This paper gives a detail review on industrial major accident hazard control. A major hazards control system must contain four areas of activities that is identification of major hazards, assessment and analysis of major hazards, management of major accident prevention system and emergency operations. The details of the discussion is available in full text article

Ahmad, Khairudin

Songip, Ahmad Rahman

English

Universiti Teknologi Malaysia Institutional Repository

OVERVIEW ON TNDUSTRIAL MAJOR ACCIDENT HAZARDS CONTROLThis paper ls writ ten based on inri ters' part icipation Inthe seminar on the fndustrial Major Accident HazardsControl which lvas hefd recently in Kuala Lunpur.The objectives of the seminar are to create awareness onsafety in industries that have the potential to presentMajox Accident Hazal:ds and to lmpart to the part icipantsthe basic pr inciptes of  control  of  these najor hazaras.  .An important concept that should be ful ly understoodFirsL is that  safety in jndusLr ies is very essenl ia land must be incorporateal in af1 steps of establishingthose inalustr ies. Some of the wellknown steps are siLeselection, plaEt layout. plant and equipment alesigns,ete. Accident is l ikely to occur i f  safetl ,  measures areneglected in any one of-those steps. Safety measures!,/1lI  be brlef ly discussed in the later part of thispaper.To understanal further the concept of safety, let usexamine the definit ion of keyl iords in the above l i t le.The f irst keyword is 'Major Accident'  nhich as definedas fof lows:AHMAD RAHMAN SONGTPKHA]RUD IN AHMADAn i_,ccurance such as a major emlssionr f ire orexplosion result ing from uncontrol leal developnentsin the course of an industrial activity, leadtngto a serious danger to men. immealiate or delayed.inside or outside the establlshment, and/or tothe environment, and involving one or moreuor:Ys! uurIndustrial activit ies mean any operation carried out inan industrial instal lat ion and such operations should in-volve i langerous substances and should be capable of pre_senting major accident haz ards.The other keyrvorcl is 'contrdl ' .  Control can be consideredin two t ime frameq, that of after the event where peopleare f iqhting to control the outcome of a disaster, analthe control that is buil t-up and establisheal to preventthe accidenL f  rora hdppening.The major hazardor+s accialents can be classif ieal into sevencategories depending on the chemical and physical propert lesof the material and the ty?e of instal lat ion involved.They are:I .2.3.Bolling Liquld Expanding Vapour Bxplosion (BLEVE)confined Vapour Explosion (c\,€) :Unconf ined vapour c loud Explosion ( t rycE)Detonatlon (DET))27.Flre Bal l  (FB)Release of Toxic Subtances (TOX) andRelease of Radioadtlve l4aterials (RAD)iPreventing and control l ing accidents from happeningr oneneeals to understand the underlying anal immealiate causesthat lead to a al isaster. There are three maiD causes,n arne ly rl .  Abnorrial Proeess Conalit ione. g. excess [emperatule. pressure2. Interference by Anothe! Activitye.9.  an aeroplane crashed onto the plant3. Natural Inf luencesHaving understooal the causes and consequences of majoraccident hazafds,  the next step thal  have to be done isto try to inLroduce control system that at least wil- l. I imit those costly conseqHlnces into rninimal. A majorhazards control system i lust contain four areas of1. Identif ication of Major l lazarals2. Assessment and Analysis of l4ajor Hazards3. l , lanagement of Major Accident prevention System4. Emergency 0perations1. Identif ication of Major HazardsIdentif ication fol. lowed by carefuf plannlng shouldstart from the early stages of inst.al lat ion such assi te select ion,  pLant layoLrt ,  p lanL design andoperating procedures.Si t ing pol ic ies shouLd be establ ished. This refersto the separation between the instal lat ion and thepublic and contr.ol