES / MANUFACTURING UNITS LIKE Oil and gas industries Pharmaceutical and its intermediates Paper industries Food manufacturing industries Fertilizer industries Petroleum industries Speciality Chemical manufacturing

12. CARE TAKERS OF PROCESS SAFETY

13. PROCESS SAFETY INFORMATION It is a set of written compiled information which concerns process CTE

14. PROCESS SAFETY INFORMATION EX. :

15. PROCESS SAFETY INFORMATION IMP. :

16. WHATS NEXT ?

17. PROCESS SAFETY MANAGEMENT Successful when implementing below elements as a professional way.

18. Important Element s for Chemical Engineers : 2. Process safety information Process hazard analysis 7. Pre-Start Up safety review (PSSR) 8. Mechanical integrity 10. Management of change 13. Compliance audits Process safety cycle and solutions }

19. HEAT TRANSFER – Energy liberation, consumption, losses and accumulations MASS TRANSFER – Occupancy of equipment's, Flow properties. CRE – Reaction mechanism, Route of synthesis CHEMICAL TECHNOLOGY – Mechanical integrity APPLICATION OF SUBJECTS:

20. SOME INCIDENTS IN HISTORY DUE TO LACK OF PROCESS SAFETY

21. Cyclohexane Release & Explosion at Nypro Plant - Flixborough , England - June 1, 1974 ( killed 28 people and seriously injured 36 out of a total of 72 people on site at the time ) Flammable LPG in Tank Explosion – Mexico City, Mexico – November 19, 1984 ( 500–600 people killed, and 5000–7000 others suffering severe burns )

22. Bhopal Gas Tragedy December 2, 1984 (METHYL ISOCYNIDE) Immediate death toll was 2,259. confirmed a total of 3,787 deaths related to the gas release A government affidavit in 2006 stated that the leak caused 558,125 injuries, including 38,478 temporary partial injuries and approximately 3,900 severely and permanently disabling injuries. Others estimate that 8,000 died within two weeks, and another 8,000 or more have since died from gas-related diseases.

23. Why PSM ? Ammonium nitrate explosion at Beirut , Lebanon capital - August 4, 2020 ( killed 204 people and seriously injured 6500 employees and surrounding areas. Property loss – 15 billion US$ ) – Due long time storage in closed area and uncertain climatic conditions.

24. SOME BOOKS TO GAIN PROCESS SAFETY KNOWLEDGE Standard book for Process safety with case studies and calculations

25. Book for Managing Hazardous Reactions

26. Book for Process safety Fundamentals

27. Any