chemical process safety what chemical engineering students
TRANSCRIPT
2008 SACHE FACULTY WORKSHOP
Chemical Process Safety What Chemical Engineering Students
Need to Know
September 14-17, 2008
Hosted by:
Rohm & Haas, Company, Croydon, PA Sunoco Inc., Philadelphia, PA Arkema Inc., Philadelphia, PA
Sponsored by:
AICHE/CCPS/Safety and Chemical Engineering
Education (SACHE)
3
Workshop Staff
Workshop Director: Ronald J. Willey
Professor
Department of Chemical Engineering
Northeastern University
Boston, MA
Rohm and Haas Company Kathleen Kas
Rohm & Haas Company
3100 State Road
Croydon, PA 19021
Sunoco, Inc. Andrew Slivjak
Sunoco, Inc. (R&M)
4701 Bermuda St.
Philadelphia, PA 19137-1193
Arkema, Inc. Rich Matusewicz
Arkema Inc.
900 First Ave
King of Prussia PA 19406
AIChE-CCPS representative: Scott Berger
American Institute of Chemical Engineers
Center for Chemical Process Safety (CCPS)
Three Park Avenue
New York, NY10016
Copyright Statement Copyright @ 2008
American Institute of Chemical Engineers
3 Park Avenue, 19th Floor
New York, NY 10016-5991
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, except for classroom use, without the prior permission of the copyright owner.
It is sincerely hoped that the information presented in this document will lead to a better
understanding of process safety concepts among engineering students and an even more
impressive safety record for the entire industry; however, neither the American Institute of
Chemical Engineers, its consultants, CCPS Subcommittee members, their employers, their
employers officers and directors, nor Northeastern University, Rohm & Haas Company, Sunoco,
Inc. or Arkema, Inc. members of its faculty or staff, their assistants or consultants warrant or
represent, expressly or implied, the correctness or accuracy of the content of the information
presented in this document. As between the American Institute of Chemical Engineers, its
consultants, CCPS Subcommittee members, their employers, their employer=s officers and
directors, Northeastern University, Rohm & Haas Company, Sunoco Inc., &Arkema members of
its faculty or staff, their assistants and consultants, and the users of this document, the user
accepts any legal liability or responsibility whatsoever for the consequence of its use or misuse.
Acknowledgements
This package was prepared for use by SACHE (Safety and Chemical Engineering Education)
members.
CCPS appreciates the work of the contributors, the workshop staff, Rohm & Haas Company,
Sunoco, Inc., andArkema Inc. and the direction and guidance of the Undergraduate Education
Committee.
Undergraduate Education Committee of CCPS
CHAIR:
Wendy Smades
Email [email protected]
CO-CHAIR:
Bob Rosen, BASF Corporation (retired)
COMMITTEE MEMBERS:
LowelAplebaum, AIChE
Scott Berger, AIChE
Robert Bethea, Texas Tech University
John Birtwistle, RRS Engineering
John Blouin, USEPA
James T. Cobb, University of Pittsburgh
Stephen Coe, Irving Oil Limited
Ken Cox, Rice University
Daniel A. Crowl, Michigan Technological University
Susan R. Cyganiak, Pharmacia Corporation
Ron Darby, Texas A&M University
John Davenport, CCPS emeritus
Art Dowel, Rohm and Haas
Stan Grossel, Process Safety & Design, Inc.
Dennis Hendershot, Retired Rohm & Haas
Robert Hesketh, Rowan University
Robert Johnson, Unwin Company
Christine Kelly, Syracuse University
Brian Kelly, CCPS emeritus
NirKeren, Iowa State University
Jim Klein, Dupont
Jean-Paul Lacoursiere, PE, Univ. de Sherbooke
Joseph F. Louvar, CCPS StaffConsultant)
Thomas R. Marrero, Univ. of Missouri
Georges A. Melhem, ioMosaic Corporation
Michelle Middleton, AIChE
David A. Moore, AcuTech Consulting Group
John N. Murphy, University of Pittsburgh
Nahan Nguyen, USEPA
Bob Ormsby, CCPS emeritus
Oscar Pagola, Argentina AAIQ
Karen Person, AIChE
Ralph W. Pike, Louisiana State University
Bob Rosen, Retired BASF
John Schaab, Intel
Steve Selk, CSB
Thomas O. Spicer, University of Arkansas
Adrian Sepeda, CCPS emeritus
Amy Theis, Fauske and Associates, LLC
Tony Thompson, CCPS emeritus
Vincent Van Brunt, Univ. of South Carolina
Jan Wagner, Oklahoma State University
J. Reed Welker, University of Arkansas
Vince Wilding, Brigham Young University
Ronald J. Willey, Northeastern University
John Yacher, NIOSH (retired)
Liu Yi China Univ. of Petroleum
6
Sache Product List Period Number Title Author
1991 1 Problem Set and Instructors Guide Welker/Springer
1992 2 Explosions (slides and test) Welker
3 Industrial Hygiene (course outline) Bethea
Text 4 Engineering Controls for Industrial
Hygiene (course outline)
Bethea
Text 5 Process Dynamics and Control (prob) Crowl
6 Process Hazards Management (video) Chevron
7 HAZOPS (video) JBF
1993 8 HAZOPS-A Team in Action (video) Chevron
Text 9 Hazard Evaluation Manual (text) Cyanmid/Page
10 Tank Failures (slides and text) Willey
11 Fires (slides and text) Welker/Springer
12 Explosion Proof Electrics (slides and
text)
Cyanamid/Page
Text 13 Stoichiometry (problem set) Crowl
Text 14 Kinetics (problems) Willey
1994 15 Explosion Suppression (video and text) Fenwal/Louvar
16 PSM, Flixborough and Pasadena (slides
and text)
Bethea
17 Nitroaniline Reactor Rupture (slides) Willey
Text 18 Unit Operations Lab. Safety (text) Crowl
19 Seveso (slides and text) Willey
1995 20 Dust Explosion Control (video slides
text)
Louvar/Schoeff
21 Toxicology and the Chemical Engineer
(slides and disk)
Welker/Springer
Disk 22 Consequences of Operating Decisions
(lecture on disk)
Cobb
Text and
Disk
23 Industrial Hygiene and the Chemical
Engineer (slides, text and disk)
Springer/Welker
24 Process Design (problems on disk) Crowl et. al.
1996 25 Phillip’s Explosion (video and disk) Bethea
26 Inherently Safe Plants (slides and text) Kubias
27 Utilization of SACHE Products (lecture) Cobb
Text 28 Thermodynamics (problems) Welker
1997 29 Relief System Design Guide (text) Darby
30 Properties of Materials (slides and text) Willey
CD 31 Informal Safety Review (CD ROM) Kubias/Louvar
Text 32 Computer Based Problems (disk) Crowl
Disk 33 HAZOPS – Software and text Wagner&Dyadem
Disk 34 Utilization of SACHE Products (disk) Cobb
7
Period Number Title Author
1998 35 Emergency Response Planning (video and
text)
Bethea
36 The Human Health Risk Assessment
Process (slides and disk)
Jayjock
Disk 37 Risk Assessment (disk) Wagner
1999
CD
38 Explosion Research and Bldg. Vents
(video and CD ROM)
Howard/Louvar
Disk 38.5 Potential Accidents for Safety Systems
(disk)
Hendershot/Dowell
39 Bhopal (slides, video and text) Willey
40 Reactive Chemicals (video) Willey
40.5 LPS CD-ROM with Folio Hendershott/Freeman
CD 41 NIOSH Guide for Chemical Hazards
(CD)
Yacher
2000 42 Explosions (video and text) Welker
Text 43 Mass Transfer (problems - text) Willey
CD 44 Design for Over and Under Pressure (CD
ROM)
Grossel/Louvar
CD 45 Polystyrene Reactor Runaway (CD-
ROM)
Willey
2001 46 Fire Behavior and Protection (produced
via product 55) (CD)
Welker
CD 47 Methacrylic Acid Tank car Explosion
(CD-ROM)
Willey
Disk 48 HicksonPharma (Disk) Birtwistle
CD 49 Vapor Cloud Dispersion Modeling (CD) Darby
50 Piper Alpha (video and text) Willey
2002 51 Risk Assessment (CD-ROM) Pike
52 Experiments for Runaways (CD-ROM) Darby
53 Problems, Volume 2 (CD) Welker, et. Al.
54 Flixborough (CD-ROM) Sterling
55 Fire Protection Concepts (DVD) Welker
56 AIChE Design Problem Solution for 2002
(CD-ROM)
Horsch/Louvar
NOTICE ALL OF THE FOLLOWING
PRODUCTS ARE ON THE
SACHE.ORG SITE
2003 57 Mini Case Histories Louvar
58 The Hazards of Hydroxylamine; Case
History
Christine Kelly/John
Birtwistle
59 SHE Text for Textbooks Louvar, et. al.
60 Practical Design Practices for Relief
Valve Sizing
Sterling/Parvin
2004 61 Consequence Modeling Wagner
8
62 Transportation Case Histories Willey
63
ioMosaic
64 Green Engineering Schonnard
65 Metal Structured Packing Fires Mark Roberts
66 Improving Communication Skills Bethea
** Guidelines for Design Solutions for
Process Equipment Failures
CCPS Book
2005 67 Emergency Relief System Design for
Single and Two-Phase Flow
Darby
68 Electronic Version: Problem Set – Vol 1 Wagner
69 Electronic Version: Problem Set – Vol 2 Willey, Crowl,
Welker, and Darby
70 Mach II (Digital Solutions)
71 Experiments for Runaways Darby
72 Chemical Reactivity Hazards Johnson
73 Introduction to BioSafety Schwartz
74 Simplified Relief System Design Package Kitchen
75 University Access to SuperChems Melhem
2006 76 Design for Overpressure and
Underpressure Protection
Grossel& Louvar
76 Dust Explosion Prevention and Control Louvar &Schoeff
77 Inherent Safer Design Hendershot
78 Student AIChE Design Problem Solution
(2002 Problem)
Horsch, Louvar,
Wehman
2007 79 CCPS Process Safety Beacon Archive Spicer
80 Piper Alpha Lessons Learned Louvar
81 Properties of Materials Willey
82 Rupture of a Nitroaniline Reactor Willey
83 Static Electricity I -- Everything You
Wanted to Know about Static Electricity
Rothschild
84 Venting of Low Strength Enclosures Howard, Louvar
2008 85 Inherently Safer Design Conflicts and
Decisions
Hendershot, Murphy
86 Risk Assessment Pike
87 Seminar on Tank Failures Willey
88 Seveso Accidental Release Case History Willey
89 Static Electricity as an Ignition Source Manjunath
2009 90 Process Hazard Analysis: An Introduction Mody
91 Process Hazard Analysis: Process and
Examples
Mody
92 Reactive and Explosive Materials Willey,Louvar
9
Workshop Instructors, Speakers, and Staff Associates
Tom Archibald
Rohm and Haas Company
Philadelphia, PA
Scott Berger
American Institute of Chemical Engineers
Center for Chemical Process Safety (CCPS)
3 Park Avenue, 19th Floor
New York, NY 10016-5991
646-495-1370
Daniel A Crowl
Michigan Tech University
1400 Townsend Drive
Houghton, MI 49931
906-487-3221
Glenn E.Hessler
Sunoco, Inc. (R&M)
4701 Bermuda St.
Philadelphia, PA 19137-1193
Joseph D Jacobs
Rohm and Haas Company
200 Route 413
Bristol, PA 19021
215-785-7429
Robert W. Johnson
Unwin Company
1920 Northwest Blvd., Suite 201
Columbus, OH 43212
614-486-2245
Phil G. Lewis
Rohm and Haas Company
3100 State Road
Croydon, PA 19021
Rich Matusewicz
Arkema Inc.
900 First Ave
King of Prussia PA 19406
610-878-6722
Michelle Middleton
Sponsored Relations, AIChE
3 Park Avenue, 19th Floor
New York, NY 10016-5991
212-591-7699
James B Mynaugh
Rohm and Haas Company
3100 State Road
Croydon, PA 19021
215-785-7213
Jeffrey Oland, PE
Sunoco, Inc. (R&M)
4701 Bermuda St.
Philadelphia, PA 19137-1193
Stephen Selk
US Chemical Safety & Hazard Investigation
Board
2175 K ST NW, Suite 400
Washington, DC 20037
10
Gary R Van Sciver
Rohm and Haas Company
3100 State Road
Croydon, PA 19021
215-785-7429
Andrew M. Slivjak
Sunoco, Inc. (R&M)
4701 Bermuda St.
Philadelphia, PA 19137-1193
215-537-2442
Jan Wagner
Oklahoma State University
School of Chemical Engineering - 423 EN
Stillwater, OK 74078
405-744-5280
Ronald J Willey
Northeastern University
342 SN
Boston, MA 02115
781-492-6420
11
Workshop Participants JamesM.Bosworth
University of Florida, Department of
Chemical Engineering
PO Box 116005
Gainesville, FL32611
352-392-6243
R.MarkBricka
Mississippi State University
P.O. Box 9595
Mississippi stae, MS39762
662-325-1615
RonaldR.Chance
Georgia Tech
GaTech, School of Chem & biomol eng
Atlanta, GA30332
404-385-1931
AnujChauhan
University of Florida
4921 SW 10th Lane
Gainsville, FL32607
352-392-2592
J. (Joseph)P.Conlon
Marshall University
One John Marshall Drive
Huntington, WV25755-2921
304-696-3067
KennethR.Cox
Rice University
806 Misty Lea Lane
Houston, TX77090
281-866-0412
IlchgerelDash
South Dakota School of Mines and
Technology
501 E. St. Joseph St.
Rapid City, SD57701
605-394-2421
LindaS.Davis
Purdue University, School of Chemical
Engineering
Purdue University, 480 Stadium mall drive
West Lafayette, In47907-2100
765-496-1710
YasarDemirel
University of Nebraska-Lincoln
Department of Chemical & Biomolecular
Engineering
207 Othmer Hall
Lincoln, NE68588-0643
402-472-2745
JagdishC.Dhawan
University of South Alabama
Chem Eng Dept. Eglb 252
Mobile, AL36688
251-209-9129 CELL
JasonC.Ganley
Howard University
2300 6th street NW
Washington, DC20059
202-806-4796
YuyanGuo
Mary Kay O'Connor Process Safety Center,
Texas A&M University
Mary Kay O'connor Process Safety Center,
3122 TAMU
College Station, Tx77843
979-845-3557
12
NiveditaR.Gupta
University of New Hampshire
W313 Kingsbury Hall
Durham, NH03824
6036596209
WilliamC.Hecker
Brigham Young University
350 CB, BYU ChENg
Provo, UT84602
801 422 6235
ThomasR.Marrero
University of Missouri-Columbia
1313 Fieldcrest
Columbia, MO65203
573-882-3802
LingMiao
Texas A&M University
MKO Process Safety Center
Texas A&M University
College Station, TX77843
979-862-6910
DedyNg
Texas A&M University
3122 TAMU, Mary Kay O'connor Process
safety center
College Station, TX77843
979-229-8826
IrvinW.Osborne-Lee
Prairie View A&M University
6810 Pebble Beach Drive
Houston, TX77069
936-261-9500
RandelM.Price
Christian Brothers University
650 East Parkway South
Memphis, TN38104
901 321 3412
JoshuaD.Ramsey
Oklahoma State University
423 Engineering North
Stillwater, OK74074
405-744-5280
RobinL.Shepard
Washington University at St. Louis
3910 Old Hwy 94 S.
Ste 112
St. Charles, MO63304
636-498-2778
SpyrosA.Svoronos
University of FLorida
chem eng., u florida
Gainsville, FL32611
352-392-9101
GerardPetervan Walsum
University of Maine
5737 Jenness hall #311
Orono, ME04469-5737
207-581-2226
WilliamH.Velander
University of Nebraska-Lincoln
Dept of chemical & Biomolecular
Engineering 207 Othmer Hall
Lincoln, NE68588-0643
402-472-3697
13
RobbM.Winter
South Dakota School of Mines and
Technology
501 E. St. Joseph St.
Rapid City, SD57701
605-394-2421
14
Biographies of Workshop Lecturers, Panelists, and Staff
Thomas L. Archibald, Vice President, Director of Engineering and Operations, Rohm
and Haas, Philadelphia, PA
Tom Archibald joined Rohm and Haas in 1972 as a Development
Engineer in the Louisville Plant. He remained at the plant until 1981,
holding positions of increasing responsibility, including Development
Group Leader, Process Technologist, and Assistant Area Manager.
In 1982, Mr. Archibald moved to the Bayport Plant to assume the
position of Manufacturing Manager. Three years later he was named
Operations Director for the Latin American Region. In 1988, he became
Manager of Process Engineering at the Engineering Division in Bristol, Pennsylvania.
He returned to Louisville in 1990 when he was promoted to the position of Plant
Manager.
Elected a Vice President in 1997, Mr. Archibald was named Director of Engineering and
Manufacturing at that time. In 1999, Mr. Archibald was named the Director of
Engineering and Operations.
Mr. Archibald earned a B.S. degree in Chemical Engineering from Northeastern
University in 1972.
Scott A. Berger, Center for Chemical Process Safety of the American Institute of
Chemical Engineers, New York, NY
Mr. Berger is Director of the Center for Chemical Process Safety, an
Industrial Technology Alliance of the American Institute of Chemical
Engineers. Mr. Berger holds SB and SM degrees in Chemical
Engineering from the Massachusetts Institute of Technology and has a
30-year career working in and with industry to foster and develop
"greener" and "inherently safer" technologies. Mr. Berger began his
career at Rohm and Haas where he held a range of positions in R&D,
engineering, production, and Environment, Health and Safety. He then
worked at Owens Corning where he held positions in Environment, Health and Safety,
including Director of Strategic EHS management, before coming to the Center for
Chemical Process Safety
15
Center for Chemical Process Safety of the American Institute of Chemical
Engineers.
The Center for Chemical Process Safety (CCPS) was founded in
1985 shortly after the 1984 Bhopal incident to develop technology
and management practices that mitigate or eliminate chemical
process accidents. Since that time, CCPS has published more than
80 books and held 24 annual conferences, each representing the
most advanced thinking in process safety. CCPS is supported by
the contributions and voluntary participation of more than 120
companies. Sponsors receive benefits including learning from the best in the industry,
discounts on books and courses, special workshops, and an extended network of contacts.
CCPS is also the world’s largest provider of undergraduate engineering curriculum
materials through its SACHE program, with more than 130 universities around the world
participating.
Daniel A. Crowl, Herbert H. Dow Professor for Chemical Process Safety, Michigan
Technological University, Houghton, MI
Dr. Crowl’s interests are in teaching and research in chemical process
safety and loss prevention. His research is in gas and liquid
flammability and chemical reactivity. He is co-author of the textbook
Chemical Process Safety - Fundamentals with Applications, a
textbook specifically intended for undergraduate and graduate
chemical engineering education in process safety. He is a member of
the AIChE Center for Chemical Process Safety (CCPS)
Undergraduate Education Committee, the CCPS Technical Steering
Committee and the AIChE 11a Committee on Loss Prevention. He
has also served as editor of the process safety section of the 8th
edition of Perry's, and editor of the AICHE journal Process Safety Progress. He is
currently the national safety coordinator for the AICHE ChemE car safety program.
Joseph D. Jacobs, Technical Manager, Polymers Area, Rohm and Haas, Bristol, PA
Joe Jacobs manages the Technical Group in the Rohm and Haas
Bristol Polymers Plant. He has production, design, and quality
control experience in polymer reaction & devolatilization, solids
handling, monomer handling & storage, and process safety; along
with process research experience in solution step growth and acrylic
free-radical polymerization. During his nineteen-year career, Joe
has been extensively involved in process safety through research,
design, review, construction, start-up, & operation. Joe is graduate
of Penn State, with a bachelor of science degree in Chemical
Engineering.
16
Robert W. (Bob) Johnson, President &CEO ,Unwin Company, a process safety and risk
management consultancy based in Columbus, Ohio.
Bob has assisted industry and government clients analyze,
prioritize and manage their chemical risks since 1978, holding
previous senior-level positions with Battelle, Du Pont and Hercules
Incorporated. Mr. Johnson is principal author of three AIChE
Center for Chemical Process Safety books and has many articles
published on various process safety and risk analysis topics. He is
currently Chair of the AIChE Safety & Health Division and is a
member of the SACHE Committee. His academic involvement has
included presenting process safety lectures to chemical engineering
students at universities in Ohio, and participating on the Board of Industrial Advisors for
the University of Cincinnati's Chemical and Materials Engineering Department. Mr.
Johnson holds BS and MS degrees in chemical engineering from Purdue University. He
is a Fellow of AIChE.
Kathleen A. Kas, PE – Team Leader/Risk Analyst, Risk Management Services
Department, Rohm and Haas Company, Bristol, PA
Kathy Kas is the Bristol Team Leader for the Risk Management
Services Department for the Rohm and Haas Company. She joined
Rohm and Haas in 1985 as a production engineer at the Philadelphia
Plant. Since that time, she has held a number of positions in research,
process scale-up, finance, and production management at several
locations before becoming a Risk Analyst. Her current responsibilities
include coordinating and conducting activities to identify, quantify, and
manage process hazard risks at Rohm and Haas manufacturing sites worldwide.
