Health and Safety in the Production Plant Environment

health and Safety in the Production Plant Environment4.1INTRODUCTIONEnvironmental and base hit be the aspects that conduct to be considered in any merchandise plant as these aspects could affect the production work on, human health, and environment. Raw textiles, product, byproduct, and equipment be the most important elements included in safety mea convinced(predicate)ment of production plant. In this chapter, every element that could be danger to human and environment are discussed for example how raw materials and equipment could be a threat to human and how by-product could be a threat to environment. This chapter will be discussed on how to apply and implement Hazard Identification, Risk Assessment and Risk Control (HIRARC) according to designated plant. Enforcing the fair play of Occupational Safety and Health, HIRARC are greatest important.4.2SAFETY CONSIDERATIONIn order to maintain optimum productivity of plant production, employee and employers have to work toge ther to ensure a safe work place for manpower activities. Plus, the need of safe work place environment and safety consideration to cheer populate from any hazard are utmost important. Efficient method to rank the risk involving process and implement the most practical and applicable measure to slim down and manage the risk is by implementing Hazard Identification, Risk Assessment and Risk Control (HIRARC).4.2.1 Objective of Hazard Identification, Risk Assessment and Risk Control (HIRARC)HIRARC is a fundamental of basic risk management in management, operation, and practice of planning of a business. The purposes of HIRARC are as followsTo identify any element that could be hazard to employee and othersTo consider the chances of any harms to be hazard in the circumstances of a particular case and possible sourness obtained from those harmsTo enable employee planning an optimum safety measures to ensure the risks are controlled all the time4.2.2.1 Material Safety Data Sheet (MSD S)MSDS is list of information on the hazards, safety and emergency measures cerebrate to particular products. All the information about the product and by product will be list in this sheet and the hazard of the product will alike be identified.4.2.2.2 Hazard IdentificationsHazard identification doer the identification of unwanted proceedss that brings to materialisation of the hazard and the mechanism by which those unwanted events could occur. In other word, to identify hazard that can wooing injury exist around the plant which can be separate into three main groups, health hazards, safety hazards, and environmental hazards. Therefore, it can be simplified that there are three pillowcases of common accident base on the past study. The utmost accident that happened in chemic plants is fire, followed by explosions and toxic release.4.2.3 chemical substance substance substance Hazard and Risks in the WorkplaceIn chemical safety term, hazard refers to the inherent hazardous p roperties of a chemical or chemical operation, while risk generally means the likelihood of the hazardous properties of a chemical that whitethorn cause harm to the people surrounding and the severity of that harm. The risk dealing with chemical or in a chemical operation depends on the inherent hazard, the running(a) environment, physical form of the chemical baffling and the method of handling and lastly the operating outgrowths.4.2.4 Chemical Hazards of Vinyl Acetate Monomer (VAM)VAM is a flammable, activated, colourless liquid that is partly soluble in water system. At high levels, VAM odour could be sharp and awful while it has fruity smell when at lower levels.FlammabilityVAM is a flammable liquid with flash point is to a lower place 37C. It form flammable desiccation when mix with air at room temperature. Plus, its vapours are heavier than air and may travel a massive distance to an ignition source very much(prenominal) as a flame or electric spark and then flash b ack.ReactivityVAM is a reactive molecule and it could polymerize uncontrollably if did not handled or stored properly. Pro bulkyed or intense exposure to heat, sunlight, ultraviolet light or x-rays may result in polymerization. Furthermore, spontaneous polymerization may also result from exposure to amines, strong venomouss, alkalis, silica, alumina, oxidizing agents. However, hydrolysation in water not considered as hazardous reaction.Health EffectsVAM is irritating to the upper respiratory tract, skin and eyes. Potential hazard to eyes are irritation, redness and swelling but cause a low acute perniciousness by all routes of exposure. Report based on lab experiment verbalize that high level inhalation exposure to VAM in animal results in deaths from pulmonary edema. Moreover, lifetime drinking water or inhalation exposure to VAM shown cancer effects in laboratory animals which tumor reported localize straight to attached part with VAM. Tumor observed at high exposure concentrat ions are not considered to be relevant to humans exposed to low concentrations down the stairs typical use conditions.Environmental EffectsVAM tends to stay in the air where it is rapidly degraded by photochemical course of instructionways. It has 0.6 days atmospherical half-life and 7 days hydrolytic half-life at pH 7 and 25C. Volatilization of VAM could occur once it is