PLANT SAFETY

Safety is defined as the condition of being protected from or unlikely to cause danger, risk,
or injury. Safety is very important in order to avoid accident in the plant thus make the process of
the manufacturing to run smoothly. As chemical industry continue to grow in size and complexity,
there have been rise in hazards to which both plant workers and laboratory personnel are being
exposed.

Safety in the process industries, especially chemical industry, cannot be treated as a

separate subject like design, production or maintenance, but it is inseparably interwoven into these
and other activities. It depends on both the technical competence and safety awareness of all staff
and employees.

If all the hazardous chemical properties or capability are not fully understood and
precautions do not taken seriously, accidents could happen anytime during the processes.
Chemicals in any form can be carefully used, handled and stored if their hazardous chemical and
physical properties are well aware and the necessary precautions to be taken including the use of
good personal protective equipment and safeguard are monitored.
Handling

Every chemical substances have special instruction and training that before handling the
chemicals to assure safe handling by the workers. There are four ways that chemical can enter our
body which are skin absorption or eye contact, inhalation, swallowing or ingestion and direct
penetration; which can be either through open cut or injection.

When handling the chemical substance, our part of body must be protected because the
chemical substances may poses many risks including causing the following injuries or diseases:

Allergies
Allergies contact dermatitis
Asphyxiation
Asthma
Chemical burns
Death
Irritant contact dermatitis
Skin cancer
Skin infections

Head Protection
Special headwear is provided for industrial workers to protect against particular hazards.
Safety helmets are provided to protect against impact of chemical splashes, falling objects,
exposure to abnormal heat, contact with high-voltage sources and risk of sideways crushing. Safety
helmet also contains space to hold long hair and prevents its entanglement with machinery;
protects the wearer from rain and extremes temperature; and also shades the eyes.
Other safety headwear includes shot-blasting helmets, air-stream helmets, welders helmets
to which visors or face shields are attached, acoustic helmets for those exposed to high noise
levels, bump caps and scalp protectors for protection against bruising in confined places.

Eye Protection
 The main forms of protection are safety spectacles, safety goggles and shields. Safety
spectacles have toughened glass or plastic lenses in various tints, with plastic or metal frames, and
may have ventilated side shields for protection against low-energy droplets and particles.

Safety goggles which enclose the eyes completely, with or without ventilation, and which
are kept position by an elastic headband, provide more complete protection than spectacles but are
less comfortable to wear. Conditions where goggles should be consider include work in dusty
atmospheres, work in injurious chemicals (in fine sprays or mists form), work with toxic and
irritating gases; and work where impact from large particles are possible.

Respiratory Protection
Respiratory Protective Equipments (RPEs) are of two main types; respirators and breathing
apparatus. Respirators depend on the oxygen in the air surrounding the wearer for respiration and
provide means for removing the hazardous contaminants from the air before it is breathed. They
may not be used in oxygen-deficient atmospheres or in ones that present an immediate danger to
life.

Breathing apparatus provides an independent supply of air or oxygen for the wearer and
does not depend for oxygen on the surrounding atmosphere. It can be used for a wider range of
hazards. There are five main types of breathing apparatus include:

1. Self-contained closed circuit which the exhaled air is passed through a chemical which
replaces its carbon dioxide with oxygen
2. Self-contained open-circuit which supplies air on demand (through a lung-governed valve)
or at constant flow (through a pressure reducer and flow controller) to a full-face mask with
an exhalation valve. For professional use, a limited supply of compressed air is contained in
a cylinder attached to the wearers body
 3. Compressed air-line which is similar to open-circuit apparatus with a small-diameter air
hose from a safe compressed air source replacing the compressed air cylinder, routinely
used in industry for tasks such as cleaning and paint spraying
4. Fresh air hose in which air suitable for respiration is drawn from an adjacent
uncontaminated area through a larger-diameter hose by the breathing of the wearer, with or
without a blower
5. Escape breathing apparatus, a simple form of self-contained breathing apparatus for shot-
duration use which is usually of open-circuit type, with its own small compressed air
cylinder (King, R., 1990)

Body Protection
We should consider the environmental conditions as an important factor that could
endangered the workers lives if it is not be taken seriously. For that reason, the body protection;
the chemical protective clothing has been introduced for safety measurement for the workers while
performing their duties. Chemical protective clothing has been divided into three groups; light,
medium and heavy duty.