Kathy earned a BChE degree from the University of Delaware and a MBA from Rutgers
University. She is a licensed Professional Engineer in the Commonwealth of
Pennsylvania.
Philip G. Lewis, Vice President, Director of Global Environmental, Health and Safety,
Rohm and Haas
Philip G. Lewis joined Rohm and Haas Company in 1983 as associate corporate medical
director. He was promoted to corporate medical director in 1988. Dr. Lewis was named
director of Safety, Health and Environmental Affairs in 1989. In 1993, he was given
responsibility for Product Integrity and elected a vice president. Prior
to joining the company, he served as Chief of Preventive Medical
Activity and Epidemiologist for the III Corps and Darnall Army
Hospital in Fort Hood, Texas. Dr. Lewis received a bachelor of
science degree in Chemistry from Widener University in 1972; a
master of public health in epidemiology from the Johns Hopkins
University Bloomberg School of Public Health, and a doctor of
17
medicine from the Johns Hopkins University School of Medicine both in 1976. He
finished his residency in general preventive medicine in 1978 at Walter Reed Army
Institute of Research in Washington, D.C., and his clinical fellowship in dermatology,
occupational and environmental medicine at Johns Hopkins Medical Institutions in 1983.
Dr. Lewis is an adjunct faculty member in the Division of Occupational and
Environmental Medicine at the University of Pennsylvania School of Medicine and at the
Division of Occupational Medicine in the Department of Environmental Health Services
at the Johns Hopkins University Bloomberg School of Public Health. He was a Clinton
Presidential appointee to the Board of Directors of the Mickey Leland Urban Air Toxics
Research Center; and is a Fellow of both the American College of Preventive Medicine
and the American College of Occupational and Environmental Medicine. Dr. Lewis has
won many awards over the years, including the George M. Sternberg Medal for
Excellence in Preventive Medicine and Epidemiology. He is widely published and has
lectured extensively on preventive, occupational and environmental medicine, public
health and risk assessment and risk management.
Rich Matusewicz, P.E., Process Risk Engineering Fellow, Corporate Health, Safety and
Environmental Department, Arkema, Inc., King of Prussia, PA
Rich received his degree at the Polytechnic Institute of Brooklyn in
1974. He started his career with ICI America as a Process
Engineer, working at their Atlas Point Plant in New Castle,
Delaware. After serving five years in various plant engineering
positions, he joined Pennwalt Corporation's Central Engineering
Department, Process Engineering Group. This staff engineering
position provided valuable experience and insight to the diverse
specialty chemical operations and businesses of the company,
including thio-, fluoro-, agricultural and inorganic chemicals. After
Pennwalt's acquisition by Elf Aquitaine in 1990, he was named lead process engineer on
a world-scale hydrofluorocarbon project at the company's Calvert City, Kentucky site.
He was promoted to Process Technology Manager of U.S. thiochemicals and amines
operations in 1997. He served in this role until 2002, when he was given an opportunity
to apply his technical skill set to a safety-related position as Process Safety Manager,
Technology Division. In 2004, he moved over to the technical ladder and is now serving
in the Corporate Industrial Safety Group at the company’s research and technical center
in King of Prussia. Each fall Rich recruits new chemical engineers for Arkema at Ohio
State. He and his wife are empty-nesters in Blue Bell, Pennsylvania. His spare time is
filled with barbershop singing, and general aviation.
18
James B Mynaugh, Director of Manufacturing Services, Rohm and Haas Company,
Engineering Division, Bristol, 3100 State Road, Croydon, PA
Jim Mynaugh is the Director of Engineering and Manufacturing Services
for the Rohm and Haas Company. A graduate of Villanova University,
Mynaugh and his team of capital project engineers, risk management
staff, technical specialists, and reliability engineers support more than
100 international manufacturing sites. He has over 28 years of
experience with Rohm and Haas, largely in manufacturing. He has
served as site manager for the company's plant in Grangemouth,
Scotland, and has held other senior management roles at Rohm and Haas' offices in
Houston, Texas, Knoxville, Tennessee, and Bristol, Pennsylvania.
Albert Ness, Senior Risk Analyst, Risk Management Services Department, Rohm and
Haas Company, Bristol, PA
Al has 32 years with Rohm and Haas, the last 20 of them as a Risk
Analyst. Prior to that, he worked as a Research Process Engineer,
working on the scale up of process to make Agricultural Chemicals and
Ion Exchange Resins.
Al has a BS in Chemical Engineering from the University of Arizona
and an MS in Chemical Engineering from the University of Illinois. He
is the Secretary/Treasurer of the Safety and Health Division of the AIChE, a member of
the NFPA 654 technical committee and has participated in the writing of several books
and guidelines for the Center for Chemical Process Safety. He is the author of several
papers that have been published in Process Safety Progress and Chemical Engineering
Progress.
Gary Van Sciver, Hazard Analysis Engineer, Rohm and Haas, Bristol, PA
For the past 2 years, Gary Van Sciver has been a Senior Engineer for the
Engineering Technical Center of Rohm and Haas, specializing in
emergency relief and heat transfer design. He started his career with 8
years as a Rohm and Haas Process Design Engineer and then spent 22
years as a Rohm and Haas Risk Analyst. He is a chemical engineering
graduate from Drexel University.
Steve Selk, PE, P.Eng. - Investigations Manager, Chemical Safety Board, Washington,
DC.
Steve Selk joined the CSB in 2000 as an incident investigator for the board. He has
worked in the oil and chemical industry for 25 years with an extensive background in
safety standards, regulations, and incident investigation. He presently oversees all Board
investigations. He graduated from the University of Toronto in 1976.
19
Jan Wagner,Professor of Chemical Engineering, Oklahoma State University. Stillwater,
OK
Jan’s teaching interests are process design and process safety. His industrial experience
includes internships in both Process Engineering and Process Safety at Celanese
Chemicals in Clear Lake Texas. He is a member of the CCPS Undergraduate Education
Committee and Editor of SACHE News.
Ronald J. Willey, Professor of Chemical Engineering, Northeastern University, Boston,
MA
Ron’s research interests are in catalysis, aerogels,
characterization of porous materials, and reactions in high
pressure systems. He is a member of the Board of
Registration for Engineers and Land Surveyors for the
Commonwealth of Massachusetts. He has written over 10
SACHE teaching modules, and has been involved in
academia over 20 years. He recently took on the position of
co-editor of Process Safety Progress.
20
Program Grid Theme: Process Safety: What do you and your students need to know? Audience: Professors in Chemical Engineering
Sunday, September 14 Monday, September 15 Dust Explosions
Tuesday, September 16 Reactivity
Wednesday, September 17 Sunoco Chemical Plant
7:30 Bus Leaves hotel. 8:00 Cont. Breakfast R&H 8:15 Welcome& Orient 8:30-9:30 Steve Selk from the CSB
7:30 Leave hotel. 8:00 Arrival-Cont. Breakfast 8:15 - 8:20 Announcements 8:20 - 9:30 Bob Johnson“Chemical Reactivity Hazards”
7:30 Leave hotel 8:00 Arrival-Cont. Breakfast 8:15 - 8:30 Announcements 8:30 - 9:30 Sun Chemical “History & Overview of the Frankford Cumene-To-Phenol Production Process”
9:30-9:45 Break 9:30 – 9:45 Break 9:30 – 9:45 break
9:45-11:45 “Dust Explosion Basics” Richard Matusewicz “Conditions for Dust Explosions” Al Ness
9:45 – 10:30 – Gary Van Sciver “Emergency Relief” 10:30-1“Develop a Design Basis for ERS”Table Top Exercise:
9:45 – 12:00 Sun Chemical Process Safety experts lead by Jeff Oland “Process Safety as Related to Storage Tanks and Firefighting at Sunoco Chemical –Frankford”
11:45 to 12:30 Lunch 11:45-12:30 Lunch 12:00 – 1:00 Working Lunch After 1 PM Faculty arrive at Hotel Holiday Inn Select, Bucks County, 4700 Street Rd, Trevose, PA
12:30 – 2:00 Static ElectricityAl Ness 2:00 – 2:20 Break 2:20 – 3:20 Human factors,Kathy Kas 3:20 – 4:30 Inherent safety, Kathy Kas 4:30 – 5:00 Ron Willey
12:30 – 1:15 Process Chemistry & Safety Concerns Bristol Plant Personnel 1:15-1:45 – Safety indoctrinationJoe Jacobs Bristol Plant Bristol Plant Personnel 2:00 – 4:30 Tour of Bristol Plant, showing ERS on a batch reactor, fire protection, control room/interlocks, and grounding & bonding.
1:00 – 2:30 Walking tour of facility: S-1 focus of personnel protection at OX-801- fire, ear protection, shower, emergency stations, S-2 OX-501Secondary containment fire monitor fire protection around a storage tank, S-3 control room review of emergency equipment there in.
5:00 Return to hotel 5:00 Leave for dinner via hotel. 2:30 – 3:00 Workshop wrap up 6-7:00 PM Buffet 7:00 – 8:00 PM Welcome Jim Mynaughteam building
6:00 Buffet at hotel Dan Crowl “How to make an Explosion Safe,” and Scott Berger, CCPS (Funding Courtesy of R&H)
6:30 Dinner Sponsored by R&H &Arkema& Sunoco @ Franklin Inst. Phil Lewis, VP Env Health & Safety for R&H &Tom Archibald, VP Manufacturing for R&H. “The Value of an EHS Education”
3:15 PM bus departs for Airport
Hotel: Holiday Inn Hotel: Holiday Inn Hotel: Holiday Inn
Good afternoon everyone and thank you for inviting us to speak at your meeting.
I do attend and speak at a lot of other meetings related to the chemical industry. And when I
do so I have learned that folks really do want to see photographs of accidents. I suspect there
is more than one reason for that but I think one of them is that they find the photos awe-
inspiring. The fact that you are all here suggest to me that you don’t need any inspiration.
However, it might be that the young people you teach don’t appreciate risk quite the same
way. So perhaps you can use the information and photos in this presentation to inspire your
students to be more aware of the need for a high level of rigor in process safety and
particularly with respect to the hazard of uncontrolled chemical reactions
SLIDE 2
All CSB presentations at meetings such as this include a disclaimer. It says that I am here
providing my views and not necessarily the Board’s views. Well why do we always have this
disclaimer? Well the answer is the Board is a collegial body. As a collegial body they are
equals – and they vote on the agency’s work. None is more powerful than the other. Each
has one vote. So they speak with an official voice by the products and policies that are
successfully voted on. Where any one member may stand on an issue is merely their
personal view. This is in my view a very worthy method.
SLIDE 3
When I was a kid I could take a shortcut to school by walking across a railroad bridge. It’s my
guess that many of you can associate this photo with at least some degree of fear. Not just
the photo itself but memories you may have such as the thrum of an approaching train or
perhaps the doppler effect of the train whistle. And you recognize that a speeding train has a
great deal of kinetic energy and likely extend that thinking to the conclusion that the train
can’t stop that easily.
In reality is bit hard to stop a train but maybe not for the reason you might expect. The two
prime reasons trains don’t stop in a short distance like cars are first it takes some time for the
pneumatic signal to get the brakes fully applied along the full length of the train and second
because the coefficient of friction of the steel wheels on the steel track is low. Because in
fundamental physics the stopping distance of breaking vehicles is independent of the weight.
But what can be quite impossible to stop is a runaway chemical reaction.
SLIDE 4
This is the head from a 3” thick reactor. A pressure vessel this thick could easily withstand a
fuel-air explosion. An internal fuel-air explosion wouldn’t impact a vessel like this at all. But a
runaway chemical reaction can involve much more energy. This is a fragment is from the
second accident I will discuss.
I brought had a thousand lbs of TNT here with us in this room we would all respect it. Yet, my
sense from years of experience in the chemical industry is that often we don’t visualize
chemical reactions like we would this train.
SLIDE 5
This is the site of the first accident in Pascagoula, Mississippi, In the foreground is the First
Chemical Corporation plant where the accident occurred. In the background is the Chevron
refinery.
The crane you can see in the picture is supporting a damaged distillation column. You can’t
see it clearly in this picture but the top has been blown of the column. That happened
because there was a runaway reaction inside.
SLIDE 6
Here is a closer in view. The column that failed is in the center. As built it was 7 feet in
diameter and 145 feet high. It was used to distil mono-nitrotoluene. You can see that one of
the column courses near the top has folded out. And the top head has blown off.
This isn’t really a very striking photograph. But the next is.
SLIDE 7
This is one of the fragment from column. You can see it is actually quite a large and it weighs
about 6 tons.
The fragment was hurled 1,110 feet and landed adjacent to a large crude oil storage tanks at
the Chevron refinery. Other fragments were thrown even farther.
Now, the top head of the vessel was never found in spite of the fact that investigators
expended considerable resources trying to locate it.
Let’s take a moment to think about that the physics of pressure vessel failure. This column
failed because it was over-pressured by a runaway chemical reaction. Now when a cylindrical
pressure vessel like this is under pressure how are the forces distributed?
SLIDE 8
Well, circumferentially the pressure is acting in all directions. And that puts the shell – under
what engineers call hoop stress. But up until the time of burst there is no eccentric sideways
force on the longitudinal shell. It is only once the vessel bursts that eccentricity force
develops in the form of gas jet action creates a sideways thrust that launched that 6 ton
fragment.
Now the force situation is quite different for the heads of a pressure vessel.
SLIDE 9
Consider the top head for a moment. It experiences an upward force before burst takes place
and after. This partly explains why the top head was never found. Maybe in landed in the
ocean more than a mile away.
SLIDE 10
A smaller fragment did hit this mono storage tank. It was full of mononitrotoluene that
burned.
SLIDE 11
No one was seriously hurt in this incident. But the potential was certainly there. And what if the top head had hit one of these LPG storage spheres. This shot is taken from the First Chemical Plant looking towards Chevron.
SLIDE 12
Looking in the other direction there was a fertilizer plant. This is very large refrigerated liquid
ammonia storage tank.
SLIDE 13
The 145 foot column was equipped with structured packing. This is an actual shot of some
spare packing on site.
When I was at the scene I said I wanted to look inside the column and someone replied: There
is nothing to see. But I went up in a crane basket anyway and when I looked inside it was
completely empty. All the packing, trays and internals were ejected. So, column in effect
acted like a shotgun.
SLIDE 14
And here is some of it but it was actually strewn about a very wide area. In fact some of it
landed on top of oil storage tanks at the Chevron refinery. It’s not something you would want
to get hit by. It’s sharp, it’s hot and it’s moving fast.
As you have seen this column failed at the near the top. And failed that way for 2 reasons.
First when we build them we make the upper courses thinner because there is less need for
structural support up top. And second it was corroded. And it had corroded from the outside
in. Because moisture had become trapped under the insulation.
And in the end it was actually fortunate that it failed up high. Because the blast wave from the
burst damaged the control room. It was so badly damaged that it had to be shored up after
the incident. If the column had of failed low the damage to the control room might have been
catastrophic. This was an old plant and the control room was located too close to the
process. That’s something I often see in older plants.
SLIDE 15
How did it happen?
When this acid occurred the production unit was actually shutdown and it had been shutdown
for weeks.
But the block valves for the steam heater column reboiler leaked and the material sat in the
bottom of the tower at elevated temperature and eventually self heating initiated and the
material decomposed.
Now the company knew the material had the potential to runaway. And they knew from
calorimetry testing what the onset temperature was. But what they knew less about was that
the onset temperature could be lower if the material had a thermal history. This is the so
called induction period. Some materials if held at an elevated temperature but a temperature
below the onset temperature may develop a new lower onset temperature. At least that’s what
the CSB report concluded.
SLIDE 16
At a different level of causation we found that there had been no formal hazard analysis
The layers of protection inadequate
And there wasn’t even a documented relief system basis
When we came back from the field and briefed the Board I told them it appeared management
had cut back staff to a very low level. That may be one reason they didn’t get these essential
things done.
SLIDE 17
Let me turn now from a close call to a true tragedy. The recent accident that occurred at T2
Labs in Jacksonville, Florida
Note that these firefighters are wearing their Scott packs. And that is so important. Because
at one time firefighters might use them at their option and they would be exposed to
potentially harmful chemicals. In Jacksonville the fire chief told our investigators if he
catches a fireman not wearing his scott pac he makes them wear it for a month.
T2 was a very small privately company - just a hand full of employees. The principles were
mature individuals with substantial professional experience. One was a chemist and the other
a chemical engineer.
And, later in their careers they teamed up and became entrepreneurs. Someone said to them
if you can make this particular chemical I can sell all you can make. And that chemical was
MMT.
SLIDE 18
Methyl cyclopendadienyl manganese tricarbonyl. It is a gasoline octane improver that is used
as a substitute for tetraethyl lead the use of which was banned long ago.
Before T2 came along there was only one other manufacturer of MMT in the western world –
Afton Corporation
Afton is the successor to what used to be Ethyl Corporation.
SLIDE 19
So what these entrepreneurs did was pull together the old Ethyl Corporation patents for MMT
which had expired and they used those patents to figure out how to make it. And they did so
in the lab as you might expect and they were successful.
They went out with their newfound ability and obtained a small amount of financing and they
scaled up their lab work and built a small process unit. And they began to successfully make
and sell MMT. And we have found that some of the engineering as pretty good actually. But it
wasn’t good enough.
Now let me state emphatically that a chemical reaction conducted on a commercial scale is
apt to runaway much easier than the same reaction conducted on a lab scale. This is the so-
called scale-up problem.
This reaction ranaway in the first phase of the synthesis. That reaction of
methylcyclopentadiene with liquid sodium. And it was what we call a tempered reaction. The
liquid sodium was reacted with the diene in the presence of a dyglyme solvent.
VIDEO
Coast Guard security camera recorded the explosion. You will see a stack at a power plant.
That stack is about 650 feet high and the explosion occurs a mile in the distance behind the
stack. The blast from the explosion actually tripped accelerometers on rotating equipment at
the power plant causing the power plant to shut down.
SLIDE 21
A further indication of the severity of the explosion is apparent in this photograph. What we
see is cratering. And that’s quite unusual. This reactor pressured up to roughly 5000 lbs
maybe higher before bursting. That’s part of the vessel in the background.
Other parts were hurled offsite maybe more than a mile.
Recall the fragment from the top head that I showed you at the beginning of the presentation.
Well in spite of extensive searching we never found 2/3. That missing 2//3 is about 3 tons of
steel.
SLIDE 22
This is a steel column that was part of the structure that supported the reactor. It ways about
half a ton and it came to rest about 1000 feet away adjacent this building. This object it has
been translated by the impulse of the explosion. The impulse being the blast overpressure
integrated over time. The time being duration of the overpressure curve.
SLIDE 23
Let me switch now to some important technology that you are likely aware of but I want to
show just in case you are unfamiliar. And that’s adiabatic calorimetry
These laboratory test machines come in various alterations of a fundamental design.
There is a test cell and it is fabricated from very thin metal and that’s important. There are
heating elements to get the reaction going. And there are temperature and pressure sensors.
The whole thing is then encapsulated in a containment chamber. A critical feature is that as
the pressure rises in the test cell nitrogen is rapidly injected into the containment chamber.
What this does is it keeps the test cell from exploding because the internal and external test
cell pressure remain somewhat balanced.
That allows this test cell to be made of such thin metal that the experiment is quite adiabatic.
And a factor called the phi factor is used to represent the degree of adiabaticity.
It has been my experience that in many instances the test cell still blows up and damages the
instruments. But hopefully by that time we have acquired some meaningful data.
SLIDE 24
The data generated takes the form of pressure and temperature plots as a function of time.
Now this all sounds straightforward but of course it isn’t necessarily so and it takes people
like yourselves to thoughtfully design these experiments and moreover to thoughtfully
interpret the results.
SLIDE 25
For a well tempered system the energy output can be obtained by integrating this equation.
But keep in mind the energy out is a variable and one has to integrate over the appropriate
interval.. And that can often mean that it is quite necessary to stay out of the elbow range of
the temperature curve – beyond the elbow range the energy output is rising sometimes
exponentially and the reaction has completey runaway so trying to restrain via heat transfer
would be impossible.
Sometimes there are systems that are referred to as gassy systems versus tempered and
these are producing gases so that pressure is a more important variable.
And then there are hybrid systems.
Now I am sure it is apparent that the design of experiments in this area can be complex. But
what is also very challenging is engineering. For reacting systems physical properties need
to be generated for the system as a function of temperature and pressure and one can
visulalize that a finite difference mathematics may be necessary to represent the system. And
then a greater problem is coping with the fluid mechanics analysis of two phase flow.
This is not necessarily within the reach of small companies and even larger ones. My
experience is that very few engineers can cope with the complexity of this work.
SLIDE 26
Toxic
SLIDE 27
Now there is a chance that your work does not involve systems with runaway potential. Or
perhaps your organization already has a handle on this issue.
But if you don’t here is a place you might start. And it’s the CCPS book on reactive hazards.
It includes some material on the technology and I emphasize some material. And it includes
some management systems. Management system are worthy of your consideration because
they are tools that can help both human and organizational performance when dealing with
complexity.
SLIDE 28
I thank you for your attention today ladies and gentlemen and I encourage you to visit our
website from time to time to look for new investigation reports that may be of interest to you.
