DKK3423

PLANT SAFETY & HEALTH

CHAPTER 6:
PRACTICAL SH&E ASPECTS IN A
CHEMICAL PLANT
By:
Mr. Junaidi Zakaria
Lecturer, FKKSA, UMP
junaidibz@ump.edu.my

Edited by : Bijarimi

INTRODUCTION

SH&E aspects can be succeeded in chemical plant when

the entire workers participate in the action.
The plant normally organized SH&E committee and
usually involves the highest ranking of management
such as CEO or Plant Manager.
SH&E committee consist of: SH&E/ safety officer, plant
employee and manager or CEO.
Every worker should get the proper training including
the safety and health precaution prior to be assigned to
the workplace.
Some success plant hires plant emergency responder to
overcome the emergency situation.
The hired SH&E officer to conduct the periodic safety
audit.

6.1: HAZARD IDENTIFICATION

Definition:**refer to chapter 1
Step:
i.
ii.
iii.
iv.
v.
vi.

Laws and practice code

Accident data
Observation
MSDS
Inspection
JSA ( Job Safety Analysis)

6.1: HAZARD IDENTIFICATION

Hazard is classified into:

physical
chemical
biological
ergonomic
psychological

6.2: RISK ASSESSMENT

Collect all the information of every identified

hazard.
The number of persons who were exposed to each
hazard and the time of exposure.
Use the above information to assess the possibility
and the severity of every hazard.
The possibility and the probability of hazard
situation occur.
Very

likely often
Likely sometime
Unlikely seldom
Very unlikely very seldom

6.2: RISK ASSESSMENT

What is the effect of the hazard?

Fatality
Severe

injury (cannot recover to normal)

Slight injury (usually can recover)
First Aid

Use the risk table to evaluate the RISK

involved in every hazard.

6.2: RISK ASSESSMENT

6.3: SH&E MANAGEMENT COMMITTEE

Business survive when got profit and the

profit is proportional to the production.
Human productivity can increase due to the
good quality performance. This good
performance is due to the safety and health of
the human.
Systematic approach is used to manage OSH
according to OSH Act 1994. The Act of OSH
(OSHAct 94) put the responsible or compulsory
on the employer to form and assure SAFE
WORK SYSTEM which covers the workers
exposed the occupational hazard

6.3: SH&E MANAGEMENT COMMITTEE

SH&E Management is the process of planning,

organizing, and controlling to establish the
integrity of safety and health in every single
process and activity certain organization
The Principles of Occupational Safety and
Health (OSH) Management
Effective

managerial control
Delegation of responsibility
Monitoring of performance
Integration of safety and health
Efficient safe working

6.3: SH&E MANAGEMENT COMMITTEE

The Essential Components and Element in

OSH Management
Management

Leadership

Full responsibility
Declaration of Occupational Safety and Health Policy
Policy implementation

Assigning

the responsible
Supervise and practice the safe work

Safety inspection, safe work analysis, audit etc

Engineering explanation
Procurement
The role of supervisor

6.3: SH&E MANAGEMENT COMMITTEE

Safety

training

Motivation
Hazard identification, assessment and control
Safety inspection

Storage

system of accident and incident record

Emergency Response Program (ERP) and first aid
Employee responsibility

6.3: SH&E MANAGEMENT COMMITTEE

Manager and Managing Director Responsibility

The

management is responsible to control the

hazard since it appears due to the occupational
activities effect which is conducted and established
by the management.
The control : according to the Hierarchy of control
The management is responsible to assure the
workplace where is under its supervision and
authority must be physically and mechanically safe.
The management is responsible to occupy its
authority and capability to prevent and avoid any
unsafe action or activity done by the worker.

6.3: SH&E MANAGEMENT COMMITTEE

Supervisor Responsibility
To implement

the procedure and regulation of OSH.

To train all the worker about the OSH.
To inspect the environment and safe work
compliance.
To report all the accident or incident.
To establish Job Hazard Analysis for every
assignment.
To assure that the worker is capable to handle the
equipment or the machine safely.
To manage a department meeting of OSH.
To discuss OSH with the workers including accepting
the comment about OSH.

