Loss Prevention

Process Safety, Health and
Environment (CN3135)
Soh Guat Hiong

chesgh@nus.edu.sg
Outline of CN3135
Importance of process safety design and
operation
Identifying safety and health hazards eg.
HAZOP
Predicting consequences
Design for sustainable processes eg. reliability
engineering, sustainable engineering
12/8/2018
NUS CN3135 Introduction to Loss Prevention
Module Learning Outcomes

On successful completion of this module, students
will be able to:
Describe and identify chemical process hazards
Analyze and assess the potential impacts of
hazards on safety, health, and the environment
(SHE)
Develop methods for controlling process hazards
and minimizing their associated risks.
Describe the principles and aims of sustainable
development
Prepare for final year design project
12/8/2018
Lectures and Tutorials Schedule

Week
Lecture Date Lecture Topic
Lecturer
Tutorial Date
Tutorial Topic
Tutor
Soh Guat Hiong
12-Aug
Introduction to Occupational
Health and Safety 1
Soh Guat Hiong
19-Aug
Fire and explosion 1
Ramasami Sundaresan
20-Aug
Introduction to
Occupational Health and
Safety 1
26-Aug
Ramasami Sundaresan
27-Aug
Ramasami Sundaresan
2-Sep
Consequence Modelling 1
Ramasami Sundaresan
3-Sep
Ramasami Sundaresan
9-Sep
Consequence Modelling 2
Ramasami Sundaresan
10-Sep
Consequence Modelling 1 Ramasami Sundaresan
16-Sep
Introduction to Occupational
Health and Safety 2
Soh Guat Hiong
17-Sep
NC Hor
1-Oct
Consequence Modelling 2 Ramasami Sundaresan

Introduction to
Occupational Health and
Safety 2
Soh Guat Hiong
Hazard Identification and Risk

Assessment Procedure (HAZOP) NC Hor
8-Oct
Pressure Relief
NC Hor
NC Hor
RECESS
7
30-Sep
7-Oct
Pressure Relief
14-Oct
Reliability Engineering 1
Leslie Tsen
15-Oct
Hazard Identification and

Risk Assessment
Procedure (HAZOP)
10
21-Oct
Leslie Tsen
22-Oct
Leslie Tsen
11
28-Oct
Management of SHE
Soh Guat Hiong
29-Oct
Leslie Tsen
12
4-Nov
Environmental Impact
Soh Guat Hiong
5-Nov
Management of SHE
Soh Guat Hiong
13
11-Nov
16-Nov
Industry and Environment

Reading Week
Soh Guat Hiong
12-Nov
Environmental Impact
Soh Guat Hiong
Examinations
2 weeks
12/8/2018
Tutorial Groups and Venue

CN3135 Tutorial
Group
12/8/2018
Day
Start
End
Venue
Wednesday
15:00
16:00
E5-03-22
Wednesday
9:00
10:00
E5-02-32
Wednesday
16:00
17:00
E5-03-22
Wednesday
11:00
12:00
E5-03-22
Wednesday
12:00
13:00
E5-03-22
Wednesday
17:00
18:00
E5-03-22
Wednesday
10:00
11:00
E5-02-32
Wednesday
14:00
15:00
E5-03-22
Tutorial Exercises
Will be assigned by individual
lecturers during each lecture
12/8/2018
Module Assessment
Mid term test (date, topics, duration) 10%
HAZOP/ Reliability Engineering project 30%
Final Examination 60%
12/8/2018
Textbook for CN3135

Chemical Process Safety:
Fundamentals with
Applications,
International Edition, 3/e
Author
: CROWL
LOUVAR
Publisher : Pearson
ISBN
12/8/2018
: 9780132782838
Expectations
IVLE/CN3135
Lecture materials - download
Tutorial problems Attempt
Register your project teams
o Form team of 4 5 members
o Register: IVLE/Workspace/Groups/Sign-up
Bring textbook for lecture
12/8/2018
Lecture 1
Introduction to Loss
Prevention
Learning Outcomes
Review major process safety accident cases
Assess loss prevention in process design and
operation
Analyse incident statistics
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11
Process Safety Focus

Prevention of incidents involving leaks, spills,
fires or explosions
Facilities are well designed, safely operated
and properly maintained
Facilities are designed and engineered
properly with systems to monitor and control
hazards
Includes technical, management and
operational systems working together to
achieve desired outcome
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12
Process Safety Pyramid
12/8/2018
Source: WSH Guidelines on Process Safety Performance Indicators, WSH Council
13
Source : The 100 Largest Losses, 1974-2013