Stephen Selk PEManager, Investigations
Two Industrial Accidents involving
Chemical ReactionsSept. 15, 2008
www.csb.gov2
DisclaimerThe presentation entitled: Three Industrial Accidents involvingChemical Reactions given by Stephen Selk of the UnitedStates Chemical Safety and Hazard Investigation Board onSeptember 15, 2008 at the AIChE SACHE Faculty Workshop is given for general informational purposes only. It represents the individual views of the presenter and all references, conclusionsor other statements regarding current on-going CSB investigationsare preliminary in nature and limited to information that is already inthe public domain. Furthermore, this presentation is not a product ofthe Board and its contents have not been reviewed, endorsed, orapproved as an official CSB document. For specific and accurateinformation on completed investigations, please refer to the finalpublished investigation report by going to the CSB website atwww.csb.gov and clicking on the specific report desired under“Completed Investigations.” To the extent this paper includesstatements about the conclusions, findings, or recommendations ofthe Board, such statements come under the general prohibition in 42U.S.C. §7412(r) (6) (G).
www.csb.gov4
First Chemical Corporation, Pascagoula, MS
www.csb.gov8
www.csb.gov9
www.csb.gov15
How did it happen?• Unit was shutdown
• Mono-nitrotoluene left in tower
• Reboiler steam valves leaked
• Extended thermal history
• Runaway thermal decomposition
www.csb.gov16
Causes
• No formal hazard analysis
• Inadequate layers of protection
• No documented relief system basis
T2 Labs, Inc. Jacksonville, FL
www.csb.gov18
MMTMethyl-cyclopentadienyl manganese
tri-carbonyl
www.csb.gov19
www.csb.gov20
VIDEO
N2
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P2
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ventCONTAINMENT CHAMBER
TEST CELL
Control
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])/()/[2/ ms dtdTdtdTCpq
www.csb.gov26
October 7, 2008
Visit our Web Page
www.csb.gov
September 15, 2008Page 1 of 24
Dust Explosions:Basics and Prevention
SACHE Faculty Training Seminar
Rich MatusewiczArkema Inc.
September 15, 2008
September 15, 2008Page 2 of 24
Presentation Outline
� Personal Introduction
� Dust Explosion Pentagon
� Fuel
� Oxygen
� Ignition
� Dispersion
� Confinement
� Mitigation
� Inerting
� Ignition Sources
� Explosion Venting
� Suppression
� Safeguards in Combination
� Closing
� Suggested References
� Questions
September 15, 2008Page 3 of 24
Flammability Triangle
Ignition
Oxygen Fuel
September 15, 2008Page 4 of 24
Dust Explosion Pentagon
IgnitionOxygen
Fuel
Dispersion Confinement
September 15, 2008Page 5 of 24
Dust Explosion Requirements - Fuel
� Any Organic Dust Having a Particle Size Below 400 Microns (0.016 Inches) Should Be Evaluated.
� Examples Include:� Cornstarch� Flour� Polymer Fines
� Metallic Dusts are also Hazardous.
� Some Dusts With a High Halogen Content (e.g., Halon ®) Have Fire Retardant Properties.
Fuel
September 15, 2008Page 6 of 24
Dust Explosion Requirements – Fuel (cont’d.)
Polyethylene Dust Data
0
1
2
3
4
5
6
7
8
9
10
0 50 100 150 200 250 300 350 400
Particle Size (microns)
Exp
losi
on P
ress
ure
(bar
)
September 15, 2008Page 7 of 24
Dust Explosion Requirements – Fuel (cont’d.)
� The Severity of a Potential Explosion Is Predicted Based on Standardized Laboratory Tests.
� “Explosion Severity” – K St (bar ����m/sec)
� Examples:Dust KSt Rating
� Coal Dust 129 Moderate� Flour 202 Severe� Polymer 383 Very Severe
Fines� Magnesium 508 Very Severe
Powder
Fuel
September 15, 2008Page 8 of 24
Dust Explosion Requirements – Fuel (cont’d.)
� The Explosivity of a Dust Depends on:
� Moisture Content� Particle Shape� Morphology� Et Cetera . . .
� It Is Very Important to Adhere to the Standard Method Procedures to Determine K St.
� It Is Also Important to Obtain a Representative Sample for Analysis.
Fuel
September 15, 2008Page 9 of 24
Dust Explosion Requirements - Oxygen
� MOST Dust Explosions Require Oxygen from an Outside Source
� Most Common Source – Air
� Oxygen Could Be Included in Fuel Molecule.
� MOC – Minimum Oxygen Concentration
Oxygen
Examples: MOCDust O2 in N2 (vol%)
� Coal Dust 12 - 14� Flour 11� Polymer 10 - 11
Fines� Magnesium 3
Powder
September 15, 2008Page 10 of 24
Dust Explosion Requirements - Ignition
� Minimum Amount of Energy Required to Initiate an Explosion -MIE
Examples: Dust MIE (mJ)
� Cornstarch 300� Wheat Flour 540� Copolymer 11
Fines� Aluminum > 1,800
Shavings
Ignition
September 15, 2008Page 11 of 24
Ignition
� Thermal:
� Flames (Cigarette, Welding)
� Glowing Embers (Decomposition, i.e. “Smoldering Nest”)
� Hot Surface (Overheated Motor, Heater Malfunction)
� Mechanical
� Spark (Metal to Metal Contact)
� Excessive Friction
� Electrical
� Contact Spark
� Static Discharge
Dust Explosion Requirements – Ignition Sources
September 15, 2008Page 12 of 24
Dust Explosion Requirements - Dispersion
� No Dispersion ���� No Explosion
� Surface Burning on Layer of Dust
� Degree of Dispersion = f(particle size, air flow, dust flow)
� Watch for Secondary Explosions in Areas with Poor Housekeeping
Potential Problem Areas: � Baghouses� Silos/Hoppers (While Filling)� Charge Chutes� Mixers/Blenders� Dryers
Dispersion
September 15, 2008Page 13 of 24
Dust Explosion Requirements – Dispersion Limits
0
2
4
6
8
10
12
0 50 100 150 200 250 300 350
Dust Concentration (g/m3)
Exp
losi
on P
ress
ure
(bar
)
Minimum Explosive Concentration (MEC)
September 15, 2008Page 14 of 24
Dust Explosion Requirements - Confinement
� Explosion or Flash???
� No Confinement ����
No High Overpressure -Flash Only
� Fireball/Flash Fire is Still Dangerous
Confined Systems: � Baghouses� Silos/Hoppers� Charge Chutes� Mixers/Blenders� Dryers
Confinement
Non-Confined Systems: � Bulk Powder
Unloading� Bag Charging� Open Mixers
September 15, 2008Page 15 of 24
Dust Explosion – Mitigation Options
� Prevention:
� Inertion
� Eliminate Ignition Sources
� Protection:
� Explosion Venting
� Suppression
� Containment
� Isolation
September 15, 2008Page 16 of 24
Dust Explosion – Prevention: Inerting
� Operate Below Minimum Oxygen Concentration - MOC
� Use Nitrogen, Carbon Dioxide, Combustion Gases
� Effective, But Can Be Expensive
� Need for Quality Oxygen Sensors
� Dust Proof
� Well Maintained
Oxygen
September 15, 2008Page 17 of 24
Dust Explosion – Prevention: Ignition
� Follow Electrical Classification Requirements
� Ground Equipment to Safely Discharge Static Charges
� Eliminate “Hot Spots”
� No Open Flame Policy
� Use Magnets to Trap Stray Metal Pieces
� Etc.
Ignition
Good Ideas!!! Prudent Practices!!!
BUT . . .
Can You Really Guarantee NO Ignition Sources???
� Eliminate Ignition Sources:
September 15, 2008Page 18 of 24
Confinement
Dust Explosion – Protection (Added to Prevention)
� Vent Opens Automatically at Onset of Pressure Wave
� Will Still Have Fireball/Flash
� Vent Discharges to a Safe Location
� Requires Careful Design
� Explosion Venting:
September 15, 2008Page 19 of 24
Dust Explosion – Protection: Suppression
� High Tech Explosion Suppression Systems can be Designed and Integrated as Part of the Equipment Configuration
� Extinguishers Discharge Inside of Confined Vessel• Halogenated Hydrocarbons• Ammonium Hydrophosphate (Monobasic)• Others
� Fast Activation at Onset of Minute Increases in Pre ssure
� Suppression Occurs Before Design Pressure of the Vessel is Exceeded
September 15, 2008Page 20 of 24
Dust Explosion – Protection Suite Example
To Packaging
Bag
House
Dryer
To Packaging
Explosion Vents Protect Dryer/Baghouse
SuppressionSystem
PTPT
Suppression System Extinguishers Are Activated by Pressure Rise
Rotary Valves Isolate Dryer/ Baghouse from Packaging
Water Deluge Puts Out Residual Fire
September 15, 2008Page 21 of 24
Closing
� Dust Explosions Represent a Considerable Hazard
� Once the Mechanisms are Understood, More Easily Mitigated
� Mitigation Consists of Prevention and Protection Safeguards
� Knowledge is the Key
September 15, 2008Page 22 of 24
References
Butterworth – Heinemann
Second Edition – 1997© Reed Educational and
Professional Publishing Ltd.
September 15, 2008Page 23 of 24
References (cont’d)
November, 2004© John Wiley & Sons, Inc.
September 15, 2008Page 24 of 24
Questions???Questions???
9/4/08
1
Conditions for Dust Explosions Albert Ness
SAChE Workshop Sept. 15, 2008
Dust Explosion Pentagon
Combustible Dust
Confinement
Turbulence (dispersed with
[C] > MEC) Oxidant
Ignition Source
(< 420 microns)
9/4/08
2
Questions
• Is this a dust explosion? • Why or why not?
Venting
Mental / Visual Exercise
9/4/08
3
Remember Dispersion Limits?
Minimum Explosible Concentration
• Lower limit 10 – 30 g/M3 – Polymethylacrylate 15 g/M3 – Ground Dextrose 20 g/M3 – Flour 60 g/M3
Questions
• Given a 10M x 10M x 3M room • How many grams of flour are needed
to be above the MEC? • How many 2.2 kg (~ 5 lb) bags of
flour are needed to exceed the MEC?
• How many bags of flour are needed to exceed the MEC in this room?
• Does that seem like a lot of flour on the floor?
18,000
8
9/4/08
4
Secondary Explosions
Why do we care?
What is the effect?
• Poor housekeeping, and secondary explosions, heighten the damage potential – Larger portion of facility, and more people,
potentially involved – Longer duration events greater impulse more
damage to structures and equipment
Housekeeping
• Importance stressed and guidance provided in NFPA 654 – Dust layers >1/32 inch deep are a concern – Can be hazardous if >5% of floor area covered – Beams, ductwork, cabling, piping, walls all gather
dust and should also be considered – Construct buildings and equipment for ease of
cleaning
9/4/08
5
2008 - Imperial Sugar, GA
Want Proof?
13 Dead, > 40 injured
Q; Are these layers > 1/32 in?
West Pharmaceuticals, NC 6 Dead
37 Injured
2003 - West Pharmaceutical, NC
9/4/08
6
CTA Acoustics, KY 7 Dead
37 Injured
2003 – CTA Acoustics, KY
Case Study – Mill / Cyclone / Baghouse
Organic chips ground to 10 (Kst = 150) Conveyed to cyclone and baghouse for collection
Questions
• Do the conditions exist for a dust explosion? • Where? • What are potential the ignition sources? • If yes, how would you protect the system? • If there were 10 of these units in a building, how
would you protect them?
9/4/08
7
Our Answer
9/4/08
1
Static Electricity
A shamelessly stolen introduction Albert Ness
September 15, 2008
Sensory Effects
Slide 2 Static Electricity -David Wechsler October, 2002
Visual Effects
Slide 3 Static Electricity -David Wechsler October, 2002
9/4/08
2
Workplace Effects?
Slide 4 Static Electricity -David Wechsler October, 2002
Static Electricity
• 3 Steps 1. Generation 2. Accumulation 3. Discharge
• Control & Mitigation
1) Whenever two materials are placed in contact, an exchange of charge occurs between them.
2) Unless the materials are conductive and electrically bonded together, when the surfaces are separated each acquires an equal and opposite net charge. The net charges drain away to ground at a rate that depends on the conductivity of the materials.
3) Electric charges may build up on ungrounded conductive materials (such as metals) non-conductive materials (most plastics) until
The electrical breakdown field of the surroundings (usually air) is exceeded and an electrostatic discharge (such as a spark) occurs. The static discharge may be of sufficient energy to ignite vapors or dust, depending on the Minimum Ignition Energy (MIE) of the ignitable mixture.
A General Static Condition -
Slide 6 Static Electricity -David Wechsler October, 2002
9/4/08
3
Generation - Streaming Current
Splash Charge
+
+ + + + + + - - - - - - - - - - - - - - - - - - - - -
+ + + + + + + + + + + +
Dumping Powder
9/4/08
4
Contact and Frictional Charging
Induction
9/4/08
5
Accumulation of Charge
Charge out + + + Charge in + + +
Charge Out (grounded vessels) • Conductive liquid – Nearly instantaneous • Non-conductive liquid - eventually
dissipates in grounded vessels.
5 min 1 min
Relaxation Time
30 min
10,000 gal 5–10,000 gal <5,000 gal
Extra kicker - Examples of some nonconductive liquids that will accumulate charge and are flammable:
gasoline propane toluene butadiene benzene mineral spirits styrene monomer
Slide 15 Static Electricity -David Wechsler October, 2002
9/4/08
6
Accumulation of Charge on Equipment
• Charge on fluid places opposite charge on equipment.
• Conductive equipment (metal), if grounded, safely brings charge to ground.
• Charge on non-conductive (or non-grounded) equipment will linger on equipment.
+ + + +
• Accumulated charges remain in non conductive and in non-grounded vessels.
Conductive Sections in non-conductive Line
9/4/08
7
Discharge
Flammable Limits -
Lower (LFL) and Upper (UFL)
Flammable Limits
Slide 20 Static Electricity -David Wechsler October, 2002
A p p r o x i m a t e V a l u e s O f M . I . E . I n A i r *
1 . G a s e s : 0 . 1 M i l l i j o u l e H y d r o g e n = 0 . 0 2 m J
2 . L i q u i d s 1 . 0 M i l l i j o u l e P e n t a n e = 0 . 5 4 m J S t y r e n e = 0 . 3 0 m J
3 : D u s t s 1 0 M i l l i j o u l e O r M o r e
* O x y g e n - E n r i c h e d F u e l s H a v e M u c h L o w e r M . I . E . ’ s
Minimum Ignition Energy
Slide 21 Static Electricity -David Wechsler October, 2002
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Spark
Spark
Discharge
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Static Electricity Control
• Ground all isolated conductors • Reduce flow velocity • Install dip pipes • Move filters further upstream • Eliminate top electrodes • Antistatic additives, materials • Increase Humidity • Ionize the air
Grounding & Bonding
• Grounding. The process of bonding one or more conductive objects to the ground, so that all objects are at zero (0) electrical potential; also referred to as “earthing.”
• Bonding. The process of connecting two or more conductive objects together by means of a conductor so that they are at the same electrical potential, but not necessarily at the same potential as the earth.
Example
Bonding
Grounding
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Slide 28 Static Electricity -David Wechsler October, 2002
Example of a tank car dip-pipe liquid transfer system
Safe Charge Discharge from Bags
+ + + - - - - - - -
Conductive Bag
Conductive Gloves
Conductive Shoes
Conductive Floor
• Reduce charge velocity
• Ground all isolated conductors
• Move filter further upstream
• Install dip pipe • Eliminate top
electrodes
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
xyzx
micro filter
Prevent Static Discharge
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Inert Environment
Vent N2 to a safe place!
Important Summary Points
1- Ground and Bond prior to any transfer 2- Non conductive fluids are more likely for static generation 3- Bottom filling or top fill using dip tube less static generation 4- Slow filling will generate less static than rapid filling. Magic number slow start velocity of 3 feet per second until loading lance is submerged. 5- Spray filling- keep nozzles from extending into the container to avoid pulling in air and creating flammable vapor mixture. 6- Inerting eliminates the potential for combustion, but does not eliminate the static. Padding with nitrogen may not achieve the same full potential as inerting (5% or less oxygen).
Slide 32 Static Electricity -David Wechsler October, 2002
With respect to “Static electricity” before you transfer a flammable liquid material
from a 55 gal drum to an open container, what should you do?
A. Make sure it is raining and you have rubber boots on, so static will not be generated
B. Make sure that the 55 gal. Drum and the open container are grounded and bonded
C. Make sure you fill the container very slowly with a thin stream and place the filling
nozzle close to the bottom of the container.
You have just finished unwrapping a skid of material with several layers of
saran wrap and are going to remove and add a combustible dust material into a
reactor containing a flammable solvent. What steps should you take.
A. Open the reactor, start the agitator, and dump the contents into the reactor
B. Open the reactor, ground the reactor, bond the agitator, start the agitator,
dump the contents and close the reactor.
C. Ground the reactor, bond the agitator, open the reactor, dump the contents, close the
reactor, start the agitator.
Slide 33 Static Electricity -David Wechsler October, 2002
Quiz
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With respect to “Static electricity” before you transfer a flammable liquid material
from a 55 gal drum to an open container, what should you do?
A. Make sure it is raining and you have rubber boots on, so static will not be generated
B. Make sure that the 55 gal. Drum and the open container are grounded and bonded
C. Make sure you fill the container very slowly with a thin stream and place the filling
nozzle close to the bottom of the container.
You have just finished unwrapping a skid of material with several layers of
saran wrap and are going to remove add a combustible dust material into the
reactor containing a flammable solvent. What steps should you take.
A. Open the reactor, start the agitator, and dump the contents into the reactor
B. Open the reactor, ground the reactor, bond the agitator, start the agitator,
dump the contents and close the reactor.
C. Ground the reactor, bond the agitator, open the reactor, dump the contents,
close the reactor, start the agitator.
Slide 34 Static Electricity -David Wechsler October, 2002
Quiz - Answers
You are preparing to load a non conductive flammable solvent into a tank truck
via the top manway. From a static's perspective, what two things should be done?
A. Ground the tank truck and get the filling done as fast as possible
B. Ground the tank truck and fill slowly through a grounded down pipe
C. Stand way back and fill the tank quickly
You are asked to load a tank car and in checking the grounding clamp, you
notice that it is heavily corroded. What should your action be?
A. Continue on with the loading operation, but don’t use the grounding clamp.
B. Continue on with the loading operation by repairing the ground clamp yourself.
C. Get the ground clamp repair and then continue with the loading operation.
Slide 35 Static Electricity -David Wechsler October, 2002
Quiz
You are preparing to load a non conductive flammable solvent into a tank truck
via the top manway. From a static's perspective, what two things should be done?
A. Ground the tank truck and get the filling done as fast as possible
B. Ground the tank truck and fill slowly through a grounded down pipe
C. Stand way back and fill the tank quickly
You are asked to load a tank car and in checking the grounding clamp, you
notice that it is heavily corroded. What should your action be?
A. Continue on with the loading operation, but don’t use the grounding clamp.
B. Continue on with the loading operation by repairing the ground clamp yourself.
C. Get the ground clamp repair and then continue with the loading operation.
Slide 36 Static Electricity -David Wechsler October, 2002
Quiz - Answers
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More Info
• NFPA 77 • IChemE Guides • Knovel
– Avoiding Static Ignition Hazards in Chemical Operations
– Electrostatic Hazards – Electrostatic Ignition of Fires and Explosions
1
Human Factors
Risk Management Services Department
Are You Perfect?
• Have you ever pushed the wrong button on a soda machine, left your car headlights on, or unintentionally deleted a file on your computer?
• Wonder how often these (and more serious) errors occur?
Laws of Nature
We accept and design for the laws of nature.
Example: If a bridge falls down, we don’t list “gravity” as the root cause.
Example: If there is an asphyxiation, we don’t list “people need oxygen” as the root cause of an injury.
2
Human Error
• Law of nature:
HUMANS MAKE MISTAKES!
• DON’T BLAME IT…PLAN FOR IT!
How Often Do Humans Make Mistakes?
• Trained, not under stress, not fatigued or overloaded, and enough time:
Error occurs about 1 in every 100 times the operation is done
How Often Do Humans Make Mistakes?
• Not trained, or under stress, or overloaded or short period of time:
Error occurs about ½ to every time the operation is done
3
• Trained and not under stress and not fatigued and not overloaded and enough time AND with built in feedback:
Error occurs about 1 in every 1,000 times the operation is done
How Often Do Humans Make Mistakes?
What is Feedback?
• Buzzer when you leave your lights on • Bell if the keys are in the ignition when the
car door is opened • Control system asking you to confirm that
the charge amount you entered was correct and showing the proper pumps and valves are open/closed
If you can see that you are doing the right thing, then you can be sure that you did it.
Can a Human Check a Human?
• Principle: If a person knows that someone else checked, they are not likely to reliably recheck
Human checking is not generally a reliable safeguard against errors made by other humans
(Exception: airline industry, although it is not 100% reliable…)
4
Helios Plan Crash Aug. 2005
3 checks by two pilots missed the switch in the wrong position
Ineffective response to loss of cabin pressure and incapacitation of crew
Is Technology the Panacea?