6.3: SH&E MANAGEMENT COMMITTEE

The Responsible of OSH Officer

Share

the management responsible.

consult and advise the management about OSH
Periodically inspects the plant, machine,
equipment and work operation.
Contribute the new idea, train and instruct the
worker in promoting the safe work system.

6.4: OFFICERS AND COMMITTEE

SH&E committee: Another way to promote safety.

Functions: provide a formal structure where all
can funnel concerns and suggestions about SH&E.
Combination between executive level + technical
level improves the communication and action.
Chairperson can be SH&E officer or not (more
ownership of the committee).
Work identify hazards and take steps to
eliminate them.
SH&E officer functions: as an advisor, facilitator
and catalyst - OSHA, 1994, section 29(2)

6.4: OFFICERS AND COMMITTEE

SH&E committee should:

Suggest

to improve SH&E.
Train the committee member.
Authorize the committee.
Encourage employee involvement.
Be patient and reasonable to time constraint.
Reward progress, participation and partnership.
Train management for SH&E awareness.
Stagger committee memberships variety of
levels.

6.4: OFFICERS AND COMMITTEE

SH&E committee should not:

As

safety cops because management deserve it.

Discuss topics unrelated to SH&E. Stay away from
labor and personnel issues.
Rotate members too quickly. 1 year is norm.
One way communication during the meeting.
Encourage and maintain the equal participation.
Just bring the problems. Have them bring the
solution as well.
Scapegoat seeking. Management is responsible.
Punish. Do hold persons accountable for their
responsibilities

6.5: PERSONAL PROTECTIVE

EQUIPMENT

Last line of defense.

Have to adopt and wear discomfort.
Respirator, coat/ jacket, goggles, gloves and shoes
specified by the task.
Gloves
PVC

abrasion and min cut resistance. Avoid high T

Leather abrasion and min cut resistance
Cotton min abrasion and min cut resistance.
Stainless steel cord (wrapped in synthetic fiber) abrasion
and optimal cut resistance
Butyl rubber heat and some chemical resistance
Chain link / metal mesh max abrasion and cut resistance
Viton rubber heat and all chemical resistance

6.5: PERSONAL PROTECTIVE

EQUIPMENT

Respirator
Mouth

O2>19.5%, single use, PEL > 0.05 mg/m3

Mouth

and nose with chemical cartridge

O2>19.5%, cartridge: [organic] < IDLH and GMC [Cl2,

HCl and SO2] < IDLH

Full

and nose dust mask

face mask with chemical canister

O2>19.5%, N canister higher [gas] exposure.

Self-contained

breathing apparatus (SCBA)

all condition. Capacity between 30 60 min per spec.

6.5: PERSONAL PROTECTIVE

EQUIPMENT

Shoes
Steel-toed

safety shoes
PVC and nitrile knee boots
Puncture-resistant soles
Slip-resistant soles
Electrical resistant material

6.5: PERSONAL PROTECTIVE

EQUIPMENT

Cloth
Jacket
Coverall

suit work thats need to variety of

position.
Splash suit nonflammable chemical splash
Rain coat during rain
Personal fall arrest harness
Vinyl apron resist most chemical

6.6: CHEMICAL SAFETY

Refer back to industrial hygiene.

**MSDS

and CSDS
**Ventilator
**Fume hood

Refer back to chemical process safety

**Release

model
**Relief system

6.7: APPLICATION OF PERMIT TO

WORK

What is the Permit to Work System?

A

Permit to Work System provides a systematic

disciplined approach to assessing the risks of a
job and specifying the precautions to be taken
when performing hot work and/or working in a
confined space.

The permit to work system:

Specifies

the work to be done and the

equipment to be used
Specifies the precautions to be taken when
performing the task

6.7: APPLICATION OF PERMIT TO

WORK
Gives

permission for work to start

Advises occupants of plant building that work is
being performed within their building/ part/
unit.
Provides a check to ensure that all safety
considerations have been taken into account,
including the validity of permits and certificates
and compliance to the policies and procedures
On completion of work it provides a checking
mechanism that all work has been completed up
to the companys satisfaction.