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14
Source : The 100 Largest Losses, 1974-2013

12/8/2018
15
Major Process Safety Accidents
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16
Video: Bhopal
12/8/2018
17
Taiwan Gas Blast

Kaohsiung
31st August 2014
At least 25 fatalities and
270 injured
12/8/2018
18
Major Process Safety Accidents
Fire at Shell Bukom

Fire had started in the course of open de-oiling of
naphtha from a pipeline that ran through a pump
house at the refinery
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19
Fire at Shell Bukom

Started 28th Sept 2011@ 1.15pm
Fire broke out in the pump room of Shell's halfa-million barrel per day Singapore plant
6 people suffered superficial wounds and 3 fire
engines were damaged from the fire
Damage was contained to the vicinity of the
pump-house, in an area 50m by 150m
Caused temporary shut down of refinery
Extinguished 29th Sept 2011 @9.18pm
Final handover by SCDF 2nd Oct 2011
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20
Shell was charged under Section 11(a) of the Workplace Safety and Health Act
(Chapter 354A) for having failed in its duty as an occupier to take reasonably
practicable measures to ensure the safety of persons at its workplace
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21
Worrying Trend Continues.

>30 Fatalities since Jan 2014 !!!
Source: SPH Website, 29 Jan 2014
12/8/2018
22
12/8/2018
23
Top 5 Incident Agents

Falls
Collapse/failure of structure/equipment
Struck by moving Objects
Caught in/between objects
Electrocution
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24
12/8/2018
25
Top 5 Occupational Disease

Noise induced deafness
Work-related musculoskeletal disorder
Occupational skin disease
Occupational lung disease
Barotrauma
12/8/2018
26
Definitions
Safety: Strategy of accident prevention. Main emphasis is
on worker safety
Loss Prevention: Prevention of accidents through use of
appropriate technologies to identify and eliminate hazards
before an accident occurs. Includes protection of people,
equipment, production, property and the environment
Hazard: An inherent physical or chemical characteristic of a
material, system, process or plant that has the potential for
causing harm or damage
Risk: A measure of the likelihood of occurrence and
consequence of an accident (severity)
Accident: Incident which results in consequent losses
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27
Definitions
Incident: An unplanned or undesired event
that adversely affects a companys work
operations
Include work-related fatalities, major injuries,
minor injuries, first aid cases, occupational
illnesses, property damage, spills, fires,
dangerous occurrences or near miss events
12/8/2018
28
Accident Pyramid
1
100
500
10 000
Disabling Injury
Minor Injury
Property Damage
No Damage
Source: Chemical Process Safety, Crowl & Louvar

12/8/2018
29
VISION
ZERO
Zero Harm
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30
What is Acceptable
Risks?
Acceptable Risks
Any risk that is currently tolerated is considered
to be acceptable (US EPA)
Tolerable risk: risk which is accepted in a given
context based on the current values of society
(ISO & IEC)
Level of potential losses that a society or
community considers acceptable given existing
social, economic, political, cultural, technical
and environmental conditions (UN)
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32
Acceptable Risks
Cannot eliminate risks totally
At design stage, need to decide if risks are
acceptable
< Normal day-to-day risks in non-industrial
environment
Risks from multiple exposures are additive
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33
Acceptable Risks
Risk acceptance is a function of many factors
and varies considerably across industries
Company culture and the culture of the country
in which a facility is located influence risk
acceptability
Risk acceptability is also time dependent what is acceptable today may not be
acceptable tomorrow, next year or next decade
12/8/2018
34
Severity of Hazard
Level
Score
Severity
Description
Catastrophic Fatality, fatal diseases or multiple major injuries

Major
Serious injuries or life-threatening occupational disease

(includes amputations, major fractures, multiple
injuries, occupational cancer, acute poisoning)
Moderate
Injury requiring medical treatment or ill-health leading

to disability (includes lacerations, burns, sprains, minor
fractures, dermatitis, deafness, work-related upper
limb disorders)
Minor
Negligible
Injury or ill-health requiring first-aid only (includes

minor cuts and bruises, irritation, ill-health with
temporary discomfort)
Not likely to cause injury or ill-health
Code of Practice on Risk Management

by Introduction
Workplace
safety and Health Council
NUS CN3135
to Loss
12/8/2018
Prevention
35
Likelihood of Occurrence
Level
Score
Likelihood
Rare
Remote
Occasional
Frequent
Description
Not expected to occur but still possible
Not likely to occur under normal
circumstances
Possible or known to occur
Common occurrence
Almost Certain Continual or repeating experience
Code of Practice on Risk Management by Workplace safety and Health Council