Principle: If a safety system is installed to protect against human error, the human will depend on it. Then the safety system becomes the only layer of protection.
Principle: All mechanical things break. Safety systems need to be tested to ensure that they are working properly.
Real-Life Example
• An operator loading a tank overflowed the tank
• Management put a high level shutoff on the pump
• The operator relied on the switch and did not watch the tank level closely
• One day, the switch failed and the tank overflowed
5
BP Texas City
• Operators did not fully understand Raffinate Splitter Tower operation • Startup procedures not fully followed • Material fed to column but did not exit; critical valve not opened during startup • Level exceeded safe limits; level device failed; not recognized • Level instrumentation in blow-down tank failed, but not repaired • Blow-down tank overflowed, material reached an ignition source, and a vapor cloud explosion resulted
BP Texas City Explosion / Fire March 23, 2005
Caveat
Any system human beings devise to prevent failure can be overcome by
human beings with sufficient determination and authority
If there is a will, there is a way!
6
Guiding Principles for Preventing Human Error
• Humans and systems designed by them are vulnerable to error
• Existing facilities contain many traps that can cause human error
• Designers can provide systems to facilitate error/deviation detection and to enable recovery before the error/deviation becomes serious
Design Considerations
• Ergonomics – Can the operator reach what he needs to and work safely?
• Operability – Is the work flow designed to minimize taking shortcuts?
• Procedures – Are they clear, easy to follow, and explain the consequences of deviations?
• Maintenance – Is there access and capability to maintain equipment?
• Simplify – less chance of error
Design Considerations
• Be consistent – orient valves the same way, use computer diagrams that look like the equipment layout
• Human limitations – consider color-blind operators, different heights
• Safety systems – make sure they can’t be bypassed
• Alarm management – Don’t shower the operator with alarms he can’t process at once!
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Chernobyl Nuclear Reactor Runaway �April 26th 1986
Chernobyl, Soviet Union 1986
• Nuclear meltdown resulted in 56 direct deaths, relocation of 336,000 people, and a plume of radioactive fallout
• Significant design flaws in reactor
• Safety systems switched off
• Operator errors/training
• Alarm showers confused the operators (also at Three Mile Island)
Cultural Stereotypes
• GREEN is on, RED is off…but not in Japan!
• H is hot water, C is cold…except in non-English countries (chaud or caliente both mean hot in French and Spanish)
• Light switch is up for on…except in the UK!
8
Human Factors Philosophy
1. Make the right way THE ONLY WAY
2. Make the right way THE EASIEST WAY
3. Give the operators feedback that it was
done the wrong way
4. Provide safeguards for when it is done the
wrong way
Remember Other Operations…
Don’t forget about maintenance, startup, and shutdown. These are the most risky times in a process. There must be EHS reviews, management of change, permitting procedures, training and communication systems to avoid human error.
Piper Alpha, 1987
9
Piper Alpha, 1987
Piper Alpha, North Sea, UK
• Operators switched on a pump that was undergoing maintenance – poor lockout/tagout and communications
• Significant leak/fire ensued
• Piper Alpha was destroyed
• 167 fatalities, loss of millions in revenue per day
Safety Culture A safety culture that promotes and reinforces safety as a fundamental value is inherently safer than one which does not
- Do we have to follow the standards? - Do we really have to shut down? - Do we have to install this safety system?
If these questions are asked, it is an indication of a poor safety culture!
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Summary
• Human error is a fact of nature – plan on it • Design process to minimize “traps” • Provide training and clear guidance • Provide feedback that the operator action taken
is right/wrong • Don’t expect humans to check humans • Provide safety systems • Remember to consider startup, shutdown, and
maintenance • Support an interdependent safety culture
1
1
Introduction to Inherently Safer Concepts
Presented by: Kathy Kas, PE Developed by: Art Dowell, PE Risk Management Services
2
Why Inherently Safer Design?
Flixborough, UK, 1974
Pasadena, TX, 1989
Allentown, PA, 1999
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Inherently Safer Background
• Recognized in 1970’s for chemical industry – Trevor Kletz, “What You Don’t Have Can’t Leak”
• 1996: CCPS Concept Book – Inherently Safer Chemical Processes- A Life Cycle
Approach
2
4
American Institute of Chemical Engineers
Center for Chemical Process Safety
Concept Book (1996)
5
Inherent Safety
• Inherent - “...existing in something as a permanent and inseparable element, quality, or attribute.”
American College Dictionary
6
What is inherently safer design?
• Inherent - “existing in something as a permanent and inseparable element...” – safety “built in”, not “added on”
• Eliminate or minimize hazards rather than control hazards
• More a philosophy and way of thinking than a specific set of tools and methods – Applicable at all levels of design and operation from conceptual
design to plant operations
• “Safer,” not “Safe”
3
7
Inherently Safer Design Strategies Strategy Examples
Substitute Replace material with a less hazardous substance.
Minimize Use smaller quantities; eliminate unnecessary equipment; reduce size of equipment or volumes processed.
Moderate Use less hazardous conditions, a less hazardous form of material or facilities which minimize the impact of a release.
Simplify Design facilities which eliminate unnecessary complexity and make operating errors less likely.
8
Substitute
• Chlorine for Cooling Tower Water Treatment – 5 1-tonne cylinders per tower, manifolded, 1 hooked
up at a time. • Replaced with bleach solution in water
– Eliminated downwind chlorine exposure from leak – Provided better control for water treatment
9
Substitution - Refrigeration
• Many years ago (pre-1930) – Toxic, flammable refrigerants
• Ammonia, light hydrocarbons, sulfur dioxide • Quantity – often several kilograms
• Inherently safer alternative (1930s) – CFCs
• Discovery of environmental problems (1980s) – “Green” alternatives include light hydrocarbons – Require re-design of home refrigerators to minimize quantity
of flammable hydrocarbon (currently as little as 120 grams of hydrocarbon refrigerant)
4
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Reaction Chemistry - Acrylic Esters
• Acetylene - flammable, reactive • Carbon monoxide - toxic, flammable • Nickel carbonyl - toxic, environmental hazard (heavy
metals), carcinogenic • Anhydrous HCl - toxic, corrosive • Product - a monomer with reactivity (polymerization)
hazards
Reppe Process
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• Inherently safe?
• No, but inherently safer. Hazards are primarily flammability, corrosivity from sulfuric acid catalyst for the esterification step, small amounts of acrolein as a transient intermediate in the oxidation step, reactivity hazard for the monomer product.
Propylene Oxidation Process
Alternate Reaction Chemistry
12
Minimize • Houston Plant had 7 multi-tonne Ammonia
Blimps – why? – Heavy user of ammonia – Formerly had ammonia production plant, but – Ammonia now comes by pipeline
• Post-Bhopal: – Reduced inventory to 50% of 1 blimp. – 1 blimp in service, 1 undergoing inspection – Other blimps converted to N2, salt, H2SO4 service – Reduced maintenance costs
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Moderate
• Dilution • Refrigeration • Less severe processing conditions • Containment
– Better described as “passive” rather than “inherent”
14
Dilution
• Aqueous ammonia instead of anhydrous • Aqueous HCl in place of anhydrous HCl • Sulfuric acid in place of oleum • Wet benzoyl peroxide in place of dry • Dynamite instead of nitroglycerine
15
Effect of dilution
6
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Impact of refrigeration
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Less severe processing conditions
• Ammonia manufacture – 1930s - pressures up to 600 bar – 1950s - typically 300-350 bar – 1980s - plants operating at pressures of 100-150 bar
were being built • Result of understanding and improving the
process • Lower pressure plants are cheaper, more
efficient, as well as safer
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Inherently Safer Containment Dikes
• What physical parameters control evaporation from a spilled liquid in a storage tank containment dike?
7
Liquid Pool Behavior
•
20
Chlorine storage
21
Liquified Gas storage example
8
22
Simplify • Eliminate unnecessary complexity to reduce
risk of human error – QUESTION ALL COMPLEXITY! Is it really
necessary?
23
Controls on a stove
From Don Norman, “Turn Signals are the Facial Expressions of Automobiles”
Simplify
24
Did somebody really do this?
Simplify
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25
Conflicts and Tradeoffs
“It’s always a trade-off”
26
Some problems
• The properties of a technology which make it hazardous may be the same as the properties which make it useful – Airplanes travel at 600 mph – Gasoline is flammable
• Any replacement for gasoline must have one similar characteristic - the ability to store a large quantity of energy in a compact form
– a good definition of a hazardous situation – Chlorine is toxic
• Control of the hazard is the critical issue in safely getting the benefits of the technology
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Multiple hazards
• Everything has multiple hazards – Automobile travel
• velocity (energy), flammable fuel, exhaust gas toxicity, hot surfaces, pressurized cooling system, electricity......
– Chemical process or product • acute toxicity, flammability, corrosiveness, chronic
toxicity, various environmental impacts, reactivity.......
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What is the hazard of concern… …if you live on top of a hill in Detroit? …if you live on the ocean front at the shore?
Which is inherently safer?
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At what phase of design should engineers and chemists consider inherently safer design? • My answer – at all levels! • Inherently safer design is not a meeting, or a review
session. • 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 of a chemist, engineer, or other designer as he goes about his work.
30
Questions a designer should ask when he has identified a hazard In this order 1. Can I eliminate this hazard? 2. If not, can I reduce the magnitude of the hazard? 3. Do the alternatives identified in questions 1 and 2 increase the
magnitude of any other hazards, or create new hazards? (If so, consider all hazards in selecting the best alternative.)
4. At this point, what technical and management systems are required to manage the hazards which inevitably will remain?
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31
Better may be harder to invent
“There are two ways of dealing with this problem: one is complicated and messy, and the other is simple and elegant. We don’t have much time left, so I’ll show you the complicated and messy way.”
- Richard P. Feynman Nobel Prize winning physicist, discussing
approaches to understanding a physics problem
32
Reference Slides
• For inherently safer design
33
Process Safety Risk Management Strategies • Inherent
– Eliminate or modify the hazard and/or risk by employing one of four strategies of substitution, minimization, moderation, simplification.
• Passive – Minimize the hazard by process and equipment design features which
reduce either the frequency or consequences of the hazard without the active functioning of any device.
• Active – Using controls, safety interlocks, and emergency shutdown systems to
detect and correct process deviations.
• Procedural – Using operating procedures, administrative checks, and emergency
response to prevent incidents, or to minimize the effect of an incident.
12
34
Layers of Protection
35
Inherently Safer Approach to Analyzing & Managing Process Risks
36
Continued
13
37
For More Information - Books
• Inherently Safer Chemical Processes - A Life Cycle Approach, American Institute of Chemical Engineers, New York, 1996.
• INSET Toolkit, Commission of the European Community, 1997. – available for free download from AEA Technologies: http://www.aeat-safety-and-risk.com/html/inset.html
• Guidelines for Engineering Design for Designing Solutions for Process Equipment Failures, American Institute of Chemical Engineers, New York, 1998.
• Kletz, T. A., Process Plants - A Handbook for Inherently Safer Design, Taylor and Francis, London, 1998.
Fatality Rates Technical Notes
Census of Fatal Occupational Injuries (CFOI) Bureau of Labor Statistics
February 2006 Fatality rates are used to compare the risk of incurring a fatal work injury among worker groups with varying employment levels. Since employment data are not collected by the Census of Fatal Occupational Injuries (CFOI), fatality rates were calculated using estimates of employed civilian workers (age 16 and older) from the Current Population Survey (CPS) supplemented with counts for resident armed forces provided by the Department of Defense (DOD). To accurately describe fatality risk for a worker group, the numerator (fatalities) and denominator (employment) of the rate must refer to the same group of workers. Because the employment data used in the rate calculations exclude workers under the age of 16, fatalities occurring to these workers were also excluded from the numerator. Fatality rates, expressed as the number of fatal work injuries per 100,000 workers, were calculated as follows:
Fatality rate = (N / W) x 100,000 N = the number of worker fatalities, age 16 and older (CFOI) W = the annual average number of employed workers, age 16 and older (CPS and DOD)
To illustrate, in 2003, there were 5,575 workplace fatalities according to CFOI. Of these, 5,550 occurred to workers age 16 and older. According to the combined CPS and DOD figures, employment estimates for workers age 16 and older totaled 138,928,000.
N = 5,550 W = 138,928,000 Fatality rate = (N / W) x 100,000 Fatality rate = (5,550 / 138,928,000) x 100,000 = 4.0 Fatality rate = 4.0 fatalities per 100,000 workers
There are a number of limitations to these fatality rates:
• The CPS employment data used to calculate rates are estimates based upon a sample rather than a complete count. Therefore, the CPS estimates and fatality rates have sampling errors. The figures obtained for the rates may differ from figures that would have been obtained if it had been possible to take a census of employed persons. See Explanatory Notes and Estimates of Error in the February 2004 Employment and Earnings for an explanation of CPS sampling and estimation methodology, and standard error computations. The relative standard errors of the CPS employment estimates can be used to approximate confidence ranges for the fatality rates.
• The CPS categorizes workers according to their primary job, which may differ from the job the deceased was working in when fatally injured as reported in the Census of Fatal Occupational Injuries.
• The rates are based on employment. They factor out differences in the number of fatal work injuries between worker groups due to different employment levels. They do not take into account differences in the number of hours worked. Hours-based rates, which factor out these differences, are generally considered more accurate. However, because of limitations in the availability of data for hours worked, the rates are employment based.
• Rates are calculated at the level of detail available from the CPS and DOD employment data. Additionally, rates are only calculated for those occupations and industries which met minimum thresholds in the base year (2003), having at least 30 fatalities and 40,000 employed.
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003
Total 5,575 2,364 902 913 696 486 198
Private Industry 5,043 2,057 802 885 662 445 180
Goods Producing.................................................................................................... 2,401 808 139 614 446 279 111 Natural Resources and Mining................................................................................... 850 401 61 253 44 55 35 Agriculture, Forestry, Fishing and Hunting................................................................... 11 709 353 59 208 34 45 10Crop Production....................................................................................................................... 111 334 194 19 84 17 17 3 Oilseed and Grain Farming................................................................................................. 1111 35 15 -- 13 3 3 -- Soybean Farming.......................................................................................................... 11111 3 -- -- -- -- -- -- Wheat Farming.............................................................................................................. 11114 5 4 -- -- -- -- -- Corn Farming................................................................................................................. 11115 15 4 -- 7 -- -- -- Rice Farming................................................................................................................. 11116 3 3 -- -- -- -- -- Other Grain Farming...................................................................................................... 11119 4 -- -- -- -- -- -- Vegetable and Melon Farming............................................................................................ 1112 17 7 -- 5 -- -- -- Vegetable and Melon Farming....................................................................................... 11121 17 7 -- 5 -- -- -- Potato Farming......................................................................................................... 111211 6 -- -- -- -- -- -- Other Vegetable (except Potato) and Melon Farming.............................................. 111219 6 -- -- 3 -- -- -- Fruit and Tree Nut Farming................................................................................................ 1113 13 9 -- -- -- -- -- Noncitrus Fruit and Tree Nut Farming........................................................................... 11133 11 7 -- -- -- -- -- Grape Vineyards....................................................................................................... 111332 3 3 -- -- -- -- -- Berry (except Strawberry) Farming........................................................................... 111334 3 3 -- -- -- -- -- Other Noncitrus Fruit Farming.................................................................................. 111339 3 -- -- -- -- -- -- Greenhouse, Nursery, and Floriculture Production............................................................ 1114 18 8 6 3 -- -- -- Food Crops Grown Under Cover................................................................................... 11141 3 -- -- -- -- -- -- Nursery and Floriculture Production.............................................................................. 11142 13 6 5 -- -- -- -- Nursery and Tree Production.................................................................................... 111421 12 6 5 -- -- -- -- Other Crop Farming............................................................................................................ 1119 77 51 3 19 -- 3 -- Tobacco Farming........................................................................................................... 11191 9 7 -- -- -- -- -- Cotton Farming.............................................................................................................. 11192 4 3 -- -- -- -- -- Sugarcane Farming....................................................................................................... 11193 6 5 -- -- -- -- -- Hay Farming.................................................................................................................. 11194 11 8 -- 3 -- -- -- All Other Crop Farming.................................................................................................. 11199 44 27 3 13 -- -- -- All Other Miscellaneous Crop Farming..................................................................... 111998 43 27 3 12 -- -- --Animal Production.................................................................................................................... 112 159 63 28 37 13 15 3 Cattle Ranching and Farming............................................................................................. 1121 116 44 25 29 9 7 -- Beef Cattle Ranching and Farming, including Feedlots................................................. 11211 39 16 13 5 4 -- -- Beef Cattle Ranching and Farming........................................................................... 112111 37 14 13 5 4 -- -- Dairy Cattle and Milk Production................................................................................... 11212 56 18 7 19 5 5 -- Hog and Pig Farming.......................................................................................................... 1122 9 -- -- 3 -- 3 -- Hog and Pig Farming..................................................................................................... 11221 9 -- -- 3 -- 3 -- Poultry and Egg Production................................................................................................ 1123 7 3 -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Transpor- tation
incidents3
Assaults and
violent acts4
Event or exposure2
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 1 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Animal Aquaculture............................................................................................................. 1125 5 3 -- -- -- -- -- Animal Aquaculture........................................................................................................ 11251 5 3 -- -- -- -- -- Finfish Farming and Fish Hatcheries........................................................................ 112511 4 3 -- -- -- -- -- Other Animal Production..................................................................................................... 1129 16 7 -- 3 -- -- -- Apiculture....................................................................................................................... 11291 4 -- -- -- -- -- -- Horse and Other Equine Production.............................................................................. 11292 9 5 -- -- -- -- --Forestry and Logging............................................................................................................... 113 120 30 -- 82 3 -- -- Logging............................................................................................................................... 1133 118 30 -- 81 3 -- -- Logging.......................................................................................................................... 11331 118 30 -- 81 3 -- --Fishing, Hunting and Trapping................................................................................................. 114 49 37 -- -- -- 8 -- Fishing................................................................................................................................ 1141 47 35 -- -- -- 8 -- Fishing........................................................................................................................... 11411 47 35 -- -- -- 8 -- Finfish Fishing........................................................................................................... 114111 8 5 -- -- -- -- -- Shellfish Fishing........................................................................................................ 114112 22 16 -- -- -- 4 --Support Activities for Agriculture and Forestry........................................................................ 115 44 29 8 3 -- 3 -- Support Activities for Crop Production................................................................................ 1151 24 15 -- -- -- 3 -- Support Activities for Crop Production........................................................................... 11511 24 15 -- -- -- 3 -- Soil Preparation, Planting, and Cultivating............................................................... 115112 6 6 -- -- -- -- -- Crop Harvesting, Primarily by Machine.................................................................... 115113 4 -- -- -- -- -- -- Postharvest Crop Activities (except Cotton Ginning)................................................ 115114 3 -- -- -- -- -- -- Farm Labor Contractors and Crew Leaders............................................................. 115115 6 -- -- -- -- -- -- Support Activities for Animal Production............................................................................. 1152 8 -- 4 -- -- -- -- Support Activities for Animal Production........................................................................ 11521 8 -- 4 -- -- -- -- Support Activities for Forestry............................................................................................. 1153 11 11 -- -- -- -- -- Support Activities for Forestry........................................................................................ 11531 11 11 -- -- -- -- -- Mining5............................................................................................................................... 21 141 48 -- 45 10 10 25Oil and Gas Extraction5............................................................................................................ 211 17 9 -- 3 -- -- 4 Oil and Gas Extraction5....................................................................................................... 2111 17 9 -- 3 -- -- 4 Oil and Gas Extraction5.................................................................................................. 21111 17 9 -- 3 -- -- 4 Crude Petroleum and Natural Gas Extraction5.......................................................... 211111 16 9 -- -- -- -- 4Mining (except Oil and Gas)5................................................................................................... 212 55 17 -- 19 6 5 5 Coal Mining5........................................................................................................................ 2121 27 8 -- 9 -- 3 -- Coal Mining5................................................................................................................... 21211 27 8 -- 9 -- 3 -- Bituminous Coal and Lignite Surface Mining5........................................................... 212111 6 -- -- -- -- -- -- Bituminous Coal Underground Mining5..................................................................... 212112 19 5 -- 6 -- 3 -- Metal Ore Mining5............................................................................................................... 2122 3 -- -- -- -- -- -- Nonmetallic Mineral Mining and Quarrying5........................................................................ 2123 24 8 -- 9 3 -- -- Stone Mining and Quarrying5......................................................................................... 21231 10 -- -- 5 -- -- -- Dimension Stone Mining and Quarrying5.................................................................. 212311 4 -- -- -- -- -- -- Crushed and Broken Limestone Mining and Quarrying5........................................... 212312 3 -- -- -- -- -- -- Other Crushed and Broken Stone Mining and Quarrying5........................................ 212319 3 -- -- 3 -- -- -- Sand, Gravel, Clay, and Ceramic and Refractory Minerals Mining and Quarrying5................................................................................................... 21232 13 6 -- 4 -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 2 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Construction Sand and Gravel Mining5..................................................................... 212321 10 4 -- 4 -- -- --Support Activities for Mining5................................................................................................... 213 69 22 -- 23 4 4 16 Support Activities for Mining5.............................................................................................. 2131 69 22 -- 23 4 4 16 Support Activities for Mining5......................................................................................... 21311 69 22 -- 23 4 4 16 Drilling Oil and Gas Wells5........................................................................................ 213111 26 5 -- 13 -- -- 5 Support Activities for Oil and Gas Operations5......................................................... 213112 42 17 -- 10 -- 3 10 Construction................................................................................................................ 1,131 290 37 231 364 179 29 Construction..................................................................................................................... 23 1,131 290 37 231 364 179 29Construction of buildings......................................................................................................... 236 227 51 13 39 96 25 -- Residential Building Construction....................................................................................... 2361 129 32 8 21 50 18 -- Residential Building Construction.................................................................................. 23611 129 32 8 21 50 18 -- New Single-family Housing Construction (except operative builders.................................................................................................... 236115 57 17 -- 10 20 8 -- New Multi-family Housing Construction (except operative builders)................................................................................................... 236116 9 -- -- -- 4 -- -- Residential Remodelers............................................................................................ 236118 29 -- 6 4 12 5 -- Nonresidential Building Construction.................................................................................. 2362 80 10 5 16 39 7 -- Industrial Building Construction..................................................................................... 