pol icies that needs to be exertedto stop the pub,l ic and other alevelopment from gett ingThe besE process planL Iayout is the arrangemenL ofvessels,  p ip ing. conveyors etc.  that  sat isf ies theconstraints of  operat ion.  safety,  environmentalprotection, maintenance and constructlon for the leastcost of the equipment and the rnost econonlc use ofci+a ^r  l - \ r r i l^ ihnUnlike many inaustriaf activit ies srhere different partsof  a manufactur ing plaDL are del iberately p,Lacedadjacent to each other to minimise interstage transport,most Process Indust.ry sites are laid out with plantunits careful ly segregated, albeit at some extra cost.Three main considerat ions 1ie behind thls pol icy.ofsegregataon:541. Safety and foss Prevention- ExPlosion- Flre- Leakage- structural col laPse2. Housekeeping- Fumes- Dust3. Acceqs for constructioD and maintenance.Another step of identif ication is idenLifying majorhazarals activit ies. Dame and quantity of hazardousmaler ia l ,  f inal ly the management should not i  f t t  localcompetent authority abolrt Ehose hazards identif lcations,Iocation, schealule of start-up and shut-do\dn operatj-on.2. AssessmenL and Aralysis of Major HazardsTechniques anaa."a available fo! assessment ancianalysis purposes age:- HAZOP (Hazards and operabil i ty Studies)- HAZAN (Hazards Analysis )- Hazarals Assessment-  RisK Anafys is- Rlsk As sessment3. Management of Major Accident Prevention SysternIn reviewing the management of  major hazard instal tat lons,Dow Safety Director for Pacif ic Area. Mr. Brian Hagrestnention€d that "total loss dollars" are mainly due to"Natural  Causes" such as f loodingr Hurr icane etc.Whereas "Process Incialents" occur most frequently.but represent a relat ively minor part  of  total  lossdollats. He then outf ined nine factors v/hich fronthe underlying basis for the management or control of" industr ia l  major dccident hazards, , .  They are:1.  Plant Design2. Safety Systems in Use3. Operator Training and Responsibi t - i ty4. Srtart-up and shut down operations5. Ways by which control of plant can be losr6.  Recordkeeping7, Housekeep in g8. Maintenance procedLrres and permit  to work9. Procedures for Modl f ications4. Emergency operat ions -a) 0n-Si te And 0f f -Si te Emergency planningThe othen factor in ensuring safety in anajor.hazardinstal lat ions is the availabi l i ty of "Energencyoperations or plannlng.". I t  cannot be considered56lntoisolation and lts proper place ls as a back-upthe prevent ive l l leasures discttssed earl ier 'The employer bears most of the responslbi l i ty forthese measures, which can be sununalised as fol lowsensure that the plant anal storage vessels aredesigned and instal led to a good standard andin a locat ion where hazards are unl ikely toarise from other pfant or buildings nealby.t .2.3.ensure that proper vork routj-nes and effectivemaintenance procedures are set up.assess what coulct  st i l f  happen Lo causeemergency si tudLion: [ur ther preventrvemeasures may st i l -L be possible.4. assess wrrat dangers could arise to people bothon-gite and off-site as a result of theseforeseable emergencies and hovt these could belr i t igated IJV pre-planned remealial anal rescuemeasures uti f ising t lre resources of the majornazard j 'nstaflat ions and the public emergencyservices..Item (4) wall  require the formulation of a emergencyplan whlch as in two separate parts: the on_site5'7pIan, covering the actlon to be taken on theinstal lat ion and the off-site plan covering theaction to be taken in the neighbourhood around it .b) Igrmulation of the 0n-Emp-Loyers should set up a plan based on thespeci  f ic  needs oT the part jcu Lar s i te.  Al l  pLanswoulal. however, need to maintain the fol lolving keyelements:-  assessment of  the s ize and nature of  the eventsforeseen and Lhe probabr i i l l  lhdt  E.hev miqnL occur-  Lormutat ion of  toe plan and f . id ison with DuL-s ide arr thor i1- ;ae in^lrrr l ihd,hi  Am-r^an^' ,-  nr^^6. l , r rac rr i  c i  n^ +ha_.._ al  arm dnd cof i$unicaLions.