Chemicals have become a part of our life for sustaining many of our day-to-day activities, preventing and controlling diseases, and increasing agricultural productivity etc. An estimation of one thousand new chemicals enter the market every year, and about 100000 chemical substances are used on a global scale. These chemicals are mostly found as mixtures in commercial products. Over one million such products or trade names are available.
The chemical industrial sector is highly heterogeneous encompassing many sectors like organic, inorganic chemicals, dyestuffs, paints, pesticides, specialty chemicals, etc. Some of the prominent individual chemical industries are caustic soda, soda ash, carbon black, phenol, acetic acid, methanol and azo dyes. Chemical manufacturing sector in India is well established and has recorded a steady growth in the overall Indian industrial scenario. The Chemical and allied industries have been amongst the faster growing segments of the Indian industry. The Indian chemical industrial sector had a turnover of around Rs.1200 billion in 2001-2002. The chemical exports also accounts for more than 16.20% of the total Indian exports during 2001-2002.
The risks associated with the chemical industry are commensurate with their rapid growth and development. Apart from their utility, chemicals have their own inherent properties and hazards. Some of them can be flammable, explosive, toxic or corrosive etc. The whole lifecycle of a chemical should be considered when assessing its dangers and benefits. Though many of chemical accidents have a limited effect, occasionally there are disasters like the one in Bhopal, India, in 1984, where lakhs of people were affected and LPG explosion in Vizag refinery where huge property damage in addition to 60 deaths was experienced. Therefore chemicals have the potential to affect the nearby environment also.
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Design and Pre-modification review : Improper layout
like location of plant in down wind side of tank farm , fire station near
process area , process area very close to public road and wrong material of
selection had caused severe damages to the work and outside environment
·
Chemical Risk Assessment: Not assessed for
new chemicals from the point of view of compatibility, storage, fire
protection, toxicity, hazard index rating, fire and explosion hazards
·
Process Safety Management: HAZOP, FTA,
F&E Index calculation, reliability assessment of process equipment,
incorporating safety trips and interlocks, scrubbing system, etc. not done
before effecting major process changes, lack of Management of Change procedure
(MoC), etc.
·
Electrical Safety: Hazardous area classification ,
protection against static electricity , improper maintenance of specialized
equipment like flameproof etc were ignored.
·
Safety Audits: Periodical assessment of safety
procedures and practices, performance of safety systems and gadgets along with
follow up measures were not carried out.
·
Emergency Planning: Lack of comprehensive risk analysis
indicating the impact of consequences and specific written down and practiced
emergency procedures along with suitable facilities had increased the severity
of the emergency situations.
·
Training: Safety induction and periodical refresher
training for the regular employees and contract workmen were not carried out.
·
Risk Management & Insurance Planning: Thorough
identification and analysis of all risks and insurance planning were not done
so that interruption risks and public liability risks could also be managed
effectively.
A. Risk Management Following specialized risk management services are required to chemical industries, considering the kind of risks that exists in these plant operations:
1. STANDARD CONFORMANCE and PERFORMANCE EVALUATION (SCOPE)
SCOPE would evaluate the existing measures / system based on applicable national / international standards.
A few SCOPE reviews that we recommend for chemical manufacturing plants are:
1.1 SCOPE-FP (Fire Protection)
Indian Standards
·
IS
2189 - Standard for automatic fire detection and alarm system
·
IS
2190 - Code of practice for selection, installation and maintenance of first
aid fire extinguishers
·
IS
3844 - Code of practice for installation and maintenance of internal fire
hydrants and hose reels
·
IS
6382 - Carbon dioxide fire extinguishing system - fixed, design and
installation
TAC
StandardTariff Advisory Committee recommendations on hydrant and sprinkler system for fire protection.