Light duty chemical protective clothing generally consists of uncoated cotton or synthetic
fabrics with water-resistant finish, in the form of overalls, laboratory coats and smocks. It is used
by workers who are at slight risk from relatively harmless chemicals.

Medium duty chemical protective clothing consists of an apron of one of several

impervious and resistant materials such as natural or synthetic rubber, PVC-coated fabrics or
leather. These are useful for workers that are exposed to quite a wide range of chemicals, oils and
hydrocarbons.
 Heavy duty chemical-resistant clothing is based mainly on PVC or PVC-coated fabrics in
the form of boiler suits, long surgical coats, bib and brace overalls, leggings and three-quarter-
length suits. Contaminated chemical-resistant clothing should always be washed or hosed down
before the wearer removes it and proper provision must be made for storing, inspecting and
maintaining it. (King, R., 1990)

Hand Protection
Adverse substances usually enter the body through the skin of the hands, particularly
through cuts and abrasion. Many types of gloves, gauntlets and mittens in a variety of materials are
usable to protect the hands from corrosive chemicals and other harmful substances, as well as
abrasion, cuts, extremes of temperature and high voltages.

PVC gloves are available in various types. Smooth-surfaced gloves protects against acids,
alkalis, chemicals, solvents, oils and fats. Glove with a matt surface coating provide better grip and
abrasion resistance. Cotton linings increase comfort and absorb sweat.
Foot Protection
Most safety footwear is designed to protect the toes from impact or crushing in which the
footwear come with a steel-toe protection in case of any heavy or sharp-edges things come in
contact with the toes area. Other hazards against which safety footwear is available include
penetration trough the mid-sole and upper, oil and chemical penetration, slipping, heat and metal
turnings. Anistatic rubber footwear has adequately high electrical resistance to protect against
electrocution hazards while allowing electrostatic charges to dissipate harmlessly.

Chemical Storage and Process Vessels

All flammable gases and flammable liquids (flash point < 40 oC) are assumed capable of
supporting a Vapor Cloud Explosion (VCE). The correct way to store that chemicals substance is
very crucial in order to avoid any form of unnecessary risk. The design and the properties of the
storage tanks should be considered properly in order to eliminate the possibilities of fireball, VCE
and toxic cloud from happening. They should be well insulated by automatic or remotely operated
valves to minimize escapes. The escape of VCE from process vessels should not be ignored
especially from a high-pressure gas-filled equipment and moderate to low-pressure equipment. So
as the possibility of escaping from other parts such as pumps, stirrer glands, heat exchanger tubes
and pipeworks which are more likely to fail.
Transportation
Many accidental releases of hazardous liquids in process plants have occurred at road and
rail tanker loading and unloading stations. This is hardly surprising considering the different
hazards, which concentrate and interact at these points. They include:

Hazards of ignition both from vehicle engines and from electricity

Hazards of overfilling and errors in sequence of valve opening and closing

Hazards of temporary hose and solid pipe connections

Vehicle hazards collisions, error in parking position, unauthorized starting, and damage to
and poor maintenance of vehicles
Loading and offloading should only be allowed at precisely selected sites where necessary
facilities are installed. It should be within but near the perimeter fence, in paved, leveled or
concreted areas. The area must be clearly marked and provided with light roofs and upper side
coverings to protect against sun and driving rain, but without end wall for easy through-transit of
vehicles and good natural ventilation. Only the authorized vehicle to carry the liquids can get
access to the bay. (King, R., 1990)

Housekeeping
Chemicals and volatile flammable liquids should only be stored and handled in authorized
and clearly marked storage, which are tightly sealed. Approaches to be taken for dealing with
spillages of particular hazardous liquids and accumulations of dangerous dust must be clearly
mention in the standing instructions and followed efficiently. Processes that involving hazardous
dusts should only be allowed where there are appropriate local exhaust ventilation and other
facilities needed to protect the worker while carrying out his duty. Proper inspection is required to
the plant to ensure that good housekeeping and regular cleaning are enforced. Exits should not be
blocked for easy movements during emergency situations for instance if any mishap happens while
the processes are still running. Objects must not be placed under safety showers or block access to
fire-fighting equipment.