23621 19 -- -- 3 11 -- -- Commercial and Institutional Building Construction...................................................... 23622 55 5 3 12 27 5 --Heavy and Civil Engineering Construction.............................................................................. 237 247 90 -- 79 25 46 6 Utility System Construction................................................................................................. 2371 131 27 -- 53 16 32 3 Water and Sewer Line and related structures construction........................................... 23711 66 12 -- 39 3 11 -- Oil and Gas Pipeline and Related Structures Construction........................................... 23712 15 6 -- 3 -- -- -- Power and Communication Line and Related Structures Construction......................... 23713 49 8 -- 11 11 19 -- Highway, Street, and Bridge Construction.......................................................................... 2373 95 52 -- 23 6 12 -- Highway, Street, and Bridge Construction..................................................................... 23731 95 52 -- 23 6 12 -- Other Heavy and Civil Engineering Construction............................................................... 2379 19 10 -- 3 -- -- -- Other Heavy and Civil Engineering Construction.......................................................... 23799 19 10 -- 3 -- -- --Specialty Trade Contractors.................................................................................................... 238 629 135 21 110 235 107 21 Foundation, Structure, and Building Exterior Contractors.................................................. 2381 228 33 5 39 125 21 5 Poured Concrete Foundation and Structure contractors............................................... 23811 23 11 -- 6 -- 3 -- Residential Poured Concrete Foundation and Structure Contractors.............................................................................................................. 238111 5 -- -- -- -- -- -- Nonresidential Poured Concrete Foundation and Structure Contractors............................................................................................... 238112 5 3 -- -- -- -- -- Structural Steel and Precast Concrete Contractors....................................................... 23812 37 3 -- 8 22 4 -- Nonresidential Structural Steel and Precast Concrete Contractors.............................................................................................................. 238122 19 -- -- 4 13 -- -- Framing Contractors...................................................................................................... 23813 24 -- -- 5 17 -- -- Residential Framing Contractors.............................................................................. 238131 11 -- -- -- 9 -- -- Masonry Contractors..................................................................................................... 23814 36 9 -- 11 13 -- -- Residential Masonry Contractors.............................................................................. 238141 9 -- -- 3 -- -- -- Nonresidential Masonry Contractors........................................................................ 238142 8 -- -- -- 5 -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 3 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Glass and Glazing Contractors...................................................................................... 23815 3 -- -- -- -- -- -- Roofing Contractors....................................................................................................... 23816 76 5 3 4 58 6 -- Residential Roofing Contractors............................................................................... 238161 24 3 -- -- 18 -- -- Nonresidential Roofing Contractors.......................................................................... 238162 14 -- -- -- 11 -- -- Siding Contractors......................................................................................................... 23817 13 -- -- -- 7 4 -- Other Foundation, Structure, and Building Exterior Contractors................................... 23819 15 -- -- 5 3 -- 5 Other Residential Foundation, Structure, and Building Exterior Contractors................................................................................... 238191 3 -- -- -- -- -- -- Other Nonresidential Foundation, Structure, and Building Exterior Contractors................................................................................... 238192 6 -- -- -- -- -- 3 Building Equipment Contractors......................................................................................... 2382 160 28 7 23 44 51 7 Electrical Contractors..................................................................................................... 23821 79 8 3 8 23 34 3 Residential Electrical Contractors............................................................................. 238211 9 -- -- -- -- 6 -- Nonresidential Electrical Contractors........................................................................ 238212 32 3 -- -- 9 19 -- Plumbing, Heating, and Air-Conditioning Contractors................................................... 23822 69 19 4 13 15 15 3 Residential Plumbing, Heating, and Air-Conditioning Contractors.............................................................................................................. 238221 18 5 -- 5 4 -- -- Nonresidential Plumbing, Heating, and Air-Conditioning Contractors.................................................................................... 238222 22 7 -- 5 4 6 -- Other Building Equipment Contractors.......................................................................... 23829 11 -- -- -- 6 -- -- Other Nonresidential Building Equipment Contractors............................................. 238292 6 -- -- -- -- -- -- Building Finishing Contractors............................................................................................ 2383 104 16 5 9 46 23 5 Drywall and Insulation Contractors................................................................................ 23831 22 -- -- -- 15 -- -- Residential Drywall and Insulation Contractors........................................................ 238311 10 -- -- -- 7 -- -- Painting and Wall Covering Contractors........................................................................ 23832 55 -- -- 4 26 18 4 Residential Painting and Wall Covering Contractors................................................ 238321 17 -- -- -- 7 8 -- Nonresidential Painting and Wall Covering Contractors........................................... 238322 10 -- -- -- 5 4 -- Flooring Contractors...................................................................................................... 23833 5 4 -- -- -- -- -- Residential Flooring Contractors.............................................................................. 238331 4 4 -- -- -- -- -- Tile and Terrazzo Contractors....................................................................................... 23834 6 -- -- -- -- -- -- Finish Carpentry Contractors......................................................................................... 23835 10 4 -- -- 4 -- -- Other Building Finishing Contractors............................................................................. 23839 4 -- -- -- -- -- -- Other Specialty Trade Contractors..................................................................................... 2389 128 55 4 39 15 11 4 Site Preparation Contractors......................................................................................... 23891 84 32 3 33 7 7 -- Other Residential Site Preparation Contractors........................................................ 238911 14 4 -- 6 -- -- -- Other Nonresidential Site Preparation Contractors.................................................. 238912 32 8 -- 14 3 5 -- All Other Special Trade Contractors.............................................................................. 23899 44 23 -- 6 8 4 -- All Other Residential Special Trade Contractors...................................................... 238991 13 8 -- -- -- -- -- All Other Nonresidential Special Trade Contractors................................................. 238992 9 3 -- -- 3 -- -- Manufacturing.............................................................................................................. 420 117 41 130 38 45 47 Manufacturing................................................................................................................... 31-33 420 117 41 130 38 45 47Food Manufacturing................................................................................................................. 311 59 17 4 16 7 9 6 Animal Food Manufacturing................................................................................................ 3111 4 -- -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 4 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Animal Food Manufacturing........................................................................................... 31111 4 -- -- -- -- -- -- Other Animal Food Manufacturing............................................................................ 311119 3 -- -- -- -- -- -- Grain and Oilseed Milling.................................................................................................... 3112 5 -- -- -- -- -- -- Fruit and Vegetable Preserving and Specialty Food Manufacturing................................... 3114 5 -- -- -- -- -- -- Fruit and Vegetable Canning, Pickling, and Drying....................................................... 31142 4 -- -- -- -- -- -- Fruit and Vegetable Canning.................................................................................... 311421 4 -- -- -- -- -- -- Dairy Product Manufacturing.............................................................................................. 3115 6 3 -- -- -- -- -- Dairy Product (except Frozen) Manufacturing............................................................... 31151 5 -- -- -- -- -- -- Fluid Milk Manufacturing........................................................................................... 311511 5 -- -- -- -- -- -- Animal Slaughtering and Processing.................................................................................. 3116 19 5 -- 5 -- 4 -- Animal Slaughtering and Processing............................................................................. 31161 19 5 -- 5 -- 4 -- Meat Processed from Carcasses.............................................................................. 311612 5 -- -- -- -- -- -- Poultry Processing.................................................................................................... 311615 10 3 -- 3 -- -- -- Bakeries and Tortilla Manufacturing................................................................................... 3118 8 5 -- -- -- -- -- Bread and Bakery Product Manufacturing..................................................................... 31181 6 4 -- -- -- -- -- Commercial Bakeries................................................................................................ 311812 4 3 -- -- -- -- -- Other Food Manufacturing.................................................................................................. 3119 8 -- -- 4 -- -- -- Seasoning and Dressing Manufacturing........................................................................ 31194 3 -- -- -- -- -- -- Spice and Extract Manufacturing.............................................................................. 311942 3 -- -- -- -- -- -- All Other Food Manufacturing........................................................................................ 31199 3 -- -- -- -- -- --Beverage and Tobacco Product Manufacturing...................................................................... 312 6 6 -- -- -- -- -- Beverage Manufacturing..................................................................................................... 3121 6 6 -- -- -- -- -- Soft Drink and Ice Manufacturing.................................................................................. 31211 6 6 -- -- -- -- -- Soft Drink Manufacturing.......................................................................................... 312111 6 6 -- -- -- -- --Textile Mills.............................................................................................................................. 313 7 3 -- -- -- -- -- Fabric Mills.......................................................................................................................... 3132 4 -- -- -- -- -- -- Broadwoven Fabric Mills................................................................................................ 31321 4 -- -- -- -- -- --Wood Product Manufacturing.................................................................................................. 321 37 8 3 21 3 -- -- Sawmills and Wood Preservation....................................................................................... 3211 18 -- -- 14 -- -- -- Sawmills and Wood Preservation.................................................................................. 32111 18 -- -- 14 -- -- -- Sawmills.................................................................................................................... 321113 16 -- -- 13 -- -- -- Veneer, Plywood, and Engineered Wood Product Manufacturing...................................... 3212 7 -- -- 4 -- -- -- Veneer, Plywood, and Engineered Wood Product Manufacturing................................. 32121 7 -- -- 4 -- -- -- Truss Manufacturing................................................................................................. 321214 5 -- -- -- -- -- -- Other Wood Product Manufacturing................................................................................... 3219 12 4 -- 3 -- -- -- Millwork.......................................................................................................................... 32191 5 -- -- -- -- -- -- Wood Container and Pallet Manufacturing.................................................................... 32192 4 -- -- -- -- -- -- All Other Wood Product Manufacturing......................................................................... 32199 3 -- -- -- -- -- --Paper Manufacturing............................................................................................................... 322 17 5 -- 6 -- -- -- Pulp, Paper, and Paperboard Mills..................................................................................... 3221 9 3 -- 4 -- -- -- Paper Mills..................................................................................................................... 32212 8 3 -- 3 -- -- -- Paper (except Newsprint) Mills................................................................................. 322121 3 -- -- -- -- -- -- Newsprint Mills.......................................................................................................... 322122 3 -- -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 5 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Converted Paper Product Manufacturing........................................................................... 3222 8 -- -- -- -- -- -- Paperboard Container Manufacturing............................................................................ 32221 5 -- -- -- -- -- -- Corrugated and Solid Fiber Box Manufacturing........................................................ 322211 3 -- -- -- -- -- --Printing and Related Support Activities................................................................................... 323 7 -- -- -- -- -- -- Printing and Related Support Activities.............................................................................. 3231 7 -- -- -- -- -- -- Commercial Lithographic Printing.................................................................................. 323110 6 -- -- -- -- -- --Chemical Manufacturing.......................................................................................................... 325 28 9 -- 3 -- 3 10 Basic Chemical Manufacturing........................................................................................... 3251 5 -- -- -- -- -- -- Petrochemical Manufacturing........................................................................................ 32511 3 -- -- -- -- -- -- Resin, Synthetic Rubber, and Artificial and Synthetic Fibers and Filaments Manufacturing............................................................................................ 3252 4 -- -- -- -- -- -- Resin and Synthetic Rubber Manufacturing.................................................................. 32521 4 -- -- -- -- -- -- Plastics Material and Resin Manufacturing............................................................... 325211 4 -- -- -- -- -- -- Soap, Cleaning Compound, and Toilet Preparation Manufacturing................................... 3256 4 -- -- -- -- -- -- Soap and Cleaning Compound Manufacturing.............................................................. 32561 3 -- -- -- -- -- -- Other Chemical Product and Preparation Manufacturing................................................... 3259 12 -- -- -- -- -- 5 All Other Chemical Product and Preparation Manufacturing......................................... 32599 10 -- -- -- -- -- 5 All Other Miscellaneous Chemical Product and Preparation Manufacturing...................................................................................... 325998 9 -- -- -- -- -- 5Plastics and Rubber Products Manufacturing.......................................................................... 326 26 6 -- 5 -- 3 9 Plastics Product Manufacturing.......................................................................................... 3261 18 4 -- 5 -- 3 3 Unsupported Plastics Film, Sheet, and Bag Manufacturing.......................................... 32611 3 -- -- -- -- -- -- Other Plastics Product Manufacturing........................................................................... 32619 8 -- -- -- -- -- -- All Other Plastics Product Manufacturing................................................................. 326199 6 -- -- -- -- -- -- Rubber Product Manufacturing........................................................................................... 3262 8 -- -- -- -- -- 6 Other Rubber Product Manufacturing............................................................................ 32629 5 -- -- -- -- -- 5 Rubber Product Manufacturing for Mechanical Use................................................. 326291 5 -- -- -- -- -- 5Nonmetallic Mineral Product Manufacturing............................................................................ 327 46 18 -- 15 -- 5 7 Clay Product and Refractory Manufacturing....................................................................... 3271 3 -- -- -- -- -- -- Glass and Glass Product Manufacturing............................................................................ 3272 3 -- -- -- -- -- -- Glass and Glass Product Manufacturing....................................................................... 32721 3 -- -- -- -- -- -- Cement and Concrete Product Manufacturing................................................................... 3273 29 16 -- 11 -- -- -- Ready-Mix Concrete Manufacturing.............................................................................. 32732 20 14 -- 5 -- -- -- Concrete Pipe, Brick, and Block Manufacturing............................................................ 32733 4 -- -- 3 -- -- -- Other Concrete Product Manufacturing......................................................................... 32739 4 -- -- 3 -- -- -- Other Nonmetallic Mineral Product Manufacturing............................................................. 3279 11 -- -- -- -- -- 7 All Other Nonmetallic Mineral Product Manufacturing................................................... 32799 11 -- -- -- -- -- 7 Mineral Wool Manufacturing..................................................................................... 327993 8 -- -- -- -- -- 7Primary Metal Manufacturing................................................................................................... 331 33 6 -- 19 -- 3 -- Iron and Steel Mills and Ferroalloy Manufacturing............................................................. 3311 9 3 -- 6 -- -- -- Iron and Steel Mills and Ferroalloy Manufacturing........................................................ 33111 9 3 -- 6 -- -- -- Iron and Steel Mills................................................................................................... 331111 8 -- -- 6 -- -- -- Steel Product Manufacturing from Purchased Steel........................................................... 3312 6 -- -- 4 -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 6 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Alumina and Aluminum Production and Processing........................................................... 3313 4 -- -- -- -- -- -- Alumina and Aluminum Production and Processing...................................................... 33131 4 -- -- -- -- -- -- Foundries............................................................................................................................ 3315 12 -- -- 6 -- -- -- Ferrous Metal Foundries................................................................................................ 33151 10 -- -- 4 -- -- -- Iron Foundries........................................................................................................... 331511 3 -- -- -- -- -- -- Steel Foundries (except Investment)........................................................................ 331513 7 -- -- -- -- -- --Fabricated Metal Product Manufacturing................................................................................. 332 43 5 -- 20 5 8 3 Forging and Stamping........................................................................................................ 3321 5 -- -- 4 -- -- -- Forging and Stamping................................................................................................... 33211 5 -- -- 4 -- -- -- Metal Stamping......................................................................................................... 332116 3 -- -- -- -- -- -- Architectural and Structural Metals Manufacturing............................................................. 3323 17 3 -- 6 4 3 -- Plate Work and Fabricated Structural Product Manufacturing....................................... 33231 11 -- -- 5 -- 3 -- Fabricated Structural Metal Manufacturing............................................................... 332312 6 -- -- -- -- -- -- Plate Work Manufacturing........................................................................................ 332313 4 -- -- -- -- -- -- Ornamental and Architectural Metal Products Manufacturing....................................... 33232 5 -- -- -- 3 -- -- Machine Shops; Turned Product; and Screw, Nut, and Bolt Manufacturing....................... 3327 6 -- -- 3 -- -- -- Machine Shops.............................................................................................................. 33271 6 -- -- 3 -- -- -- Coating, Engraving, Heat Treating, and Allied Activities.................................................... 3328 4 -- -- -- -- 3 -- Coating, Engraving, Heat Treating, and Allied Activities............................................... 33281 4 -- -- -- -- 3 --Machinery Manufacturing........................................................................................................ 333 26 10 4 8 -- -- -- Agriculture, Construction, and Mining Machinery Manufacturing....................................... 3331 6 3 -- -- -- -- -- Industrial Machinery Manufacturing.................................................................................... 3332 3 -- -- -- -- -- -- Other Industrial Machinery Manufacturing..................................................................... 33329 3 -- -- -- -- -- -- All Other Industrial Machinery Manufacturing........................................................... 333298 3 -- -- -- -- -- -- Ventilation, Heating, Air-Conditioning, and Commercial Refrigeration Equipment Manufacturing............................................................................ 3334 3 -- -- -- -- -- -- Ventilation, Heating, Air-Conditioning, and Commercial Refrigeration Equipment Manufacturing....................................................................... 33341 3 -- -- -- -- -- -- Air-Conditioning and Warm Air Heating Equipment and Commercial and Industrial Refrigeration Equipment Manufacturing....................... 333415 3 -- -- -- -- -- -- Other General Purpose Machinery Manufacturing............................................................. 3339 11 5 -- -- -- -- -- Material Handling Equipment Manufacturing................................................................. 33392 8 4 -- -- -- -- -- Conveyor and Conveying Equipment Manufacturing............................................... 333922 4 -- -- -- -- -- --Computer and Electronic Product Manufacturing.................................................................... 334 11 -- -- 4 -- -- -- Semiconductor and Other Electronic Component Manufacturing....................................... 3344 3 -- -- -- -- -- -- Semiconductor and Other Electronic Component Manufacturing.................................. 33441 3 -- -- -- -- -- -- Navigational, Measuring, Electromedical, and Control Instruments Manufacturing................................................................................................ 3345 5 -- -- -- -- -- -- Electromedical and Electrotherapeutic Apparatus Manufacturing................................. 334510 5 -- -- -- -- -- --Electrical Equipment, Appliance, and Component Manufacturing........................................... 335 5 -- -- -- -- -- --Transportation Equipment Manufacturing................................................................................ 336 44 8 15 7 6 -- 6 Motor Vehicle Manufacturing.............................................................................................. 3361 4 -- -- -- -- -- -- Automobile and Light Duty Motor Vehicle Manufacturing.............................................. 33611 4 -- -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 7 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Automobile Manufacturing........................................................................................ 336111 3 -- -- -- -- -- -- Motor Vehicle Body and Trailer Manufacturing................................................................... 3362 5 -- -- -- -- -- -- Motor Vehicle Body and Trailer Manufacturing.............................................................. 33621 5 -- -- -- -- -- -- Motor Vehicle Body Manufacturing........................................................................... 336211 4 -- -- -- -- -- -- Motor Vehicle Parts Manufacturing..................................................................................... 3363 14 -- 7 -- -- -- -- Other Motor Vehicle Parts Manufacturing...................................................................... 33639 8 -- 6 -- -- -- -- All Other Motor Vehicle Parts Manufacturing............................................................ 336399 8 -- 6 -- -- -- -- Aerospace Product and Parts Manufacturing..................................................................... 3364 13 4 8 -- -- -- -- Aerospace Product and Parts Manufacturing................................................................ 33641 13 4 8 -- -- -- -- Aircraft Manufacturing............................................................................................... 336411 4 3 -- -- -- -- -- Other Aircraft Parts and Auxiliary Equipment Manufacturing................................... 336413 8 -- 7 -- -- -- -- Ship and Boat Building....................................................................................................... 3366 6 -- -- -- -- -- -- Ship and Boat Building.................................................................................................. 33661 6 -- -- -- -- -- -- Ship Building and Repairing..................................................................................... 336611 5 -- -- -- -- -- --Furniture and Related Product Manufacturing......................................................................... 337 9 5 -- -- -- -- -- Household and Institutional Furniture and Kitchen Cabinet Manufacturing.................................................................................................................... 3371 8 4 -- -- -- -- -- Household and Institutional Furniture Manufacturing.................................................... 33712 6 -- -- -- -- -- --Miscellaneous Manufacturing.................................................................................................. 339 7 -- -- -- -- -- -- Other Miscellaneous Manufacturing................................................................................... 3399 5 -- -- -- -- -- -- Service Providing................................................................................................... 2,642 1,249 663 271 216 166 69 Trade, Transportation, and Utilities........................................................................... 1,375 807 299 127 65 50 23 Wholesale Trade............................................................................................................... 42 191 92 23 40 15 11 9Merchant Wholesalers, Durable Goods................................................................................... 423 102 41 16 29 4 7 5 Motor Vehicle and Motor Vehicle Parts and Supplies Merchant Wholesalers....................................................................................................................... 4231 16 4 -- 6 -- -- 3 Motor Vehicle Supplies and New Parts Merchant wholesalers..................................... 42312 3 -- -- -- -- -- -- Motor Vehicle Parts (Used) Merchant wholesalers........................................................ 42314 8 -- -- 3 -- -- -- Furniture and Home Furnishing Merchant wholesalers...................................................... 4232 5 -- -- -- -- -- -- Home Furnishing Merchant wholesalers....................................................................... 42322 4 -- -- -- -- -- -- Lumber and Other Construction Materials Merchant wholesalers...................................... 