- appointrnent of key personnel and defining theirdut ies and r :espons i  b i  r  -L L ies .-  set t lngup of  emdrgency conLrof  cenLres.- action on site : f ire-f ightinq procedutes,reseue systems, evacuation arratgenents, f irst-aid arrdngements.- plant shut-dovin proceilureg.53c) Formulation of the off-Site EmeThe responsibi l i ty for sett ing up this part of theplan should t ie with the public authoii ty that hasconLrol  ot  resources nnd faci l iL jes in the neigh-bourhood of  Lhe instdlLat ion.  s ince Lhe employer! .? i l l  posses detai  led knowledge dbout his ptantand substances, he should pass it  on to l :he publicauEhori l ies Lo e1aole Lhem to draw up the of  f  -s i r -eplan. Thusf the on-slte anal off-site plans shoulalcomplemenl each other.In adali t ionr the employer rvi l f  need to advise theneiqhbour inq comrun-Lty ei the- direcLly or through -the public authorit ies as to the naLure ot thehazards involved and the action to be taken inthe event of an emergency.Exper ience has shown thaL - in real  emerqenciesthere is ofLen much confusion. no nateer how vnell' ts  ic  6cc6hl  i r l  rh6/6F^raLrrE Pf d,  '5that plans are Fgularfy rehearsed anal practlsedunder sirnulated energency condit ioos ln order totesL the response of  operators dnd emergencyservices personnel, test anal evaluate the inter-acLjon of  the var ious organ- isat ions invol \ , /ed.evaluate Lhe ef fecLiveness of  equjpment andincrease gains fron experience.59Final fy,  in prevenLing major industr ia l  accident,i t  is  beLter to spenal  money at  the ear ly stages sothat no majo! modif icatlons woulal have to be maaleclue to unsafe operations. Furthermore, al l  employees,l r regardless of  their  posi t ions,  should be sensi t iveand coruniLLed to the sdfeLy aspect of  their  industry.As such, jL is good to have a "safety Induct ionProgram" for dl l  nelr  employees so that they areallrays aware of the needs for safety.JabaLan Kj lang dan Jentera Malaysia hdd done asurvey on the hazardous instal lat ions - in f985.Frorn the survey, 83 major hazards industrialinstalfat ion lvere ialentif ied. More thail  half ofthese are located in an area cfassif ied as non-industry viz comprising of schoofs or resialential: ra;  ^r  n ' ,h l  i^  n l r .ae Th6 crrr \ /o ' ,  : lc^ rarraJl6. lthat 38 - 583 of the ov,r ler of those siLes lrere notavrare of HAZOP and did not carri  out HAZOP studiesand r isk analysjs.-  422 of  these si tes did notcalry out ' :ehearsaf fof  Lheir  on-si te emergency,618 was found not having emergency plan for theirneighbours {off-site emergency plan) .The International Labour oxganizatlon (IIO) hascomplled alf major. accialents hazards. It  isSi tuat ion60reported that the highest frequency accident isinvolving L.iquid Natural Gas (LNG) and LiquidPetroleu$ cas {LpG) . l4alaysia currently is novingtowards LNC and LPc ut i l izal ion for  the Publ icand industr iaf  needs. Looking at  the Lerr i fy- ingstatist ic from the JKJ'S survey and the mountinghazaralous potentiaf of ING and LPG| Lhere are st i l lalot more to be done in Malaysia to ensure safetyto the workers. public and the envlronment 1n yearsLo come. 0ne thing for sure,  p la laysians wouldcertainly do not want to see accidents that clalmedso many l ives and propert ies to happen inMdIa),s ia,  such hacl  happened in l ' lexico Cj ty in1yB4 r^7hich c I  a imeci  b ru I  i  ves and severa I  thousandsin i ' rz6^ rc :  Yoc,r l+ ^f :n T .PC explosion.ooo000061

Overview on industrial major accident hazards control

http://eprints.utm.my/6741/1/AhmadRahmanSongip1987_OverviewOnIndustrialMajorAccidentHazardsControl.pdf

Overview on industrial major accident hazards control

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