released to soil or water. In case of effect of VAM to water, VAM partitions mostly to the water where it infragoes hydrolysis and it is readily biodegraded by either anaerobic or aerobic mechanisms. Plus, VAM is considered to be moderately toxic to aquatic organisms. In conclusion, VAM considered non-harmful to environment.4.2.5 Chemical Hazards of Acetic AcidAt temperature above 16.7 C, acetic virulent is described as clear, colourless, combustible liquid with a pungent odour which is smell like vinegar.FlammabilityAcetic acid has a flash point of 39 C. Autoignitions temperature of acetic acid is at 427 C and dilute acetic acid solutions are not combustible. Fire involving acetic acid should be fought upwind and from the maximum distance possible. Moreover, vapour explosion of acetic acid may occur indoors, outdoors, or maybe in sewer. vapour travel to a source of ignition and flash back.ReactivityOverall, acetic acid is uns display panel at heating and freezing temperature. The vapour of acetic acid will form explosive mixtures with air. Plus, reaction of acetic acid with chromic acid, ammonium nitrate, sodium peroxide, nitric acid, phosphorus trichloride, or other oxidizers could cause fires or explosions. In case of hazardous decomposition, toxic gases like carbon dioxide and carbon monoxide may be released as acetic acid heated to decomposition. In concentrated form, acetid acid is highly corrosives.Health EffectsExposure to acetic acid may occur through inhalation, ingestion, skin contact and absorption through the skin. Based on lab experiment, glacial acetic acid is corrosive to tissues while concentrated acetic acid can cause moderate to severe burns. In addition, vapour acetic acid also can cause eye, skin, mucous membrane, and upper respiratory tract irritation upon exposure. In case of effect on humans, acetic acid may irritate eyes, mucous membrane, upper respiratory tract and skin.Environmental EffectsAcetic acid environmental effects depend on the concentration and duration of exposure. It can be a threat to plants, animals, and aquatic as it comes in high concentration. Acetic acid exposed to environment as a vapour and it also soluble in water but it degrades rapidly into harmless substance once releases to environment.4.2.6 Chemical Hazard of ethylene ethylene is a gaseous with boiling point of -104 C at atmospheric pressure and it is stored in the liquid state under high pressure or at low temperature. Plus, it has solubility in water of 131 mg/l at 20 C.FlammabilityEthylene gas is highly flammable and explosive.ReactivityEthylene is reactive su bstances because of double bond structure dedicate in the alkenes. Due to its high reactivity, ethylene may undergo a lot different reactions much(prenominal) as oxidation, halogenation, alkylation, hydration, and polymerisation.Human HealthEthylene has low toxic level and risk to human health is minimal. It is identified from occupational exposure, general public exposure, and instanter or indirectly exposure to environment but exposure to the gas can cause dizziness, lightheaded, and perhaps pass out. However lab experiment stated that ethylene is metabolised to ethylene oxide which can cause cancer from carcinogenic and mutagenic effect.Environmental EffectDue to its physical and chemical properties, ethylene is released mainly into the atmospheric compartment. About three quarters of atmospheric ethylene originates from natural sources, while one quarter is from anthropogenic sources. The main anthropogenic release is from burning of hydrocarbons and biomass.4.2.7 Chemical H azard of OxygenOxygen is an odourless, colourless, non-flammable gas. It is an oxidizing gas and could accelerates combustion. Oxygen is stored in cylinders at high pressure.FlammabilityOxygen is a non-flammable gasReactivityOxygen vigorously accelerates combustion. well-nigh non-combustible materials could burn with presence of an oxygen enrich atmosphere which is greater than 23%. Oxygen may form explosive compounds as exposed to combustible materials such as oil, grease, and other hydrocarbon material. Plus, heat applied on a container with oxygen can cause pressure increase hence cause container rupture.Human HealthIf oxygen is inhaled as much as 80% or above at atmospheric pressure for more than a few hours, it may cause nasal stuffiness, cough, sore throat, chest pain, and breathing difficulty. Moreover, breathing pure oxygen under pressure may cause lung damage and also central offensive system effects which cause dizziness, poor coordination, tingling sensation, visual and hearing disturbances, muscular twitching, unconsciousness and convulsions.Environmental EffectHighly concentrated sources of oxygen shape up rapid combustion and therefore are fire and explosion hazards in the presence of fuels.4.2.9 Personal Protective EquipmentPPE is equipment that will protect the user against safety at work. By this, that person will be protected against one or more risks arising from chemical or chemical operation to the persons health or safety. OSHA 1910.132 requires employers to determine the proper personal over antifertility equipment for each hazard and to train any employees the guidelines how and when to wear safety protective equipment. Example of personal protective equipment listed for the use of handling of chemicals can be classified into