4233 10 6 -- -- -- -- -- Brick, Stone, and Related Construction Material Merchant wholesalers................................................................................................................... 42332 7 4 -- -- -- -- -- Professional and Commercial Equipment and Supplies Merchant wholesalers........................................................................................................................ 4234 11 6 3 -- -- -- -- Office Equipment Merchant wholesalers....................................................................... 42342 5 4 -- -- -- -- -- Medical, Dental, and Hospital Equipment and Supplies Merchant wholesalers................................................................................................... 42345 4 -- -- -- -- -- -- Metal and Mineral (except Petroleum) Merchant wholesalers............................................ 4235 3 -- -- 3 -- -- -- Metal Service Centers and Offices................................................................................ 42351 3 -- -- 3 -- -- -- Electrical Goods Merchant wholesalers.............................................................................. 4236 6 3 -- -- -- -- -- Electrical Apparatus and Equipment, Wiring Supplies, and Construction Material Merchant wholesalers................................................................ 42361 4 -- -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 8 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Machinery, Equipment, and Supplies Merchant wholesalers............................................. 4238 26 12 -- 8 -- -- -- Construction and Mining (except Oil Well) Machinery and Equipment Merchant wholesalers................................................................................. 42381 5 -- -- -- -- -- -- Farm and Garden Machinery and Equipment Merchant wholesalers............................ 42382 6 -- -- -- -- -- -- Industrial Machinery and Equipment Merchant wholesalers......................................... 42383 11 5 -- 5 -- -- -- Service Establishment Equipment and Supplies Merchant wholesalers....................... 42385 3 -- -- -- -- -- -- Miscellaneous Durable Goods Merchant wholesalers........................................................ 4239 24 8 4 10 -- -- -- Recyclable Material Merchant wholesalers................................................................... 42393 21 7 3 9 -- -- --Merchant Wholesalers, Nondurable Goods............................................................................. 424 81 47 5 10 11 3 4 Drugs and Druggists’ Sundries Merchant wholesalers....................................................... 4242 3 3 -- -- -- -- -- Drugs and Druggists’ Sundries Merchant wholesalers.................................................. 42421 3 3 -- -- -- -- -- Grocery and Related Product Merchant wholesalers......................................................... 4244 25 21 -- -- -- -- -- General Line Grocery Merchant wholesalers................................................................ 42441 9 7 -- -- -- -- -- Packaged Frozen Food Merchant wholesalers............................................................. 42442 4 4 -- -- -- -- -- Other Grocery and Related Products Merchant wholesalers........................................ 42449 7 7 -- -- -- -- -- Farm Product Raw Material Merchant wholesalers............................................................ 4245 16 -- -- 6 7 -- -- Grain and Field Bean Merchant wholesalers................................................................. 42451 15 -- -- 6 7 -- -- Petroleum and Petroleum Products Merchant wholesalers................................................ 4247 15 11 -- -- -- -- -- Petroleum and Petroleum Products Merchant wholesalers (except Bulk Stations and Terminals)........................................................................... 42472 13 10 -- -- -- -- -- Beer, Wine, and Distilled Alcoholic Beverage Merchant wholesalers................................. 4248 5 -- -- -- -- -- -- Beer and Ale Merchant wholesalers.............................................................................. 42481 3 -- -- -- -- -- -- Miscellaneous Nondurable Goods Merchant wholesalers.................................................. 4249 14 9 -- -- -- -- -- Farm Supplies Merchant wholesalers............................................................................ 42491 7 3 -- -- -- -- -- Flower, Nursery Stock, and Florists’ Supplies Merchant wholesalers................................................................................................................... 42493 3 3 -- -- -- -- --Wholesale Electronic Markets and Agents and Brokers.......................................................... 425 7 3 -- -- -- -- -- Wholesale Electronic Markets and Agents and Brokers..................................................... 4251 7 3 -- -- -- -- -- Wholesale Trade Agents and Brokers........................................................................... 42512 6 3 -- -- -- -- -- Retail Trade....................................................................................................................... 44-45 344 82 197 25 24 12 3Motor Vehicle and Parts Dealers............................................................................................. 441 67 27 23 9 5 -- -- Automobile Dealers............................................................................................................ 4411 26 15 6 3 -- -- -- New Car Dealers........................................................................................................... 44111 12 8 -- 3 -- -- -- Used Car Dealers.......................................................................................................... 44112 5 -- 3 -- -- -- -- Other Motor Vehicle Dealers.............................................................................................. 4412 14 3 8 -- -- -- -- Motorcycle, Boat, and Other Motor Vehicle Dealers...................................................... 44122 12 3 8 -- -- -- -- Motorcycle Dealers................................................................................................... 441221 6 -- 5 -- -- -- -- Boat Dealers............................................................................................................. 441222 5 -- 3 -- -- -- -- Automotive Parts, Accessories, and Tire Stores................................................................ 4413 27 9 9 4 3 -- -- Automotive Parts and Accessories Stores..................................................................... 44131 18 8 4 3 -- -- -- Tire Dealers................................................................................................................... 44132 9 -- 5 -- -- -- --Furniture and Home Furnishings Stores.................................................................................. 442 8 -- 3 -- -- -- -- Furniture Stores.................................................................................................................. 4421 4 -- -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 9 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Furniture Stores............................................................................................................. 44211 4 -- -- -- -- -- -- Home Furnishings Stores................................................................................................... 4422 4 -- -- -- -- -- -- Floor Covering Stores.................................................................................................... 44221 3 -- -- -- -- -- --Electronics and Appliance Stores............................................................................................ 443 5 -- 3 -- -- -- -- Electronics and Appliance Stores....................................................................................... 4431 5 -- 3 -- -- -- --Building Material and Garden Equipment and Supplies Dealers............................................. 444 34 16 6 5 5 -- -- Building Material and Supplies Dealers.............................................................................. 4441 23 9 4 4 5 -- -- Home Centers................................................................................................................ 44411 4 -- -- -- -- -- -- Hardware Stores............................................................................................................ 44413 4 -- -- -- -- -- -- Other Building Material Dealers..................................................................................... 44419 14 7 -- 3 -- -- -- Lawn and Garden Equipment and Supplies Stores............................................................ 4442 11 7 -- -- -- -- -- Nursery and Garden Centers......................................................................................... 44422 9 6 -- -- -- -- --Food and Beverage Stores...................................................................................................... 445 99 5 85 -- 6 -- -- Grocery Stores.................................................................................................................... 4451 80 3 68 -- 6 -- -- Supermarkets and Other Grocery (except Convenience) Stores.................................. 44511 33 -- 22 -- 6 -- -- Convenience Stores...................................................................................................... 44512 40 -- 39 -- -- -- -- Specialty Food Stores......................................................................................................... 4452 10 -- 9 -- -- -- -- Fruit and Vegetable Markets.......................................................................................... 44523 3 -- 3 -- -- -- -- Beer, Wine, and Liquor Stores............................................................................................ 4453 8 -- 7 -- -- -- -- Beer, Wine, and Liquor Stores....................................................................................... 44531 8 -- 7 -- -- -- --Health and Personal Care Stores............................................................................................ 446 7 4 3 -- -- -- -- Health and Personal Care Stores....................................................................................... 4461 7 4 3 -- -- -- -- Pharmacies and Drug Stores......................................................................................... 44611 3 -- -- -- -- -- --Gasoline Stations..................................................................................................................... 447 42 7 33 -- -- -- -- Gasoline Stations................................................................................................................ 4471 42 7 33 -- -- -- -- Gasoline Stations with Convenience Stores.................................................................. 44711 35 5 29 -- -- -- -- Other Gasoline Stations................................................................................................. 44719 5 -- -- -- -- -- --Clothing and Clothing Accessories Stores............................................................................... 448 16 -- 13 -- -- -- -- Clothing Stores................................................................................................................... 4481 8 -- 5 -- -- -- -- Other Clothing Stores.................................................................................................... 44819 3 -- -- -- -- -- -- Jewelry, Luggage, and Leather Goods Stores................................................................... 4483 8 -- 8 -- -- -- -- Jewelry Stores............................................................................................................... 44831 8 -- 8 -- -- -- --Sporting Goods, Hobby, Book, and Music Stores................................................................... 451 5 -- 3 -- -- -- -- Sporting Goods, Hobby, and Musical Instrument Stores.................................................... 4511 3 -- -- -- -- -- --General Merchandise Stores................................................................................................... 452 11 -- 6 -- -- -- -- Department Stores.............................................................................................................. 4521 7 -- 4 -- -- -- -- Department Stores......................................................................................................... 45211 7 -- 4 -- -- -- -- Other General Merchandise Stores.................................................................................... 4529 4 -- -- -- -- -- -- All Other General Merchandise Stores.......................................................................... 45299 3 -- -- -- -- -- --Miscellaneous Store Retailers................................................................................................. 453 25 4 13 5 3 -- -- Florists................................................................................................................................ 4531 5 3 -- -- -- -- -- Florists........................................................................................................................... 45311 5 3 -- -- -- -- -- Office Supplies, Stationery, and Gift Stores....................................................................... 4532 3 -- 3 -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 10 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Gift, Novelty, and Souvenir Stores................................................................................. 45322 3 -- 3 -- -- -- -- Used Merchandise Stores.................................................................................................. 4533 7 -- 3 -- -- -- -- Used Merchandise Stores............................................................................................. 45331 7 -- 3 -- -- -- -- Other Miscellaneous Store Retailers.................................................................................. 4539 10 -- 5 3 -- -- -- All Other Miscellaneous Store Retailers........................................................................ 45399 8 -- 5 -- -- -- -- Tobacco Stores......................................................................................................... 453991 3 -- 3 -- -- -- -- All Other Miscellaneous Store Retailers (except Tobacco Stores)...................................................................................................... 453998 5 -- -- -- -- -- --Nonstore Retailers................................................................................................................... 454 22 16 4 -- -- -- -- Direct Selling Establishments............................................................................................. 4543 20 14 4 -- -- -- -- Fuel Dealers.................................................................................................................. 45431 11 8 -- -- -- -- -- Heating Oil Dealers................................................................................................... 454311 5 4 -- -- -- -- -- Liquefied Petroleum Gas (Bottled Gas) Dealers....................................................... 454312 4 -- -- -- -- -- -- Other Direct Selling Establishments.............................................................................. 45439 8 5 3 -- -- -- -- Transportation and Warehousing................................................................................... 48-49 808 622 76 58 24 18 8Air Transportation.................................................................................................................... 481 52 52 -- -- -- -- -- Scheduled Air Transportation............................................................................................. 4811 12 12 -- -- -- -- -- Scheduled Air Transportation........................................................................................ 48111 12 12 -- -- -- -- -- Scheduled Passenger Air Transportation................................................................. 481111 7 7 -- -- -- -- -- Nonscheduled Air Transportation....................................................................................... 4812 40 40 -- -- -- -- -- Nonscheduled Air Transportation.................................................................................. 48121 40 40 -- -- -- -- -- Nonscheduled Chartered Passenger Air Transportation.......................................... 481211 23 23 -- -- -- -- -- Nonscheduled Chartered Freight Air Transportation................................................ 481212 7 7 -- -- -- -- -- Other Nonscheduled Air Transportation................................................................... 481219 7 7 -- -- -- -- --Rail Transportation.................................................................................................................. 482 18 13 -- 3 -- -- -- Rail Transportation............................................................................................................. 4821 18 13 -- 3 -- -- -- Rail Transportation........................................................................................................ 48211 18 13 -- 3 -- -- -- Line-Haul Railroads.................................................................................................. 482111 9 6 -- -- -- -- --Water Transportation............................................................................................................... 483 24 12 3 5 -- -- -- Deep Sea, Coastal, and Great Lakes Water Transportation.............................................. 4831 18 10 3 3 -- -- -- Deep Sea, Coastal, and Great Lakes Water Transportation......................................... 48311 18 10 3 3 -- -- -- Deep Sea Freight Transportation............................................................................. 483111 10 -- 3 3 -- -- -- Deep Sea Passenger Transportation....................................................................... 483112 8 8 -- -- -- -- -- Inland Water Transportation............................................................................................... 4832 6 -- -- -- -- -- -- Inland Water Transportation.......................................................................................... 48321 6 -- -- -- -- -- -- Inland Water Freight Transportation......................................................................... 483211 5 -- -- -- -- -- --Truck Transportation................................................................................................................ 484 517 437 20 32 17 7 4 General Freight Trucking.................................................................................................... 4841 363 308 16 16 15 5 3 General Freight Trucking, Local.................................................................................... 48411 42 32 -- 4 -- -- -- General Freight Trucking, Long-Distance...................................................................... 48412 293 251 13 11 12 4 -- General Freight Trucking, Long-Distance, Truckload............................................... 484121 212 179 9 9 10 4 -- General Freight Trucking, Long-Distance, Less Than Truckload............................. 484122 36 33 -- -- -- -- -- Specialized Freight Trucking.............................................................................................. 4842 128 104 4 15 -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 11 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Used Household and Office Goods Moving................................................................... 48421 11 9 -- -- -- -- -- Specialized Freight (except Used Goods) Trucking, Local............................................ 48422 66 49 -- 12 -- -- -- Specialized Freight (except Used Goods) Trucking, Long-Distance............................. 48423 48 44 -- -- -- -- --Transit and Ground Passenger Transportation....................................................................... 485 74 22 48 -- -- -- -- Urban Transit Systems....................................................................................................... 4851 3 3 -- -- -- -- -- Urban Transit Systems.................................................................................................. 48511 3 3 -- -- -- -- -- Taxi and Limousine Service................................................................................................ 4853 59 11 47 -- -- -- -- Taxi Service................................................................................................................... 48531 55 10 45 -- -- -- -- Limousine Service......................................................................................................... 48532 3 -- -- -- -- -- -- Charter Bus Industry........................................................................................................... 4855 5 3 -- -- -- -- -- Charter Bus Industry...................................................................................................... 48551 5 3 -- -- -- -- -- Other Transit and Ground Passenger Transportation........................................................ 4859 6 5 -- -- -- -- -- Other Transit and Ground Passenger Transportation................................................... 48599 6 5 -- -- -- -- -- Special Needs Transportation.................................................................................. 485991 5 4 -- -- -- -- --Scenic and Sightseeing Transportation................................................................................... 487 9 8 -- -- -- -- -- Scenic and Sightseeing Transportation, Other................................................................... 4879 5 5 -- -- -- -- -- Scenic and Sightseeing Transportation, Other.............................................................. 48799 5 5 -- -- -- -- --Support Activities for Transportation........................................................................................ 488 66 47 5 7 -- 6 -- Support Activities for Air Transportation............................................................................. 4881 7 6 -- -- -- -- -- Other Support Activities for Air Transportation.............................................................. 48819 7 6 -- -- -- -- -- Support Activities for Water Transportation........................................................................ 4883 17 8 -- 3 -- 3 -- Marine Cargo Handling.................................................................................................. 48832 7 -- -- 3 -- -- -- Navigational Services to Shipping................................................................................. 48833 6 3 -- -- -- -- -- Other Support Activities for Water Transportation......................................................... 48839 3 -- -- -- -- -- -- Support Activities for Road Transportation......................................................................... 4884 39 31 3 3 -- -- -- Motor Vehicle Towing.................................................................................................... 48841 28 23 -- -- -- -- -- Other Support Activities for Road Transportation.......................................................... 48849 11 8 -- -- -- -- --Couriers and Messengers........................................................................................................ 492 22 20 -- -- -- -- -- Couriers.............................................................................................................................. 4921 17 15 -- -- -- -- -- Couriers......................................................................................................................... 49211 17 15 -- -- -- -- -- Local Messengers and Local Delivery................................................................................ 4922 5 5 -- -- -- -- -- Local Messengers and Local Delivery........................................................................... 49221 5 5 -- -- -- -- --Warehousing and Storage....................................................................................................... 493 23 10 -- 7 4 -- -- Warehousing and Storage.................................................................................................. 4931 23 10 -- 7 4 -- -- General Warehousing and Storage............................................................................... 49311 18 8 -- 6 -- -- -- Utilities............................................................................................................................... 22 32 11 3 4 -- 9 3Utilities..................................................................................................................................... 221 32 11 3 4 -- 9 3 Electric Power Generation, Transmission and Distribution................................................. 2211 22 5 3 3 -- 8 -- Electric Power Generation............................................................................................. 22111 8 -- -- -- -- 3 -- Fossil Fuel Electric Power Generation...................................................................... 221112 5 -- -- -- -- -- -- Electric Power Transmission, Control, and Distribution................................................. 22112 14 5 -- -- -- 5 -- Electric Power Distribution........................................................................................ 221122 10 5 -- -- -- -- -- Natural Gas Distribution...................................................................................................... 2212 3 3 -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 12 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Natural Gas Distribution................................................................................................. 22121 3 3 -- -- -- -- -- Water, Sewage and Other Systems................................................................................... 2213 6 3 -- -- -- -- -- Information................................................................................................................... 64 39 8 -- 7 7 -- Information........................................................................................................................ 51 64 39 8 -- 7 7 --Publishing Industries (Except Internet).................................................................................... 511 31 25 -- -- -- 3 -- Newspaper, Periodical, Book, and Directory Publishers.................................................... 5111 29 24 -- -- -- -- -- Newspaper Publishers................................................................................................... 51111 27 22 -- -- -- -- --Motion Picture and Sound Recording Industries..................................................................... 512 5 -- -- -- -- -- -- Motion Picture and Video Industries................................................................................... 5121 3 -- -- -- -- -- --Broadcasting (except Internet)................................................................................................. 515 3 -- -- -- -- -- -- Radio and Television Broadcasting.................................................................................... 5151 3 -- -- -- -- -- --Telecommunications................................................................................................................ 517 21 10 4 -- 3 3 -- Wired Telecommunications Carriers................................................................................... 5171 13 8 -- -- -- -- -- Wired Telecommunications Carriers.............................................................................. 51711 13 8 -- -- -- -- -- Cable and Other Program Distribution................................................................................ 5175 4 -- -- -- -- -- -- Cable and Other Program Distribution........................................................................... 51751 4 -- -- -- -- -- --Internet Service Providers, Web Search Portals, and Data Processing Services................................................................................................................................ 518 3 -- -- -- -- -- -- Data Processing, Hosting, And Related Services............................................................... 5182 3 -- -- -- -- -- -- Data Processing, Hosting, And Related Services.......................................................... 51821 3 -- -- -- -- -- -- Financial Activities...................................................................................................... 129 46 48 10 14 8 3 Finance and Insurance..................................................................................................... 52 45 22 16 -- 3 -- --Credit Intermediation and Related Activities............................................................................ 522 27 8 15 -- -- -- -- Depository Credit Intermediation........................................................................................ 5221 11 5 5 -- -- -- -- Commercial Banking...................................................................................................... 52211 9 5 3 -- -- -- -- Nondepository Credit Intermediation.................................................................................. 5222 13 3 7 -- -- -- -- Other Nondepository Credit Intermediation................................................................... 52229 12 3 7 -- -- -- -- Real Estate Credit..................................................................................................... 522292 6 -- -- -- -- -- -- All Other Nondepository Credit Intermediation......................................................... 522298 6 -- 5 -- -- -- -- Activities Related to Credit Intermediation.......................................................................... 5223 3 -- 3 -- -- -- -- Other Activities Related to Credit Intermediation........................................................... 52239 3 -- 3 -- -- -- --Securities, Commodity Contracts, and Other Financial Investments and Related Activities........................................................................................................... 523 6 4 -- -- -- -- -- Other Financial Investment Activities.................................................................................. 5239 4 -- -- -- -- -- -- Investment Advice......................................................................................................... 