Chemical Plant Safety Resources

DuPont recently reported the causes of methyl chloride leak from the phosgene unit in last January at its West Virginia chemical plant, which caused one worker died. Phosgene is a hazardous chemical used for manufacturing of pesticide and plastic that can damage the respiratory system.

According to DuPont report that was published in businessweek.com, the causes of the gas leak were aging hoses, corrosion and pressure build up in the line. Combination of these factors had caused hoses failed to function properly. (more…)

Carbon monoxide (CO) or carbon oxide is one of the toxic gases that are commonly found in chemical processing plant. It is used as raw material for other chemicals production or generated as by product from certain chemical processes.

Carbon monoxide is a colorless, poisonous (toxic), odorless and tasteless gas. It is non-irritating gas, which is lighter than air. (more…)

Forklift Operation

A day ago, I found an unsafe action relation with forklift operation that I have never thought it before. When I was inspecting preparation work before product delivery, a forklift driver left the forklift machine running while it was holding 2 tons of hazardous material. The forklift driver was doing another job at an area about 10 meters away from the forklift.

At least two hazards that I was immediately thinking about. First, if the forklift fails to hold the load then the hazardous material will be spilled out. Second, if the forklift accidentally moves it will strike something or somebody in front of it. (more…)

There are many reasons why hazard identification has to be updated. Ideally, hazard identification or hazard recognition is done before unwanted events such as injury and illness health occurs, because there is still enough time to improve the hazard control.

Here are some reasons why we need to update hazard identification list.

1. Because we have mentioned updating period in the hazard identification procedure. This is a regular updates. It is the time to evaluate if we had missed a hazard to be identified during the previous hazard identification period.
2. A new job, task or activity is introduced.
3. The existing process conditions will be changed.
4. Current standard operating procedures need to be altered.
5. We plan to modify plant facility or plant layout.
6. A new equipment or machine will be installed in the plant site.
7. When new safety equipment is introduced.
8. Chemical, catalyst or fuel replacement.
9. When a new product will be produced.
10. Plant expansion project is scheduled.
11. After an incident or accident occurrence.
12. When a neighbor plant will be built near our chemical plant. It is especially associated with emergency condition, such fire accident or explosion.
13. As a result of safety audit, safety inspection, safety patrol or self-inspection system.

To make an update, follow my previous post about hazard identification/recognition method. Hazard identification update has to be implemented in the whole workplace area in the plant site. Don’t forget to include contractors and visitor activities in the plant site, non-routine jobs and hazards caused by human factors when we are going to do hazard identification.

Always bear in mind that we have to be a step ahead from the potential hazard and immediately set up appropriate hazard control to manage the risks. Hazard identification is an ongoing process.

By definition, a hazard is anything that has the potential to cause harm to people, damage to property or environment, or loss to process. OSHA defines hazard as the potential for harm that is associated with a condition or activity that if left uncontrolled can result in injury or illness. Meanwhile, according to OHSAS 18001:1999, hazard is source or situation with a potential for harm in terms of human injury or illness health, damage to property, damage to the workplace environment, or a combination of these.

Hazard recognition or hazard identification is vitally important in accident prevention. By recognizing hazards’ characteristics and properties, we can clearly determine proper controls. Unfortunately, the majority of us sometimes overlook to recognize hazards.

Hazard Recognition Methods

There are many hazard recognition methods. The more hazard recognition methods we know, the bigger our chances to recognize all hazards that exist in workplaces. A hazard might not be identified by a certain method, but it can be detected by another method. Principally, we need to assure that hazard recognition is completely done.

The following are the most useful hazard recognition methods:
1. Pre-Use Analysis
2. Multi-Step Planning Process
3. Work Permitting
4. Equipment Inspections
5. Suggestion Method
6. Walk through Safety and Health Audits
7. Safety Patrol

Now, lets talks about these methods one by one.

Pre-Use Analysis can be applied before any new equipment, device, instrumentation, personal protective equipment, machine, tool, plant facility, etc are used. This method is applied before exposure to hazards.

Multi-Step Planning Process is applied before hazard exposure and applied to every task, job and activity. To apply this method simply asks a series of questions before doing the task, job or activity. The question should be similar to:
a. What am I going to do?
b. What is the purpose to do this job, task or activity?
c. How will I do that job, task or activity?
d. How could I get hurt doing this job, task or activity?
e. What will I do to prevent accident (injury, illness health)?

Work Permitting is issued before the job, task or activity done. Some questions asked and a checklist shall be completed to assured that hazards are not overlooked. Commonly, including in the checklist are analysis of toxic gas (such as carbon monoxide), oxygen sufficiency, flammable gas concentration, etc.

Equipment Inspection is implemented to any equipment before it is used or put into operation. Equipment inspection is planned and organized to check overall equipment conditions, safety protective equipment, guarding, emergency stop, etc.

In Suggestion Method, every worker is encouraged to propose or suggest potential hazard (and control) that are contained in a job, task or activity. Workers consider their past time experiences on the shop floor and field to give suggestion and this is very good safety habit. This method can be used for improving current hazard identification list.

Safety Patrol can be carried out by every worker in the plant site, not only by persons who are in charge of health and safety matters. Safety patrol may be done during an equipment running, plant operation, plant shut down or whenever it is intended to identify potential hazards.

The best way to use these hazard recognition methods is by combining these methods one with the others.

The next question is when is the right time to apply these hazard recognition methods? Of course before exposure to the hazards is the best time, because at that time no one was injured, ill or death, and no property damage. However, during a job, task or activity is being done hazard recognition is still important especially in accident prevention, and we can stop or cancel the job, task or activity at any time whenever we see a potential hazard to cause injury, illness health or plant facility damage.

Hazards may also be recognized after a job, task or activity has been completely performed and we can plan hazard control improvement to that job.