Oil Industry Safety Directorate
·
OISD
117 - Fire Protection Facilities for Petroleum Depots and Terminals
·
OISD
142 - Inspection of fire fighting equipment and systems
·
OISD
158 - Recommended Practices on Storage and Handling of Bulk Liquefied Petroleum
Gas
NFPA
Standards
·
NFPA
12 Carbon Dioxide Fire Extinguishing Systems
·
NFPA
654 Prevention of Fire & Dust in Pharmaceutical Industries
·
NFPA
1600 Disaster Management
·
NFPA
921 Fire & Explosion Investigation
·
NFPA
45 Fire protection for Laboratories using Chemicals
1.2
SCOPE - OHS (Occupational Health and Safety)
·
IS
14489 Code of Practice for Occupational Safety & Health Audit
·
NFPA
101 Life Safety Code
1.3
SCOPE-ER (Electrical Risk)
·
Hazardous
Area Classification (base standard: IS 5572)
·
Selection
of Electrical Equipment for Hazardous Areas (base standard: IS 5571)
·
Lightning
Protection (base document: IS: 2309 /NFPA 780 /BS 6651)
·
NFPA 70 B Recommended Practice for Electrical
Equipment Maintenance
·
NFPA 70 E Standard for Electrical Safety in
Employee Work places
2.0 PROCESS
SAFETY MANAGEMENT
·
Hazard
& Operability (HAZOP) studies
·
Failure
Tree Analysis (FTA)
·
Event
Tree Analysis (ETA)
·
Primary
Hazard Analysis (PHA) using Dow Index
·
Risk
Assessment (with risk ranking technique)
3.0 ELECTRICAL
RISK ASSESSMENT
·
Review
of Hazardous Area Classification
·
Lightning
Protection Risk Assessment
·
Identification
& Control of Electro-Static Hazards
·
Review
of electrical Preventive Maintenance System
·
Electrical
Risk Assessment (fire, shock explosion) using Semi-Quantitative Risk Ranking
(SQRR) technique
4.0 FIRE
RISK ASSESSMENT
·
Identification
& assessment of fire risks during operations in receipt, storage, transfer
and handling of chemicals (raw materials and finished products)
·
Identification
& control of ignition sources in areas where flammable chemicals are stored
/ handled / transferred
o
Review
of chemical compatibility in storage areas and to suggest appropriate fire loss
control measures
o
Review
of fire detection measures adopted in the plant & to suggest suitable
improvement measures
o
Review
of the various active (fire hydrant, sprinkler, portable fire extinguishers)
and passive fire protection requirements for chemical storage and handling
areas and to suggest improvements as necessary
o
Review
of contractor safety awareness (chemical spill, fire fighting, emergency
communication, knowledge of plant hazards & safety regulations) and to
recommend suitable improvement measures to enhance contractor safety
o
Review
of safety awareness and safety training requirements ( training identification
and efficacy) of plant employees with respect to hazards present in the plant
Fire risk
assessment will be carried out based on techniques like Matrix method, Hani
Raafat Risk Calculator. The consequence, likelihood and exposure of each
hazard are arrived using a systematic approach and will help to determine the
relative importance of hazard and focus on significant risks.5.0 RISK ANALYSIS & EMERGENCY PLAN
·
Identification
of scenarios of potential disasters / emergencies leading to loss of life ,
property damage etc. and qualitative assessment of their likelihood.
·
Quantitative
risk assessment for selected scenarios of major credible events.
·
Recommendations
for risk control measures wherever applicable.
·
Preparation
of onsite emergency preparedness plan
6.0
RISK MANAGEMENT & INSURANCE PLANNING- Identification of all major internal and external pure risks including the natural risks and analysis of the impact of above risks
- Review of existing risk control measures and offering comments
- Scrutiny of all existing major insurance policies in respect of:
- Rationalization of basic rate of premium and widening of covers
- Applicability / eligibility of discounts in premium
- Application of suitable clauses, warranties and conditions
- Identification of possible areas for refund of premium and suggestions regarding procedure for the same
- Selection of insurance coverage on the basis of risk analysis
- Providing guidelines for fixation of sum insured and illustrate the same on a selected equipment
- Evaluation of business interruption exposure due to identified risks
- Providing guidelines on documentation requirements, procedures for claims under various policies, evaluation of insurers
Specialized and focussed training, if imparted effectively, can contribute significantly to Risk Management. Expert faculty, carefully selected training module, interactive and participate approach, useful training material, case studies and syndicate exercises could help in having effective risk management system in place. The training topics for bulk drug industry could be:
·
Chemical
Safety
·
Safety
with Compressed gases
·
Solvent
Safety
·
Hazard
Identification Techniques
·
Industrial
Risk Management
·
Fire
Prevention and Protection
·
Electrical
Risk Management
·
Emergency
Preparedness
·
Safety
Management system
·
Accident
Prevention
·
Personal
Protective Equipment
Nice post. Use of chemical products increasing in our daily needs. So demand of chemical increasing rapidly. Chemical industry now setting up their plants at many location so that they fulfill the demand.
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