Clear responsibilities for the receipt, storage and issue of materials used in processes must
be established. Proper arrangements for inventory control, records and security must be made.
MATERIALSAFETYDATASHEETFORETHYLACETATE

I.HazardIdentification:
HazardCategory:Class2flammableliquids,class2severeinjury/eyeirritationsubstance
LabeledContents:

Symbols: Flame,exclamationpoint
Warning: Danger
HazardWarningInformation:
Highlyflammableliquidandvaporproduceseyeirritation
HazardPreventionMeasures:
Placecontainerinawellventilatedarea.
Keepawayfrominflammables.Smokingprohibited.
Avoidcontactwitheyes.

OtherHazards:

II. Composition / Information on Ingredients

English Name: Ethyl Acetate
Synonyms: Ethyl Acetate, Acetic Ether, Ethyl Ethanoate, Acetic Acid Ethyl Ester, Acetic Ester,
Acetoxyethane, Ethyl Acetic Ester
Chemical Abstracts Number (CAS No.): 141-78-6
Percentage for Chemical Ingredient (%): 100
III. FirstAidMeasures:
Emergency and First Aid Procedures:
Inhalation:

1. If the victim is unconscious or unresponsive, take measures to ensure ones own safety
before administering first-aid.
2. Remove the pollution source or the patient to a place with fresh air.
3. If breathing has stopped, apply artificial respiration by trained professionals
immediately. If the heart has stopped, apply cardiopulmonary resuscitation.
4. Seek medical attention immediately.
Skin Contact:
1. Remove soiled clothes, shoes, and leather accessories (such as watchstraps, belts).
2. Use gentle, running warm water to rinse the injured area for more than 10 minutes as
soon as possible.
3. If irritation persists, seek medical attention immediately.
4. The soiled clothes, shoes, and leather accessories should be cleaned before re-use or
disposal.
Eye Contact:
1. Quickly and gently absorb or sweep the excess chemical substances.
2. Open the eyelids immediately and wash the injured eye with running warm water for 10
minutes.
3. Take caution when washing. Do not allow the water containing pollutants to come in
contact with the injured eye.
4. If irritation persists, seek medical attention immediately.
Ingestion:

1. If the victim is losing consciousness, is unconscious or is having convulsion, do not feed

anything through the mouth.
2. Use water to rinse the mouth thoroughly.
3. Do not induce vomiting.
4. Give 240~300 ml of water to the victim.
5. If the victim vomits spontaneously, allow the victim to rinse the mouth and provide water
repeatedly.
6. If breathing has stopped, apply artificial respiration by trained professionals immediately.
If the heart has
stopped, apply cardiopulmonary resuscitation.

Major Disease and Harm Effects: Serious exposure will cause disruption of the central nervous
system inhibition such as short of breath, headache, fatigue, and dizziness.
IV. Fire and Explosion Data

Flammability of the Product: Flammable.

Auto-Ignition Temperature: 426.67C (800F)
Flash Points: CLOSED CUP: -4.4C (24.1F). (TAG) OPEN CUP: 7.2C (45F)
(Cleveland).
Flammable Limits: LOWER: 2.2% UPPER: 9%
Products of Combustion: These products are carbon oxides (CO, CO2).
Fire Hazards in Presence of Various Substances:
Highly flammable in presence of open flames and sparks, of heat. Slightly flammable to
flammable in presence of oxidizing materials, of acids, of alkalis. Non-flammable in
presence of shocks.
Explosion Hazards in Presence of Various Substances:
Risks of explosion of the product in presence of static discharge: Not available. Slightly
explosive in presence of heat. Non-explosive in presence of shocks.
Fire Fighting Media and Instructions:
Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY chemical
powder. LARGE FIRE: Use alcohol foam, water spray or fog.
Special Remarks on Fire Hazards:
Vapor may travel considerable distance to source of ignition and flash back. When
heated to decomposition it emits acrid smoke and irritating fumes.
Special Remarks on Explosion Hazards:
The liquid produces a vapor that forms explosive mixtures with air at normal
temperatures. Explosive reaction with lithium tetrahydroaluminate.

