M.

Saban 4W4Poly2011

Know the potential hazards and appropriate safety precautions. Ask and be able to answer the following questions:
What are the hazards? What are the worst things that could happen? What do I need to be prepared? What work practices, facilities or personal protective equipment (PPE) are needed to minimize the risk?

Know the location and how to use emergency equipment including safety showers, and eyewash stations. Familiarize yourself with the emergency response procedures, facility alarms and building evacuation routes. Know the types of PPE available and how to use them for each procedure
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In the labs
Lab coat and safety glasses Gloves, hearing protection and dust masks/respirators if required

In the Pilot Plant

Coveralls, safety glasses, hard hats, static dissipating shoes Gloves, hearing protection and dust masks/respirators if required

In the Manufacturing Plant

Plant dependant; eg. in a petrochemical refinery fire retardant coveralls are a must, etc.

 Discussion topic: what are the pros and cons of PPE approach to Process Safety?
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Thermal Process Safety

Understand reaction hazards (reaction calorimetry, criticality assessment, DSC)

Consider semi-batch vs. batch reactions

Consider operation at reflux (but be aware of vapor buildup and explosion hazard) Useful Link: http://www.harsnet.net/harsbook/harsbook_02.htm Eg. XRCC Pilot Plant is designated to handle Class I, Div 2, Groups C and D materials Explosion proof equipment Intrinsically safe equipment Link: http://en.wikipedia.org/wiki/Electrical_equipment_in_hazardous_areas Run only scheduled experiments Equipment SOPs in place/Process SOPs in place

Electrical Safety

Operational Safety (XRCC PP Example)

Haz-Op review completed ahead of each new experiment

Books: Kletz, Trevor (2006). Hazop and Hazan (4th Edition). Taylor & Francis.
Link: http://en.wikipedia.org/wiki/Hazard_and_operability_study

XRCC Pilot Plant: Class I, Div II, Groups C and D

Google images for: explosion proof enclosure

Deepwater Horizon Oil Spill, Gulf of Mexico, Apr 20-July 15, 2010 (Death Toll=11) Sunrise Propane, Toronto, ON, Aug 10, 2008 (DT=2) Imperial Sugar Refinery, Port Wenworth, Georgia, Feb 7, 2008 (DT=14) CAI Inc., Danvers, Massachusets, Nov 22, 2006 (DT=0) BP Refinery, Texas City, Texas, March 23, 2005 (DT=15) Azote Fertilizant (AZF), Toulouse, France, Sept 21, 2001 (DT=31) --------Union Carbide, Bhopal, India, December 3, 1984 (DT=3,800) http://www.bhopal.com/

A Matter of Time article, Canadian Chemical News, Jan

2010, p.13 F. Stoesel, Thermal Safety of Chemical Processes, Willey-VCH, 2009. Guidelines for Hazard Evaluation Procedures, Center for Chemical Process Safety (CCPS), New York, 2008 L. G. Britton, Avoiding Static Ignition Hazards in Chemical Operations, AIChE, CCPS, 1999 G. Norval, Engaging Academia in Teaching of Process Safety via the Summer Institute, paper#1384, WCCHE#8, Montreal 2009. (G. Norval is U of T Prof. of ChemE) Consultants:
Chilworth Technology Inc. Fauske and Associates, LLC Mettler Toledo RC1

Plant/process safety is a job #1 for plant designers There are three important faucets of plant/process safety: 1. thermal process safety, 2. electrical safety and 3. operational safety It is up to you, as a plant designer, to pick the safest possible process chemistry, plant location, equipment, manufacturing process, operating procedures, and PPE for process scale-up It is a duty of every P. Eng. to keep public safety as the top priority (eg. http://en.wikipedia.org/wiki/Engineering_ethics) Although detailed safety assessment of our Specialty Polyester Resin plant is outside the scope of this course, safety process assessment should be incorporated in the final report

Safety considerations should be incorporated in the final report

Raws classification MSDS review HAZOP test

Eg. of raws classification

Solid
Flammable Combustible Noncombustible Special case

Liquid

Gas

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