6.7: APPLICATION OF PERMIT TO

WORK

Activities involving routine production and process

operations including startup, changes in operational
modes and shutdowns do not require a Permit to Work.
Normally, the activities of inspectors, surveyors,
engineers, draftspersons and visitors will not require a
Permit to Work, provided their presence in the
operational area is approved in advance by the
Responsible Officer and their activity does not interfere
with plant or equipment, nor are they carrying
potential ignition sources.
Work carried out in designated maintenance (e.g.
University workshops) and construction areas do not
require a Permit to Work.

6.7.1: SAFE WORK PERMIT

The Safe Work Permit is issued as a written

record by the person who is/ are in charge of a
unit, equipment, building area, authorizes a
worker and/or work crew to do a specific job
at that work site.
It identifies what precautions (safe work
practices) were taken and/or will be taken to
ensure that the working conditions are safe for
the type of work to be performed, in a specific
job location, during a specific time interval.
It outlines the safety equipment required and
to be used for that specific job location.

6.7.2: CONFINED SPACE PERMIT

Any area which, because of its location, contents and

the activities performed within it, may be deficient
in oxygen or contain flammable/toxic vapours and
gases.
Limited openings for entry and exit, and
unfavourable natural ventilation and not designed for
continuous worker occupancy.
Confined spaces may include, but are not limited to:
Storage tanks, boilers, pressure vessels, silos
Open topped spaces of more than 1.5m depth, such
as degreasers or pits that are not subject to good
natural ventilation
Pipes, sewers, shafts, ducts and similar structures.

6.7.3: HOT WORK PERMIT

All work with the potential to create a

source of ignition. This includes grinding,
welding, thermal or oxygen cutting or
heating, and other related heat producing or
spark producing operations.

6.7.4: LOCK OUT TAG OUT

All other employees whosework operations

are or may be in areas where energy control
proceduresmay be utilized shall be
instructed about the procedures and
prohibited from attempts to restart to reenergize equipment that has beenlocked
out or tagged out. Employee Safety and
Health will assist in development of these
programs.

6.7.4: LOCK OUT TAG OUT

Retraining shall be provided for allaffected

employeeswhenever there is a change in
their job assignments, a change inmachines,
equipment or processes that presents new
hazards, when thereis a change in energy
control procedures, or when there is reason
tobelieve that there are deviations form or
inadequacies in the knowledge or use of the
energy control procedures.

6.7.5: LINE BREAKING PERMIT

The intentional opening of a pipe, line, or

duct that is or has been carrying flammable,
corrosive, or toxic material, an inert gas, or
any fluid at a volume, pressure, or
temperature capable of causing injury.

6.8: BEHAVIORAL SAFETY

Geller, professional psychologist, used

behavioral safety for the application of
behavioral theories from the field of
psychology to the field occupational safety.

6.8: BEHAVIORAL SAFETY

Behavior safety is the "application of science

of behavior change to real world problems".
BBS "focuses on what people do, analyzes
why they do it, and then applies a researchsupported intervention strategy to improve
what people do.
To be successful a BBS program must include
all employees, from the CEO to the floor
associates.

6.8: BEHAVIORAL SAFETY

To achieve changes in behavior, a change in

policy, procedures and/or systems most
assuredly will also need some change. Those
changes cannot be done without buy-in and
support from all involved in making those
decisions.
BBS is not based on assumptions, personal
feeling, and/or common knowledge. To be
successful, the BBS program used must be
based on scientific knowledge

6.8: BEHAVIORAL SAFETY

A good BBS program will consist of:

Common

goals Both employee and managerial

involvement in the process
Definition of what is expected Specifications of
target behaviors derived form safety assessments
Observational data collection
Decisions about how best to proceed based on
those data
Feedback to associates being observed
Review

6.9: SAFETY AUDIT

Refer back to PSM **compliance audit