Professional Documents
Culture Documents
stage.
Identify the stages of industry where there
could be a potential hazard.
Classified into 3 categories
Relative safe
Potential hazard – Toxic, Flammable, explosive
Serious hazard
Laboratory- safety- fume hood, small quantity
Precautions required- flammability, poisonous reaction, runaway
reactions etc.
Nitrates, ether compounds , unstable compounds enclosed electric
heaters, adequate ventilation, MOC
Halogens, substance like metallic sodium potassium, lithium
bromide etc
Solvents of low flash point and high toxicity
Identify the 3 categories based on the information available at the
development stage.
Try for alternate – route, material, MOC, process…
Freeze the PFD in detail of each step of the process
Conduct a HAZOP study at the development stage.
Alternate process could be developed which may
be both operation and process wise more safe.
Repeated discussion with all the stake holders like
engineering, project, manufacturing , Safety and
environment would yield a balance approach to
the well designed plant
Raw material storage and warehousing.
Development laboratory and analytical laboratory.
Process Plant
Ancillary operation of the process.
Utility and services
Reaction Utilities
Isolation Drying
Reaction
Isolation
Drying
44
44 Mechanical
Process
Design
Accidents (%)
22
12
11
5 5
Mechanical Operator Error Unknown Process Upsets Natural Hazards Design Sabotage and Arson
The design of chemical processes and products with specific attention to
Eliminating hazards from the manufacturing process rather than relying on the
control of these hazards (Risk assessment based on ICH guidelines Q9)
“Once you get something dirty, the only way to get it clean is to make
something else dirty.”
The best way to keep the world clean is to not get it dirty to begin with.
Inherently
Safer
Design
Green Chemistry
and Engineering
User Requirement Specification (URS)
Functional Design Specification (FDS)
Design Qualification (DQ)
Stage wise Inspection and Factory
Acceptance Test (FAT)
Site Acceptance Test (SAT)
Installation Qualification (IQ)
Operational Qualification. (OQ)
Process Qualifications (PQ)
SEMI CONTINUOUS
BATCH REACTOR REACTOR
PROCEDURAL
• Maximum adiabatic pressure for 100% reaction is 150 psig, reactor
(normal followed design pressure is 50 psig) design to 225 psig.
• Gradually add limiting reactant with temperature control to limit
potential energy from reaction
• Train operator to observe critical operating limit
INHERANT
• Develop chemistry which is not exothermic, or mildly exothermic
Maximum adiabatic exothermic temperature > boiling point of all
ingredients.
Minimize
Use small quantities of hazardous substances or energy
• Operate below boiling point in case of exothermic reactions.
• Green chemistry/Catalytic conversions.
• Reduce hold time
• Intermediate storage reduce
• Piping minimal.
• Process equipment appropriate
• Split steps into smaller operations.
BENEFITS
• Reduced consequence of incident (explosion, fire, toxic material release)
• Improved effectiveness and feasibility of other protective systems – for example:
Secondary containment
Reactor dump or quench systems
Large
Rupture
Disk
A
B
C Condenser
D
E
Distillate
Receiver
Steam
Refrigerated
Brine
Water Return
Water Supply
Condensate
Selecting Technology? Plant Design? Equipment Details? Operations?
Best answer?– All levels!
Inherently safer design is not a meeting.
Inherently safer design is a way of thinking, a way of approaching
technology design at every level of detail – part of the daily thought
process.
Lack of maintenance schedule and proper upkeep of the mechanical and electrical systems.
Frequent check and maintenance of the vent system including flame arrestors.
Solvent handling and spillages ( use of drums instead of piped tanks and pumps).
documents.
Over period of time there could be some operational best practices observed. This
should be recorded and trained to all concerned to ensure more safety in operation.
It is a tendency that a set of equipment may be used for a different purpose than
originally intended to. It is important that the complete review from URS to IQ and
A. Product safety
B. Process safety.
C. Operational safety
D. Plant safety