avocation categories such as protective fit out, hand and foot protective gears, eye and face protective equipment and last but not least the respiratory protective equipment. This protective equipment may sa ve your life in any danger situation.4.2.9.1 Protective uniformProtective clothing may refer which gear that literally can protect body or personal clothing from contact with dangerous chemical or any spread of contamination in workplace. This may include gowns, aprons and overalls. This chemical resistance that may affect the quality of the protective clothing are the resistance to degradation of the chemical due to the spread of chemical and the permeability of the chemical.Proper selection of protective clothing may result in a better in safety and health such as any dangerous chemical operations depends on the risks involved. Suitable material of protective clothing should be in good quality and appropriate form in order to go forth protective if any danger occurred. Handling of chemical is a risk that may happen if not handled it properly, protection can be achieved by the personal clothing such as gowns and overalls made of synthetic material based of terylene or nylon with a water repellent finish.4.2.9.2 Hand Protective GearsHand protective gears may protect the hand and arm from any spills of the chemical and by prevent the spread of contamination. Generally gears are gloves used in industry. The selection of gloves usually must be based on the hazard occurred in the industry. In production of plant typically involved dangerous chemical when operating the process. In consideration, reference should be considered in order to categorise based on the chemical resistance properties and physical characteristic of the glove. The Chemical resistance, thermal protection and mechanical strength should be considered when in any different path of industry. Chemical resistance of the protection level depends on the glove material itself, the method of construction and thickness of the gloves. It should be aware that chemical resistance belongings of gloves may be adversely affected by abrasion and heat. For thermal protection gloves may made from neoprene whi ch can be used for handling oils at low temperatures and cotton gloves can operate against moderate heat level.4.2.9.3 Foot Protection GearsFoot protective gears protect the foot and leg from any dangerous chemical and to prevent the spread of contamination. Foot protection gears are shoes or boots. The footwear is selected based on the hazard involved and from the working environment. in general in plant, it is best to wear a safety boots, in order to prevent any unsafe accident occur. The type of injury should be related to the risk of the injury, the foot should at least be protected by well-made shoes. In cases it depends on the risk of the parts of the body being injure as example of ankle, knee or thigh.4.2.9.4 Eyes and Face Protection EquipmentIn process of chemical operation, eye or face might be need a protective equipment in order to prevent any hazard of splashes of hot or any dangerous liquid chemicals, flying target area as example of bursting containers, any dust or vapour that might be harmful to eye and face and lastly the intense light from the ray of light emitted to the chemical process. By that, safety goggles should be wearing during the process operation. Other than that, face shield with adjustable head harness that may protect the face but not fully at the ayes area. Besides, eye and face protective equipment is also available in tints and shades for the protection of radiation or intense light from the chemical operation.4.2.9.5 Respiratory Protective EquipmentThe potential of exposure in MEK plant may achieve 200 ppm, therefore the use of respiratory protective equipment is important in order to prevent the harmful of gas through the respiratory system. Respiratory protective system equipment also used to provide breathing air when working in any dangerous chemical environment where the presence of chemicals in air at high concentration. Be sure to consider all potential exposures when working in place where dangerous chemical expo sure occurred. Combination of filters, prefilters or cartridges to protect against different types of form such as mist, vapour, dust and other chemical mixtures must be relates. Exposure of 3000 ppm and above, the situation is absolutely dangerous to life and health. The range of exposure must be less than 3000 ppm and if possible use a NIOSH canonic self-contained breathing apparatus just to make sure the better quality and protection approved by the NIOSH.4.3RISK ASSESSMENTRisk analysis that is most effective is one that uses likelihood and severity in qualitative method. The result are present in a risk matrix is very effective method of communicating the distribution of the risk at the plant area workplace. The likelihood of an event occurring range from most likely to inconceivable are where the value came from. As shown in the table below of likelihood using the following values flurry 4.1 LikelihoodSource DOSH HIRARC GuidelineThe severity is categories into five elements. T he increasing level of severity to an individuals health, property and environment that is present in the table belowTable 4.2 SeveritySource DOSH HIRARC GuidelineTable 4.3 Likelihood vs