52393 3 -- -- -- -- -- --Insurance Carriers and Related Activities................................................................................ 524 11 9 -- -- -- -- -- Insurance Carriers.............................................................................................................. 5241 5 4 -- -- -- -- -- Agencies, Brokerages, and Other Insurance Related Activities......................................... 5242 5 4 -- -- -- -- -- Insurance Agencies and Brokerages............................................................................. 52421 4 3 -- -- -- -- -- Real Estate and Rental and Leasing............................................................................... 53 84 24 32 8 11 7 --Real Estate.............................................................................................................................. 531 52 9 25 -- 10 5 -- Lessors of Real Estate........................................................................................................ 5311 21 -- 10 -- 3 4 -- Lessors of Residential Buildings and Dwellings............................................................ 53111 17 -- 9 -- -- 3 --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 13 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Lessors of Nonresidential Buildings (except Miniwarehouses)...................................... 53112 3 -- -- -- -- -- -- Offices of Real Estate Agents and Brokers........................................................................ 5312 13 4 9 -- -- -- -- Offices of Real Estate Agents and Brokers................................................................... 53121 13 4 9 -- -- -- -- Activities Related to Real Estate......................................................................................... 5313 17 4 6 -- 6 -- -- Real Estate Property Managers..................................................................................... 53131 17 4 6 -- 6 -- -- Residential Property Managers................................................................................ 531311 10 -- 4 -- 5 -- -- Nonresidential Property Managers........................................................................... 531312 4 -- -- -- -- -- --Rental and Leasing Services................................................................................................... 532 31 14 7 7 -- -- -- Automotive Equipment Rental and Leasing........................................................................ 5321 6 6 -- -- -- -- -- Truck, Utility Trailer, and RV (Recreational Vehicle) Rental and Leasing....................................................................................................... 53212 4 4 -- -- -- -- -- Consumer Goods Rental.................................................................................................... 5322 6 3 -- -- -- -- -- Video Tape and Disc Rental.......................................................................................... 53223 3 -- -- -- -- -- -- General Rental Centers...................................................................................................... 5323 4 -- -- -- -- -- -- General Rental Centers................................................................................................. 53231 4 -- -- -- -- -- -- Commercial and Industrial Machinery and Equipment Rental and Leasing....................... 5324 12 -- 3 6 -- -- -- Construction, Transportation, Mining, and Forestry Machinery and Equipment Rental and Leasing............................................................ 53241 8 -- -- 5 -- -- -- Construction, Mining, and Forestry Machinery and Equipment Rental and Leasing................................................................................ 532412 8 -- -- 5 -- -- -- Other Commercial and Industrial Machinery and Equipment Rental and Leasing....................................................................................................... 53249 4 -- -- -- -- -- -- Professional and Business Services......................................................................... 453 173 58 83 69 53 15 Professional, Scientific, and Technical Services.......................................................... 54 97 52 24 3 8 6 --Professional, Scientific, and Technical Services..................................................................... 541 97 52 24 3 8 6 -- Legal Services.................................................................................................................... 5411 14 4 7 -- -- -- -- Offices of Lawyers......................................................................................................... 54111 9 -- 5 -- -- -- -- Other Legal Services..................................................................................................... 54119 5 -- -- -- -- -- -- All Other Legal Services........................................................................................... 541199 4 -- -- -- -- -- -- Accounting, Tax Preparation, Bookkeeping, and Payroll Services..................................... 5412 8 -- 5 -- -- -- -- Accounting, Tax Preparation, Bookkeeping, and Payroll Services................................ 54121 8 -- 5 -- -- -- -- Offices of Certified Public Accountants..................................................................... 541211 5 -- 3 -- -- -- -- Architectural, Engineering, and Related Services.............................................................. 5413 26 17 -- 3 -- 3 -- Architectural Services.................................................................................................... 54131 6 4 -- -- -- -- -- Engineering Services..................................................................................................... 54133 10 8 -- -- -- -- -- Specialized Design Services.............................................................................................. 5414 5 -- -- -- -- -- -- Computer Systems Design and Related Services.............................................................. 5415 10 8 -- -- -- -- -- Computer Systems Design and Related Services......................................................... 54151 10 8 -- -- -- -- -- Custom Computer Programming Services............................................................... 541511 4 3 -- -- -- -- -- Management, Scientific, and Technical Consulting Services............................................. 5416 12 12 -- -- -- -- -- Management Consulting Services................................................................................. 54161 10 10 -- -- -- -- -- Scientific Research and Development Services................................................................. 5417 8 -- 4 -- -- -- --
See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 14 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Research and Development in the Physical, Engineering, and Life Sciences......................................................................................................... 54171 8 -- 4 -- -- -- -- Advertising and Related Services....................................................................................... 5418 5 -- -- -- 3 -- -- Display Advertising........................................................................................................ 54185 3 -- -- -- -- -- -- Other Professional, Scientific, and Technical Services...................................................... 5419 9 -- 5 -- -- -- -- Veterinary Services........................................................................................................ 54194 5 -- 3 -- -- -- -- Administrative and Support and Waste Management and Remediation Services..................................................................................................... 56 356 121 34 80 61 47 13Administrative and Support Services....................................................................................... 561 265 70 33 60 57 38 7 Facilities Support Services................................................................................................. 5612 4 -- -- -- -- -- -- Facilities Support Services............................................................................................ 56121 4 -- -- -- -- -- -- Employment Services......................................................................................................... 5613 19 4 5 4 5 -- -- Temporary Help Services.............................................................................................. 56132 13 -- 5 3 3 -- -- Employee Leasing Services.......................................................................................... 56133 6 3 -- -- -- -- -- Business Support Services................................................................................................. 5614 7 4 3 -- -- -- -- Business Service Centers.............................................................................................. 56143 3 3 -- -- -- -- -- Private Mail Centers................................................................................................. 561431 3 3 -- -- -- -- -- Other Business Support Services.................................................................................. 56149 4 -- 3 -- -- -- -- Repossession Services............................................................................................ 561491 3 -- -- -- -- -- -- Investigation and Security Services.................................................................................... 5616 35 12 15 -- 3 4 -- Investigation, Guard, and Armored Car Services.......................................................... 56161 35 12 15 -- 3 4 -- Security Guards and Patrol Services........................................................................ 561612 31 10 14 -- -- 4 -- Armored Car Services.............................................................................................. 561613 3 -- -- -- -- -- -- Services to Buildings and Dwellings................................................................................... 5617 189 45 8 54 47 31 4 Janitorial Services.......................................................................................................... 56172 20 3 3 -- 7 3 -- Landscaping Services.................................................................................................... 56173 154 37 4 51 38 23 -- Other Services to Buildings and Dwellings.................................................................... 56179 11 3 -- -- -- 4 -- Other Support Services...................................................................................................... 5619 7 4 -- -- -- -- -- All Other Support Services............................................................................................ 56199 7 4 -- -- -- -- --Waste Management and Remediation Services...................................................................... 562 91 51 -- 20 4 9 6 Waste Collection................................................................................................................. 5621 58 35 -- 17 -- 4 -- Waste Collection............................................................................................................ 56211 58 35 -- 17 -- 4 -- Solid Waste Collection.............................................................................................. 562111 45 26 -- 14 -- 3 -- Hazardous Waste Collection.................................................................................... 562112 6 5 -- -- -- -- -- Other Waste Collection............................................................................................. 562119 4 -- -- -- -- -- -- Waste Treatment and Disposal.......................................................................................... 5622 15 8 -- -- -- -- 4 Waste Treatment and Disposal..................................................................................... 56221 15 8 -- -- -- -- 4 Hazardous Waste Treatment and Disposal.............................................................. 562211 3 -- -- -- -- -- -- Solid Waste Landfill.................................................................................................. 562212 7 5 -- -- -- -- -- Other Nonhazardous Waste Treatment and Disposal.............................................. 562219 4 -- -- -- -- -- -- Remediation and Other Waste Management Services....................................................... 5629 17 7 -- -- -- 4 -- Remediation Services.................................................................................................... 56291 5 -- -- -- -- -- -- Materials Recovery Facilities......................................................................................... 56292 3 -- -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 15 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
All Other Waste Management Services......................................................................... 56299 9 5 -- -- -- -- -- Septic Tank and Related Services............................................................................ 562991 5 5 -- -- -- -- -- All Other Miscellaneous Waste Management Services............................................ 562998 4 -- -- -- -- -- -- Education and Health Services.................................................................................. 143 79 27 5 19 12 -- Educational Services........................................................................................................ 61 41 32 -- -- 4 -- --Educational Services............................................................................................................... 611 41 32 -- -- 4 -- -- Elementary and Secondary Schools................................................................................... 6111 4 -- -- -- -- -- -- Elementary and Secondary Schools.............................................................................. 61111 4 -- -- -- -- -- -- Colleges, Universities, and Professional Schools............................................................... 6113 3 -- -- -- -- -- -- Colleges, Universities, and Professional Schools.......................................................... 61131 3 -- -- -- -- -- -- Technical and Trade Schools............................................................................................. 6115 27 27 -- -- -- -- -- Technical and Trade Schools........................................................................................ 61151 27 27 -- -- -- -- -- Flight Training........................................................................................................... 611512 27 27 -- -- -- -- -- Other Schools and Instruction............................................................................................ 6116 3 -- -- -- -- -- -- Sports and Recreation Instruction................................................................................. 61162 3 -- -- -- -- -- -- Health Care and Social Assistance................................................................................. 62 102 47 25 4 15 11 --Ambulatory Health Care Services............................................................................................ 621 36 18 9 -- 4 4 -- Offices of Physicians.......................................................................................................... 6211 7 -- 3 -- -- -- -- Offices of Physicians..................................................................................................... 62111 7 -- 3 -- -- -- -- Offices of Physicians (except Mental Health Specialists)......................................... 621111 3 -- -- -- -- -- -- Offices of Dentists............................................................................................................... 6212 5 -- 3 -- -- -- -- Offices of Dentists.......................................................................................................... 62121 5 -- 3 -- -- -- -- Outpatient Care Centers..................................................................................................... 6214 6 -- -- -- -- 3 -- Other Outpatient Care Centers...................................................................................... 62149 5 -- -- -- -- 3 -- Home Health Care Services............................................................................................... 6216 8 5 -- -- -- -- -- Home Health Care Services.......................................................................................... 62161 8 5 -- -- -- -- -- Other Ambulatory Health Care Services............................................................................. 6219 9 8 -- -- -- -- -- Ambulance Services...................................................................................................... 62191 6 5 -- -- -- -- -- All Other Ambulatory Health Care Services................................................................... 62199 3 3 -- -- -- -- --Hospitals.................................................................................................................................. 622 24 10 5 -- 5 -- -- General Medical and Surgical Hospitals............................................................................. 6221 24 10 5 -- 5 -- -- General Medical and Surgical Hospitals........................................................................ 62211 24 10 5 -- 5 -- --Nursing and Residential Care Facilities................................................................................... 623 20 4 8 -- 6 -- -- Nursing Care Facilities........................................................................................................ 6231 7 -- 3 -- 3 -- -- Nursing Care Facilities................................................................................................... 62311 7 -- 3 -- 3 -- -- Residential Mental Retardation, Mental Health and Substance Abuse Facilities.................................................................................................................. 6232 3 -- -- -- -- -- -- Community Care Facilities for the Elderly........................................................................... 6233 7 -- -- -- 3 -- -- Community Care Facilities for the Elderly...................................................................... 62331 7 -- -- -- 3 -- -- Continuing Care Retirement Communities............................................................... 623311 3 -- -- -- -- -- -- Homes for the Elderly............................................................................................... 623312 4 -- -- -- -- -- --Social Assistance..................................................................................................................... 624 20 13 3 -- -- 3 -- Individual and Family Services........................................................................................... 6241 7 6 -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 16 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Other Individual and Family Services............................................................................ 62419 3 3 -- -- -- -- -- Vocational Rehabilitation Services..................................................................................... 6243 5 -- -- -- -- 3 -- Vocational Rehabilitation Services................................................................................ 62431 5 -- -- -- -- 3 -- Child Day Care Services..................................................................................................... 6244 6 5 -- -- -- -- -- Child Day Care Services................................................................................................ 62441 6 5 -- -- -- -- -- Leisure and Hospitality............................................................................................... 275 60 149 11 24 20 11 Arts, Entertainment, and Recreation.............................................................................. 71 88 30 26 9 10 8 5Performing Arts, Spectator Sports, and Related Industries..................................................... 711 42 19 15 -- 3 4 -- Performing Arts Companies................................................................................................ 7111 6 -- -- -- -- -- -- Musical Groups and Artists............................................................................................ 71113 5 -- -- -- -- -- -- Spectator Sports................................................................................................................. 7112 25 12 9 -- -- -- -- Spectator Sports............................................................................................................ 71121 25 12 9 -- -- -- -- Racetracks................................................................................................................ 711212 5 3 -- -- -- -- -- Other Spectator Sports............................................................................................. 711219 19 9 7 -- -- -- -- Independent Artists, Writers, and Performers..................................................................... 7115 8 -- 5 -- -- -- -- Independent Artists, Writers, and Performers................................................................ 71151 8 -- 5 -- -- -- --Museums, Historical Sites, and Similar Institutions................................................................. 712 6 -- 3 -- -- -- -- Museums, Historical Sites, and Similar Institutions............................................................ 7121 6 -- 3 -- -- -- --Amusement, Gambling, and Recreation Industries................................................................. 713 40 9 8 7 7 4 5 Amusement Parks and Arcades......................................................................................... 7131 8 -- -- -- -- 3 -- Amusement and Theme Parks...................................................................................... 71311 8 -- -- -- -- 3 -- Other Amusement and Recreation Industries..................................................................... 7139 31 8 5 7 6 -- -- Golf Courses and Country Clubs................................................................................... 71391 9 3 -- -- -- -- -- Fitness and Recreational Sports Centers...................................................................... 71394 4 -- -- -- -- -- -- All Other Amusement and Recreation Industries........................................................... 71399 13 4 -- 3 -- -- -- Accommodation and Food Services............................................................................... 72 187 30 123 -- 14 12 6Accommodation....................................................................................................................... 721 40 10 20 -- 6 -- -- Traveler Accommodation.................................................................................................... 7211 28 5 16 -- 6 -- -- Hotels (except Casino Hotels) and Motels..................................................................... 72111 24 5 14 -- 4 -- -- Casino Hotels................................................................................................................ 72112 3 -- -- -- -- -- -- RV (Recreational Vehicle) Parks and Recreational Camps................................................ 7212 11 5 -- -- -- -- -- RV (Recreational Vehicle) Parks and Recreational Camps........................................... 72121 11 5 -- -- -- -- -- RV (Recreational Vehicle) Parks and Campgrounds................................................ 721211 6 3 -- -- -- -- -- Recreational and Vacation Camps (except Campgrounds)...................................... 721214 5 -- -- -- -- -- --Food Services and Drinking Places......................................................................................... 722 146 19 103 -- 8 10 5 Full-Service Restaurants.................................................................................................... 7221 39 5 26 -- 4 3 -- Full-Service Restaurants............................................................................................... 72211 39 5 26 -- 4 3 -- Limited-Service Eating Places............................................................................................ 7222 61 8 48 -- 3 -- -- Limited-Service Eating Places....................................................................................... 72221 61 8 48 -- 3 -- -- Limited-Service Restaurants..................................................................................... 722211 51 7 40 -- -- -- -- Snack and Nonalcoholic Beverage Bars.................................................................. 722213 5 -- 4 -- -- -- -- Special Food Services........................................................................................................ 7223 12 5 5 -- -- -- -- Food Service Contractors.............................................................................................. 72231 6 5 -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 17 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Mobile Food Services.................................................................................................... 72233 6 -- 5 -- -- -- -- Drinking Places (Alcoholic Beverages)............................................................................... 7224 33 -- 24 -- -- 4 5 Drinking Places (Alcoholic Beverages).......................................................................... 72241 33 -- 24 -- -- 4 5 Other Services............................................................................................................. 194 41 72 32 17 15 16 Other Services, except Public Administration............................................................... 81 194 41 72 32 17 15 16Repair and Maintenance.......................................................................................................... 811 121 16 39 30 9 13 13 Automotive Repair and Maintenance.................................................................................. 8111 87 10 33 21 8 6 9 Automotive Mechanical and Electrical Repair and Maintenance................................... 81111 57 4 25 14 5 3 6 General Automotive Repair...................................................................................... 811111 45 4 16 12 4 3 6 Other Automotive Mechanical and Electrical Repair and Maintenance..................................................................................................... 811118 9 -- 8 -- -- -- -- Automotive Body, Paint, Interior, and Glass Repair...................................................... 81112 15 3 6 3 -- -- -- Automotive Body, Paint, and Interior Repair and Maintenance................................ 811121 14 -- 6 3 -- -- -- Other Automotive Repair and Maintenance................................................................... 81119 10 3 -- -- -- -- -- Car Washes.............................................................................................................. 811192 3 -- -- -- -- -- -- All Other Automotive Repair and Maintenance......................................................... 811198 6 -- -- -- -- -- -- Electronic and Precision Equipment Repair and Maintenance........................................... 8112 5 -- 3 -- -- -- -- Electronic and Precision Equipment Repair and Maintenance...................................... 81121 5 -- 3 -- -- -- -- Consumer Electronics Repair and Maintenance...................................................... 811211 3 -- 3 -- -- -- -- Commercial and Industrial Machinery and Equipment (except Automotive and Electronic) Repair and Maintenance........................................................ 8113 19 -- -- 5 -- 6 3 Commercial and Industrial Machinery and Equipment (except Automotive and Electronic) Repair and Maintenance................................................... 81131 19 -- -- 5 -- 6 3 Personal and Household Goods Repair and Maintenance................................................. 8114 8 -- -- 3 -- -- -- Home and Garden Equipment and Appliance Repair and Maintenance....................... 81141 4 -- -- 3 -- -- -- Other Personal and Household Goods Repair and Maintenance.................................. 81149 4 -- -- -- -- -- --Personal and Laundry Services............................................................................................... 812 42 12 23 -- 3 -- -- Personal Care Services...................................................................................................... 8121 10 -- 8 -- -- -- -- Hair, Nail, and Skin Care Services................................................................................ 81211 8 -- 6 -- -- -- -- Barber Shops............................................................................................................ 812111 4 -- 4 -- -- -- -- Death Care Services........................................................................................................... 8122 8 3 -- -- -- -- -- Funeral Homes and Funeral Services........................................................................... 81221 4 -- -- -- -- -- -- Cemeteries and Crematories......................................................................................... 81222 4 -- -- -- -- -- -- Drycleaning and Laundry Services..................................................................................... 8123 16 3 10 -- -- -- -- Coin-Operated Laundries and Drycleaners................................................................... 81231 6 -- 6 -- -- -- -- Drycleaning and Laundry Services (except Coin-Operated)......................................... 81232 7 -- 4 -- -- -- -- Linen and Uniform Supply............................................................................................. 81233 3 -- -- -- -- -- -- Other Personal Services..................................................................................................... 8129 8 5 3 -- -- -- -- Pet Care (except Veterinary) Services.......................................................................... 81291 4 -- -- -- -- -- --Religious, Grantmaking, Civic, Professional, and Similar Organizations................................. 813 30 13 9 -- 5 -- 3 Religious Organizations...................................................................................................... 8131 17 7 5 -- 4 -- -- Religious Organizations................................................................................................. 81311 17 7 5 -- 4 -- -- Civic and Social Organizations........................................................................................... 8134 7 -- 4 -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 18 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Civic and Social Organizations...................................................................................... 81341 7 -- 4 -- -- -- -- Business, Professional, Labor, Political, and Similar Organizations................................... 8139 4 4 -- -- -- -- -- Labor Unions and Similar Labor Organizations............................................................. 81393 3 3 -- -- -- -- --