12/8/2018
36
Risk Ranking and Risk Matrix

Likelihood
Severity
Rare - 1
Remote - Occasional - Frequent - Almost Certain 2
Catastrophic - 5
10
15
20
25
Major - 4
12
16
20
Moderate - 3
12
15
Minor -2
10
Negligible - 1
37
Acceptability of Risk Levels

Risk Level
Risk Acceptable
Low Risk (1 3)
Acceptable
Medium Risk (4 12)
Tolerable
High Risk (15-25)
Not acceptable
38
Chemical Plant Accident

Accident
Type
Toxic
Release
Scenario
Release +
Dispersion
Probability
of
Occurrence
Potential
for
Fatalities
Toxic
Exposure to
employees
and
community
Low
High
Extensive plant
damage
Intermediate
Intermediate
High
Low to
Intermediate
Outcomes
Explosion
Ignition in
confined space
Fire
Release + Ignition Low to High

l Pre-mix with air? level of loss
12/8/2018
39
Nature of Accident Process

Most common consequence is fire
Highest percentage of large losses from vapour cloud
explosion
Toxic release can result in high human and
environmental impact
Most frequent cause is mechanical failure (>50%),
followed by operator error (18%) and design (10%) *
Most common hardware failure piping systems,
reactors and storage tanks*
* Data from Chemical Process Safety by Crowl & Louvar
12/8/2018
40
Sequence of Accidents
Initiation Event that starts the accident
Propagation Event(s) that maintain or
expand the accident
Termination Event(s) that stop the accident
or diminish it in size
12/8/2018
41
Defeating the Accident Process

Step
Desired Effect
Procedure
Initiation
Diminish
Process design
Inert atmosphere
Intrinsically safe equipment
Grounding, bonding
Procedures, permit to work
Risk assessment
Training
Propagation
Diminish
Construction materials
Plant layout
Reduce inventories of
materials
Install check and emergency
shutoff valves
Emergency material transfer
Termination
Increase
Install check and emergency

shutoff valves
Fire fighting, sprinklers,
equipment & Procedure
42
Relief system
12/8/2018
NUS CN3135 Introduction to Loss

Prevention
Inherent Safety
Minimise eg. inventory, size of tanks/reactors
Substitute eg. less toxic, less flammable
materials
Moderate eg. lower temperature, lower pressure,
dilution, particle size
Simplify eg. Design for Safety, less maintenance,
housekeeping, easy to follow. Reduce
opportunities for error
12/8/2018
43
Hierarchy of Health Hazard Control
Source
12/8/2018
Path
Receiver
52
Bhopal Accident
Methyl isocyanate used in pesticide
manufacturing
Heavier than air
Reacts exothermically with water
Substitute with less hazardous chemical that
produce a less toxic chloroformate
intermediate (Substitute)
Decrease inventory of MIC on site (Minimise)
12/8/2018
45
Video: Sugar Dust Explosion
Port Wentworth, Georgia
12/8/2018
46
Port Wentworth Accident

Conveying equipment not designed to
minimise release of sugar dust and eliminate
all ignition sources (Minimise)
Poor housekeeping (Minimise, Simplify)
Company knows but fail to correct unsafe
condition (Company leadership issue)
12/8/2018
47
Combustible Dust Explosion

Automobile Metal Parts Polishing Supplier, Kunshan
2nd August 2014

68 fatalities, about 190 injured
12/8/2018
48
Shell Bukom Fire - 3 Main Lapses

1) Contractors drain naphtha from two open
valves and an open flange joint of the pipeline
into trays.
Naphtha vapour to escape into the atmosphere
resulting in an accumulation of flammable
vapour, which would in turn pose a danger of
ignition
12/8/2018
49

2) Use of a plastic tray, which was a nonconductive container, as a receptacle for
collection of naphtha
Free fall of naphtha onto the plastic tray allowed
accumulation of static charges
A spark could be caused and be sufficient to
ignite the naphtha vapour which is within
flammable range in the atmosphere
12/8/2018
50