V. Accidental Release Measures:

Personal Protection:
1. Before the polluted area is cleaned up completely, access to the area should be
restricted.
2. Make sure the cleaning work is performed by trained personnel.
3. The personnel should wear appropriate personal protective equipment.
Environmental Protection:
1. The air in the area should be well ventilated.
2. All flammable sources should be extinguished or eliminated.
Report the accident to the safety, health, and environmental protection authorities of the
government.
MethodsforCleaningUp:
1. Donotcomeincontactwiththereleasedchemical.
2. Avoidthereleasedchemicalfromenteringthesewers,drains,orsealedspaces.
3. Stoporreducetheleakageundersafeconditionsifpossible.
4. Usesand,earth,orotherabsorbentsthatdonotreactwiththereleasedchemicalto
blocktheleakage.
5. SmallQuantity:Useanabsorbentthatdoesnotreactwiththereleasedchemicalto
absorb.Thepollutedabsorbentbecomesasharmfulasthereleasedchemicaland
shouldbeplacedintheappropriatecontainerthatiscappedandlabeled.Usewater
tocleanuptheleakagearea.Thesmallreleasemaybedilutedwithalargequantity
ofwater.
6. LargeQuantity:Contactthefirefightingdepartment,emergencyresponse
department,andthesupplierforassistance.

VI. Physical and Chemical Properties:

Physical state and appearance: Liquid.

Odor: Ethereal. Fruity. (Slight.)
Taste: Bittersweet, wine-like burning taste
Molecular Weight: 88.11 g/mole
Color: Colorless.
pH (1% soln/water): Not available.
Boiling Point: 77C (170.6F)
Melting Point: -83C (-117.4F)
Critical Temperature: 250C (482F)
Specific Gravity: 0.902 (Water = 1)
Vapor Pressure: 12.4 kPa (@ 20C)
Vapor Density: 3.04 (Air = 1)
Volatility: Not available.
Odor Threshold: 3.9 ppm
Water/Oil Dist. Coeff.: The product is more soluble in oil; log(oil/water) = 0.7
Ionicity (in Water): Not available.
Dispersion Properties: See solubility in water, diethyl ether, acetone.
Solubility: Soluble in cold water, hot water, diethyl ether, acetone, alcohol, benzene.
VII.Stability and Reactivity:

Stability: Stable under normal conditions

Special Conditions of Hazardous Reaction:
1.Strong oxidants (nitrate, perchlorate): increased risks of fire and explosion
2. Strong acids (sulfuric acid, fuming sulfuric acid, chlorosulfonic acid):
decomposition reaction to release heat
3.Potassium t-butoxide: flammable.
4.Lithium aluminum hydride, 2-chloro methyl furan: explosive

Conditions to Avoid: sparks, static electricity, fire source, moisture

Incompatibility: strong oxidants, strong acids, potassium t-butoxide, lithium aluminum
hydride, 2-chloro methyl furan
Hazardous Decomposition Products: ethanol, acetic acid

VIII. Toxicological Information:

Exposure route: inhalation, skin contact, eye contact, ingestion

Symptoms: irritation, headache, dizziness, sensation of intoxication, dry skin
Acute Toxicity:
Skin:
1. No Irritation
Inhalation:
1. Vapor irritating to nose, gums, and pharynx.
2. Exposure to 400 ppm for 3-5 minutes will cause irritation to human body.
3. Significant exposure will cause symptoms of the central nervous system
problems such as short of breath, headache, drowsiness, and dizziness.

4. One case of death was caused by luminous paint containing 80% ethyl
acetate in a truck. It was discovered that the exposure caused hyperemia of
upper respiratory tract, spleen, kidney, and lungs.
Ingestion:
1. Nausea, vomiting, short of breath, headache, drowsiness, dizziness, and
other symptoms of the central nervous system problems.
2. Due to the release of ethanol in the body, the ingestion of a large quantity will
cause shock and death.
Eye:
1. Vapor and liquid will irritate the eyes. 40 ppm of the vapor
will lead to irritation. LD50 (test animal, absorption route):
5600mg/kg (rat, ingestion)
LC50 (test animal, absorption route): 16000 ppm /6H (rat, inhalation) 400ppm/
 (human, eyes): irritation
Chronic:
1. Chronic exposure at the concentration of 4,200~13,900 ppm will cause slight
irritation to the eyes.
2. 10% solution does not cause skin irritation to the general public, but will to
hyper-allergenic people.
3. Ethyl acetate causes chronic injury to mammals.