SeveritySource DOSH HIRARC GuidelineThe priority is determined based on the following risk category for necessary actions. Table 4.4 Risk CategorySource DOSH HIRARC Guideline4.4RISK CONTROL PREVENTIVE MEASUREHIRARC last step process is risk control. The assessed hazard will be assigned by risk control step for every control needed. Suitable control requires proper evaluating and selecting long and short term controls. The short-term measures to protect workers are implementing and the long term controls can be put in place when reasonably applicable. The five type of control started from elimination, substitution, engineering control, administrative control and last defences is personal protective equipment (PPE) which used when controls measure practicable and where additional protection is needed . The hierarchy of control to be applied is shown below.Figure 4.1 Hierarchy of Control (Source DOSH HIRARC Guideline)4.4.1 EliminationElimination is the most effective hazard control which the step is by eliminating the hazard or in other words, physically removing it. Taking example when an employee is doing a job high above the ground, the hazard can be eliminatedby moving the piece they are working on to ground level to eliminate the need to work at heights.4.4.2 SubstitutionSubstitution is a preventive step involves replacing some designate that might produces hazard with something that might not. This step quite similar to elimination but it required replaced task for the eliminated task. Taking example of process of replacing raceway based paint with acrylic paint.4.4.3 Engineering ControlsThe main quarry of engineering controls is alternatively isolates people from hazards than eliminate the hazards. Capital costs of engineered controls tend to be higher(prenominal) than less effective controls in the hierarchy. However they may reduce future costs. For example, building a work platform is a chosen step rather than purchase, replace, and maintainfall arrestequipment. Plus, isolation could create a physical barrier between person and hazard. For example, using a remote control is much safer than manually control.4.4.4 Administrative ControlsDefinition of administration controls is changing the way people work. This control types need an organization that could handle all the employees. The examples of its steps are including procedure changes, employee training, and installation of signs and warning labels. Administrative controls do not remove hazards, but limit or prevent peoples exposure to the hazards, such as completing driveway constructionat night when fewer people are driving.4.4.5Personal Protective EquipmentPersonal protective equipment(PPE) includes gloves,respirators, hard hats,safety glasses,high-visibility clothing, and safety footwea r. PPE is the least effective means of controlling hazards because of the high potential for damage to render PPE ineffective. Moreover, some PPE, such as respirators, increase physiological effort to complete a task and, therefore, may require medical examinations to ensure workers can use the PPE without risking their health4.5RELEVANT OSH LEGISLATION AND REGULATIONThe legislation and regulation for occupational, safety and health need to be obey for every processing plant. The act and regulations ensuring both employer and employees to take safety and health issue in working area seriously. Safety and health objective is to provide a good safe working condition and to control plant or factory operation with respect to the safety, health and welfare of the employer and employee. The regulations need to be follow which is The Factory Act 1948 and Control of Industrial Major Accident Hazard (CIMA) 1996. Manufacture, Storage and Import of furious Chemicals Rules, 1989. As stated unde r OSHA 1994 regulation is Employers Safety and Health General Policy Statement 1995, Control of Industrial Major Accidents Hazards 1996, Safety and Health Committee 1996, Classification, Packaging and Labelling of Hazardous Chemical 1997, Safety and Health Officer 1997 and Use and Standards of Exposure of Chemical Hazardous to Health 2000. Duty to implement safety and health act are under responsible of both employer and employees and Occupational Safety and Health Act OSHA 1994 summarized the duties of employer and employees as below.Duties of EmployerProvide and maintain safe plant and system of work put to work arrangement for safe use operation, handling, storage, and transportation of plant and substances.Provide instruction, information, training and supervision.Provide and maintain safe pace of work and means of access to and turn up from any place of work.Provide and maintain safe and Healthy working environment and adequate welfare facilities.Duties of EmployeesReasonable care for safety and health him/herself and others.Co-operate with employer and others. put one across and use PPE.4.6MAJOR EQUIPMENT AND POTENTIAL INCIDENT IN PROCESS PLANTTable 4.5 HIRARC Major Equipment in Process PlantTable 4.6 HIRARC Potential chance in Process PlantHazard IdentificationRisk AnalysisRisk ControlNoHazard IdentifiesPotential AccidentAccident attendantTypes of injuryLikelihoodSeverityRisk (Likelihood x Severity)Preventive Control measurePerson in charge1PipingLeakage, Rupture gushFatalities4416(High)Detector Preventive MaintenanceInstallation, Operation and Maintenance