3) Failed to deploy portable gas monitors
sufficiently close to the open de-oiling area to
give the warning when the build-up of the
flammable vapour reached an undesirable level
12/8/2018
51
Performance Monitoring
Provide assurance that process safety risks are adequately
controlled
Leading Indicators - monitor proactively the effectiveness

of risk control systems and provide feedback on safety
performance before an incident or accident happens
- evaluate present state of workplace through routine and
systematic inspections
Lagging Indicators when desired safety outcome has
failed. Monitor reactively the effectiveness of risk control
systems, identify gaps and weaknesses in these systems,
and report on incidents or accidents
12/8/2018
52

12/8/2018
53
Examples of Leading Indicators

12/8/2018
54
Examples of Leading Indicators
Source:
WSH Guidelines on Process Safety Performance Indicators, WSH Council
12/8/2018
55
Accident Statistics
Ministry of Manpower
Fatality Rate: per 100 000 employed persons
12/8/2018
56
Accident Statistics
OSHA (Occupational Safety & Health
Administration)
# of injuries & Illness*200,000
Total hrs worked by all employees
Incidence rate per 100 worker years
40hrs 50wk
hr
WorkYear
2000
yr
wk yr
12/8/2018
57
Accident Statistics
FAR (Fatal Accident Rate): Fatalities per
1000 employees over 50 years ( = 108 working hours)
Depends on no. of exposed hours

FAR = No. of Fatalities x 108
Total hrs worked by ALL
employees during period covered
[NB. 1 worker - 40 hr/wk, 50 wk/yr, and 50 exposed- yr/lifetime = 105 exposed-hr/lifetime]
12/8/2018
58
Assessing Risks
Target FAR
For planning, design to meet national or
company requirements
Sum of risks for most exposed person on site
< 2 deaths/108 exposed-hr
Single risk < 0.4 deaths/108 exposed-hr
12/8/2018
59
Accident Statistics
FR (Fatality Rate): per person per year
Independent of hours actually worked
FR = No. of fatalities per year
Total no. of people in
applicable population
12/8/2018
60
Fatality Rate:
FR = no. of deaths x
frequency total population
Assessing Risks
Acceptability Criteria
10-3/yr
unacceptable
10-4/yr
public money spent to control
10-5/yr
some degree of inconvenience
10-6/yr
no great concern
12/8/2018
61
Your Role in Loss Prevention

Eliminate the hazard
Mitigate the risk by reducing the
severity and probability of
occurrence of the incident
12/8/2018
62
Tutorial Questions 20th Aug

Attempt problems 1-1, 1-2, 1-4
and 1-6 from textbook
12/8/2018
63

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Process Safety, Health and

Soh Guat Hiong

NUS CN3135 Introduction to Loss Prevention

Module Learning Outcomes

NUS CN3135 Introduction to Loss Prevention

Lectures and Tutorials Schedule

Lecture Date Lecture Topic

Soh Guat Hiong

Soh Guat Hiong

Fire and explosion 1

Fire and explosion 2

Fire and explosion 1

Fire and explosion 2

Consequence Modelling 1 Ramasami Sundaresan

Soh Guat Hiong

Consequence Modelling 2 Ramasami Sundaresan

Hazard Identification and Risk

Hazard Identification and

Soh Guat Hiong

Soh Guat Hiong

Soh Guat Hiong

Industry and Environment

Soh Guat Hiong

Soh Guat Hiong

NUS CN3135 Introduction to Loss Prevention

Tutorial Groups and Venue

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

Textbook for CN3135

NUS CN3135 Introduction to Loss Prevention

Bring textbook for lecture

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

Process Safety Focus

NUS CN3135 Introduction to Loss Prevention

Process Safety Pyramid

Source: WSH Guidelines on Process Safety Performance Indicators, WSH Council

Source : The 100 Largest Losses, 1974-2013

NUS CN3135 Introduction to Loss Prevention

Source : The 100 Largest Losses, 1974-2013

NUS CN3135 Introduction to Loss Prevention

Major Process Safety Accidents

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

Taiwan Gas Blast

NUS CN3135 Introduction to Loss Prevention

Major Process Safety Accidents

Fire at Shell Bukom

NUS CN3135 Introduction to Loss Prevention

Fire at Shell Bukom

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

Worrying Trend Continues.

Source: SPH Website, 29 Jan 2014

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

Top 5 Incident Agents

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

Top 5 Occupational Disease

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention

NUS CN3135 Introduction to Loss Prevention