Government6 532 307 100 28 34 41 18
Federal Government 98 56 15 8 6 9 --
Service Providing................................................................................................... 96 56 15 8 6 9 -- Trade, Transportation, and Utilities........................................................................... 12 10 -- -- -- -- -- Transportation and Warehousing................................................................................... 48-49 12 10 -- -- -- -- --Postal Service.......................................................................................................................... 491 12 10 -- -- -- -- -- Postal Service..................................................................................................................... 4911 12 10 -- -- -- -- -- Postal Service................................................................................................................ 49111 12 10 -- -- -- -- -- Public Administration.................................................................................................. 80 44 13 8 5 8 -- Public Administration....................................................................................................... 92 80 44 13 8 5 8 --Justice, Public Order, and Safety Activities............................................................................. 922 3 -- -- -- -- -- -- Justice, Public Order, and Safety Activities........................................................................ 9221 3 -- -- -- -- -- --Administration of Economic Programs..................................................................................... 926 4 -- -- -- -- -- -- Administration of Economic Programs................................................................................ 9261 4 -- -- -- -- -- --Space Research and Technology............................................................................................ 927 7 7 -- -- -- -- -- Space Research and Technology....................................................................................... 9271 7 7 -- -- -- -- -- Space Research and Technology.................................................................................. 92711 7 7 -- -- -- -- --National Security and International Affairs............................................................................... 928 61 35 10 8 -- 5 -- National Security and International Affairs.......................................................................... 9281 61 35 10 8 -- 5 -- National Security............................................................................................................ 92811 60 35 9 8 -- 5 --
State Government 102 66 17 -- 10 7 --
Goods Producing.................................................................................................... 17 16 -- -- -- -- -- Construction................................................................................................................ 16 15 -- -- -- -- -- Construction..................................................................................................................... 23 16 15 -- -- -- -- --Heavy and Civil Engineering Construction.............................................................................. 237 16 15 -- -- -- -- -- Highway, Street, and Bridge Construction.......................................................................... 2373 16 15 -- -- -- -- -- Highway, Street, and Bridge Construction..................................................................... 23731 16 15 -- -- -- -- -- Service Providing................................................................................................... 85 50 17 -- 9 7 -- Trade, Transportation, and Utilities........................................................................... 3 3 -- -- -- -- -- Transportation and Warehousing................................................................................... 48-49 3 3 -- -- -- -- -- Professional and Business Services......................................................................... 3 3 -- -- -- -- -- Education and Health Services.................................................................................. 16 7 -- -- 4 3 -- Educational Services........................................................................................................ 61 12 5 -- -- 4 3 --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 19 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Educational Services............................................................................................................... 611 12 5 -- -- 4 3 -- Colleges, Universities, and Professional Schools............................................................... 6113 11 4 -- -- 4 3 -- Colleges, Universities, and Professional Schools.......................................................... 61131 11 4 -- -- 4 3 -- Health Care and Social Assistance................................................................................. 62 4 -- -- -- -- -- -- Public Administration.................................................................................................. 60 36 15 -- 5 -- -- Public Administration....................................................................................................... 92 60 36 15 -- 5 -- --Justice, Public Order, and Safety Activities............................................................................. 922 40 22 13 -- -- -- -- Justice, Public Order, and Safety Activities........................................................................ 9221 40 22 13 -- -- -- -- Police Protection............................................................................................................ 92212 23 14 6 -- -- -- -- Correctional Institutions................................................................................................. 92214 15 7 6 -- -- -- --Administration of Environmental Quality Programs................................................................. 924 10 6 -- -- -- -- -- Administration of Environmental Quality Programs............................................................ 9241 10 6 -- -- -- -- -- Administration of Conservation Programs..................................................................... 92412 9 5 -- -- -- -- --Administration of Economic Programs..................................................................................... 926 6 5 -- -- -- -- -- Administration of Economic Programs................................................................................ 9261 6 5 -- -- -- -- -- Regulation and Administration of Transportation Programs.......................................... 92612 6 5 -- -- -- -- --
Local Government 326 179 68 18 18 25 15
Goods Producing.................................................................................................... 27 18 -- 6 -- 3 -- Construction................................................................................................................ 24 17 -- 4 -- 3 -- Construction..................................................................................................................... 23 24 17 -- 4 -- 3 --Heavy and Civil Engineering Construction.............................................................................. 237 23 17 -- 3 -- 3 -- Highway, Street, and Bridge Construction.......................................................................... 2373 21 16 -- 3 -- -- -- Highway, Street, and Bridge Construction..................................................................... 23731 21 16 -- 3 -- -- -- Service Providing................................................................................................... 299 161 68 12 18 22 15 Trade, Transportation, and Utilities........................................................................... 18 8 -- -- -- 4 -- Transportation and Warehousing................................................................................... 48-49 8 6 -- -- -- -- --Transit and Ground Passenger Transportation....................................................................... 485 5 4 -- -- -- -- -- Urban Transit Systems....................................................................................................... 4851 4 3 -- -- -- -- -- Urban Transit Systems.................................................................................................. 48511 4 3 -- -- -- -- -- Mixed Mode Transit Systems................................................................................... 485111 3 -- -- -- -- -- -- Utilities............................................................................................................................... 22 10 -- -- -- -- 3 --Utilities..................................................................................................................................... 221 10 -- -- -- -- 3 -- Water, Sewage and Other Systems................................................................................... 2213 7 -- -- -- -- -- -- Water Supply and Irrigation Systems............................................................................ 22131 3 -- -- -- -- -- -- Sewage Treatment Facilities......................................................................................... 22132 3 -- -- -- -- -- -- Professional and Business Services......................................................................... 22 18 -- -- -- -- -- Administrative and Support and Waste Management and Remediation Services..................................................................................................... 56 21 18 -- -- -- -- --Administrative and Support Services....................................................................................... 561 4 -- -- -- -- -- --Waste Management and Remediation Services...................................................................... 562 17 16 -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 20 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Waste Collection................................................................................................................. 5621 14 13 -- -- -- -- -- Waste Collection............................................................................................................ 56211 14 13 -- -- -- -- -- Solid Waste Collection.............................................................................................. 562111 14 13 -- -- -- -- -- Waste Treatment and Disposal.......................................................................................... 5622 3 3 -- -- -- -- -- Waste Treatment and Disposal..................................................................................... 56221 3 3 -- -- -- -- -- Education and Health Services.................................................................................. 50 28 6 -- 5 8 -- Educational Services........................................................................................................ 61 42 23 4 -- 5 7 --Educational Services............................................................................................................... 611 42 23 4 -- 5 7 -- Elementary and Secondary Schools................................................................................... 6111 39 20 4 -- 5 7 -- Elementary and Secondary Schools.............................................................................. 61111 39 20 4 -- 5 7 -- Health Care and Social Assistance................................................................................. 62 8 5 -- -- -- -- --Social Assistance..................................................................................................................... 624 3 3 -- -- -- -- -- Individual and Family Services........................................................................................... 6241 3 3 -- -- -- -- -- Leisure and Hospitality............................................................................................... 5 3 -- -- -- -- -- Arts, Entertainment, and Recreation.............................................................................. 71 5 3 -- -- -- -- --Performing Arts, Spectator Sports, and Related Industries..................................................... 711 3 -- -- -- -- -- -- Promoters of Performing Arts, Sports, and Similar Events................................................. 7113 3 -- -- -- -- -- -- Promoters of Performing Arts, Sports, and Similar Events with Facilities................................................................................................................ 71131 3 -- -- -- -- -- -- Public Administration.................................................................................................. 202 104 58 7 9 10 12 Public Administration....................................................................................................... 92 202 104 58 7 9 10 12Executive, Legislative, and Other General Government Support............................................ 921 16 6 3 3 -- -- -- Executive, Legislative, and Other General Government Support....................................... 9211 16 6 3 3 -- -- -- Executive Offices........................................................................................................... 92111 3 -- -- -- -- -- -- American Indian and Alaska Native Tribal Governments.............................................. 92115 4 -- -- -- -- -- --See footnotes at end of table.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 21 of 22
TABLE A-1. Fatal occupational injuries by industry and event or exposure, All United States, 2003 - continued
Other General Government Support.............................................................................. 92119 4 -- -- -- -- -- --Justice, Public Order, and Safety Activities............................................................................. 922 175 93 54 3 6 7 11 Justice, Public Order, and Safety Activities........................................................................ 9221 175 93 54 3 6 7 11 Police Protection............................................................................................................ 92212 126 65 53 -- 3 -- -- Correctional Institutions................................................................................................. 92214 5 4 -- -- -- -- -- Fire Protection............................................................................................................... 92216 38 23 -- -- 3 -- 10Administration of Environmental Quality Programs................................................................. 924 6 3 -- -- -- -- -- Administration of Environmental Quality Programs............................................................ 9241 6 3 -- -- -- -- -- Administration of Air and Water Resource and Solid Waste Management Programs................................................................................................ 92411 5 3 -- -- -- -- --
1 Classified according to the North American Industry Classification System, 2002. NOTE: Totals for major categories may include subcategories not shown separately. 2 Based on the 1992 BLS Occupational Injury and Illness Classification Manual. Dashes indicate no data reported or data that do not meet publication criteria. Data for 3 Includes highway, nonhighway, air, water, and rail fatalities. 2003 are revised and final. 4 Includes violence by persons, self-inflicted injury, and assaults by animals. 5 Includes fatalities at all establishments categorized as Mining (Sector 21) in the North American Industry SOURCE: U.S. Department of Labor, Bureau of Labor Statistics, in cooperation with Classification System, 2002, including establishments not governed by the Mine Safety and Health State and Federal agencies, Census of Fatal Occupational Injuries. Administration (MSHA) rules and reporting, such as those in Oil and Gas Extraction. 6 Includes fatalities to workers employed by governmental organizations regardless of industry.
Industry1 NAICS code1 Total fatalities (number)
Event or exposure2
Transpor- tation
incidents3
Assaults and
violent acts4
Contact with objects and equipment
Falls
Exposure to harmful sub-stances or
environments
Fires and explosions
Page 22 of 22
9/6/08
1
ReviewofSACHEProducts
RonaldJ.WilleySACHE2008FacultyWorkshop
WebSite
• www.sache.org
9/6/08
2
SlideProducts
• TwoExamples• AnexampleofarunawayreacHonaccident
• AlectureonstaHcelectricity
ProblemSets
• Volume1• Volume2
9/6/08
3
QuesHons?
9/8/2008
1
Rupture of a Nitroaniline Reactor
byRonald J. Willey
Northeastern UniversityPrepared for SACHE
A product of the CCPS AICHE
New York, New York©1994, 2007 AIChE
Acknowledgments
• This slide package was prepared by Ronald J. Willey of Northeastern University with the direction and guidance of the Undergraduate Education Committee (UEC) of the Center for Chemical Process Safety (CCPS) and with the assistance Dr. Walt B HowardWalt B. Howard.
• This package was prepared for use by SACHE (Safety and Chemical Engineering Education) members.
• CCPS appreciates the work by the author, Ronald J. Willey, and the direction and guidance of the Undergraduate Education Committee.
Location
Sauget, Illinois
Date: 8 August 196912:18 AM��
St.Louis
9/8/2008
2
Photograph Outside the Chemical Plant Fence Line (1994)
Photograph at Ground Level (1969).
“If you can imagine what hell is like, you have a rough idea how it was.” A quote from one of the four workmen caught in the explosion
Arial Photograph of Plant (1969)
9/8/2008
3
Photograph of the Autoclave Bottom (1969)
Photograph of the Autoclave Side Wall (1969)
Found 200 feet away from original position
Photograph of pipe javelined into a
railroad tie
(1969)
Found 250 feet away from original position
9/8/2008
4
Photograph of Relief System Line : Consists of a Rupture Disk and Spring Relief Valve in Series
Rupture Disk
Spring Relief Valve
The Process Chemistry
+ 2 NH3
NO2
Cl
+ NH Cl
NO2
NH2
+ 2 NH3 NH4Cl
ORTHO-NITROCHLOROBENZENE O-NITROANILINE
Schematic of the Nitroaniline Process
NH3 in H2O
ONCB
Autoclave175oC
~550 psi
NH3Separation
FilterPress
To Crystallizing
Tankso-NitroanilineProduct Stream
“fast” Orange
9/8/2008
5
1. Search for the Root and Contributing Causes
2 Recommend Preventive2. Recommend Preventive Measures
3. Ensure Effective Follow-Up
The Runaway Reaction
250
270
290
310
ure,
C
150
170
190
210
230
0 5 10 15
Tem
pera
tu
Time, Minutes
R + NO =
Materials which decompose explosively
Explosion!!!
R + NO2 =Hydrocarbon
groupNitrogroup
plus a an
9/8/2008
6
rate = k [NH3]α[ONCB]with high excess ammonia this
approximates to:a pseudo first order reaction in p
ONCB
rate ~ k’[ONCB]
On the day of the accident an excess of ONCB was
added to the reactor such that the intrinsic
rate was 2.18 times higher than normal.
Batch Temperature Early in the Run
9/8/2008
7
The Arrhenius Relationship a Point of No Return if the Heat Cannot be Removed Fast Enough
Heat Released and Removal Curves
Calculated Temperature Rise Later into the Run
9/8/2008
8
Estimated History of Temperature, Pressure, and Conversion
The Final Complication
Decomposition ofthe Product Relief Systems
Relief Systems
9/8/2008
9
Photograph of Relief System Line : Consists of a Rupture Disk and Spring Relief Valve in Series
Spring Relief Valve, SRV
Rupture Disk (RD)
Spring Relief Valve (SRV)
NO TELLTALE GAUGE BETWEEN RD AND SRV
SPACE PRESSURIZED AND CAUSED A COMPOUND PRESSURE EFFECT FOR RELIEF SYSTEM TO FUNCTION (~1400 PSI TO OPEN INSTEAD OF THE 700 PSI DESIGN)
Spring Relief Valve
Rupture Pressure
Rupture Disk on Left Developed a Pin Hole. Caused a compound effect in the pressure
required to relieve
Rupture Disk
Vessel
Actual
Vessel
Recommended
Pressuregauge
Why was the reactor over-charged with ortho-nitro-chloro-benzenewith ortho-nitro-chloro-benzene
and undercharged with ammonia?
9/8/2008
10
A management decision
Head
Tank
Normal TemporaryDump Valve
No Interlocks
The Charging System was Temporally Changed
AutoclaveAutoclavefrom a
Storage
Tank
from a Tankcar
High Level
Interlock
to Pump
No Interlock
to Pump
Finish Step 1
Lock is Open
Interlocks Prevent Missteps
Step 1p
Then
Step 2
Finish Step 2
Lock 2 is Open
9/8/2008
11
PUMP �DISABLEDAT HIGH LEVEL
INTERLOCK 2
V-1
V-1 CLOSES AT HIGH LEVEL
HEADTANK
LIC
PUMP ENABLEDIF V-2 CLOSED
INTERLOCK 1 V-2DUMPVALVE
V-1
HIC
SUMMARYCAUSE OF ACCIDENT
• No High Level InterlockN P /V l I l k• No Pump/Valve Interlock
• No Telltale
INDUSTRIAL ACCIDENT PREVENTIVE METHODS
• MOC (Management of Change)• PHA (Process Hazards Analysis)• PHA (Process Hazards Analysis)• PRE-START-UP REVIEWS• MI (Mechanical Integrity)• TRAINING
9/8/2008
12
Acknowledgments
• Dr. Walt Howard• AIChE• St. Louis Post-Dispatch• St. Louis Globe-Democrat• SACHE Committee
Problems
• See also, H. Scott Fogler, “Elements of Chemical Reaction Engineering,” 4th Edition, Prentice Hall, 2006, Chapter 9., , , p
Problem 1
• The overall intrinsic rate of reaction was given as:
• rate = k [NH3]α[ONCB]• If the normal batch charge was 500 kg of
ONCB (temp=40oC) and 2,600 kg of 26oBe (measured at 20oC) ammonia, estimate the actual amounts added to the same volume which would increase the intrinsic rate 2.18 times. Assume that α is =1.
9/8/2008
13
Problem 2
• Show that the intrinsic rate constant is directly proportional to the initial rate of conversion per minute (initial time when p (conversion = 0).
Problem 3
• If 99.54% conversion per minute is measured at 640oC and 0.225% conversion per minute is measured at p188oC, compute the activation energy for this reaction.
Problem 4
• Plot Q released by reaction and Q removed by cooling estimated by the following equations (T is in K) over a temperature range of 150 to 250oCin K) over a temperature range of 150 to 250oC.
Qrel (kJ*1E6/min)= 6.9032 X 10-5*Exp(0.034914*T)
Qremoved (kJ*1E6/min) = 0.0003*(T - 25)
9/8/2008
14
Problem 5
The first equation presented in problem 4 is empirically based. Can you write a better set of equations based on the qkinetics and Arrhenius expression given in Problems 1 and 3 respectively?
A Dust Explosion Apparatus Suitable For Use In Lecture Demonstrations
Ronald J. Willey1 and Edward Shanley2
1. Department of Chemical Engineering, Northeastern University, Boston, MA
email: [email protected] 2. Retired, Arthur D. Little, Inc., Present address: 31 Granite Ridge Road
Cumberland, ME, 04110, email: [email protected]
Abstract Classroom demonstrations enhance the sensing learning style that many
engineering students use. This simple apparatus, able to be constructed with components
found at a store such as Walmart for under $20.00, demonstrates the nature of dust
explosions very effectively. The demonstration can be used to complement a lecture in
thermodynamics (combustion, heating, and rapid expansion of gases), process design
(hazards involved with solids handling), or process safety (dust explosions and vent
sizing).
Text Any combustible solid that can be reduced to a fine powder has the potential for
involvement in a dust explosion. Many accidental dust explosions occur during
manufacturing operations associated with the preparation or use of such materials as
wheat flour, wood flour, metallic powders, powdered coal, powdered sugar, powdered
confectionery ingredients, and others. Eckhoff1 reports that during the past 20 years dust
explosions have accounted for several hundred deaths and hundreds of millions of dollars
in property damage.
Following is a description of a dust explosion apparatus suitable for use in lecture
demonstrations.
A transparent plastic food storage box with snap-on lid , about 15 centimeters
square and 18 centimeters in height, available from department stores or general
merchandise stores, hereafter called “the box”, provides a satisfactory container for the
demonstration. The exact size of the box is not important but its side walls should be
transparent. An aluminum foil heat shield should be attached to the inside surface of the
snap-on lid. Sticky tape will do. A quarter inch hole should be drilled in the side wall at
one of the bottom corners of the box.
A small tray to hold the flammable dust may be constructed of heavy kitchen -
type aluminum foil. A piece of foil is cut into the form of a regular trapezoid with edge
dimensions of about six by five by six by three centimeters. A pencil stub or similar-
sized object about four centimeters long is attached, with tacks or adhesive, to what will
become the bottom of the five inch side. Overhanging foil is bent upward to form the
outboard end of a shallow tray. The opposite, three-centimeter, side is bent upward to
form an open trough about 1 centimeter in width. The finished object is a small tray
about six centimeters long, almost flat at the wide, outboard end and formed into an open
channel about one centimeter deep at the inboard end. Placed on a flat surface, the tray
will have a gentle upward slope toward the outboard end. The dimensions noted above
are not critical. The objective is to contain the flammable dust in such a way that a puff
of air at the inboard end will lead to dispersion of the sample into the air space of the box.
Flammable dusts of many different sorts have been involved in destructive
explosions. Nevertheless, dust samples that have been held in storage for any length of
time become more difficult to ignite, possibly because of agglomeration during storage.
Lycopodium powder, readily available from reagent suppliers, is exceptional in retaining
its easy ignitibility even after prolonged storage. It is the most satisfactory fuel for dust
explosion demonstrations.
The lycopodium dust sample, about 0.5 cm3 in volume, is placed in the narrow
end of the tray after this end has been positioned directly in front of the ¼ inch hole
drilled near a bottom corner of the food storage box and intended to accept the discharge
end of the turkey baster tube. The tray should be oriented diagonally toward the opposite
corner of the box.
A short candle of the type used in candle lamps and the like, about ½ inch high
and 1 ½ inch diameter, serves as a convenient ignition source. It is placed in the inside
bottom of the box, diagonally across from the dust sample tray. If the candle is provided
with a handle, say of coat-hanger wire, it can be ignited before positioning it in the box.
Without undue delay, the snap-on top of the container is put in place, making sure that it
is firmly seated. The discharge end of the turkey baster is inserted into the quarter inch
hole in the container wall. Gentle squeezing of the baster bulb can lead to immediate
dispersion and ignition of the dust cloud, filling the container with a burst of flame and
blowing off the snap-on top with a satisfying “pop”. The candle can be re-positioned a
bit to one side if the air jet extinguishes it before the dust cloud is ignited.
Figure 1 provides a photographic illustration of the individual parts of the
apparatus described above.
The photographs in Figure 2 contain information about flame propagation rate in
the apparatus described above. In this experiment, the time from ignition to full
involvement was on the order of (200 – 70) ms or 130 ms for propagation through about
20 cm. This corresponds to a propagation rate of roughly 1.5 meters per second ,
extremely slow by explosive standards. For example, black gunpowder propagates at a
rate of about 400 meters per second, while typical high explosives such as TNT
propagate at about 4000 meters per second.
Flammable dusts rarely, if ever, constitute a hazard in the open air. Operations
capable of creating dust explosion hazards are usually conducted inside buildings such as
flour mills and grain elevators, as well as in facilities associated with the manufacture
and/or use of such products as edible flours, powdered sugar, metallic pigments and the
like. Dust concentrations capable of ignition are reported to contain on the order of at
least 50 grams of dust per cubic meter of air (Ref. 2). This is very much higher in solids
content than could be tolerated by human operators. For example, it has been noted that
minimum flammable concentrations of most dusts would limit visibility to a meter or so.
Accordingly, flammable dust – air compositions are usually found in closed processing
containers or in isolated areas within a manufacturing facility. An ignition source is also
required, perhaps a pilot flame, a welding spark, an electrical fault, or the like.
The original explosion may be too small to cause appreciable damage. The
resulting shock wave may, however, dislodge additional dust from horizontal surfaces,
cracks and crevices, storage areas, and the like. A new and perhaps larger dust cloud is
formed and may be ignited by the original source or by hot embers. This cycle, typical of
dust explosions, may repeat itself four or five times or more and culminate in complete
destruction of the facility.
Dust explosions in closed containers are reported to generate pressure on the order
of 3 to 7 atmospheres2. Buildings housing ordinary manufacturing facilities will not
support such internal overpressures. Quite modest excess pressure, on the order of a
fraction of an atmosphere, may cause roofs to rise, walls to bulge, and lead to complete
collapse of the structure3,4. This collapse represents most of the energy released during
the incident. The dust explosions proper served only to move or distort structural
elements upon which building was supported.
Authors note: As we were preparing this paper, a high school teacher, Mr. David Barr, Cranston
High School West, pointed out to us that a similar experiment used during Halloween has
been described on the Internet. Description of this alternative is given as References 5
and 6 below.
Literature Cited: 1. Eckhoff, R.K., Dust Explosions in the Process Industries. Butterworth-
Heinemann, Boston, Mass., 1997.
2. Kennedy, P.M. and Kennedy, J., Explosion Investigation and Analysis - Kennedy
on Explosions. Investigations Institute, Sarasota, FL, 1990
3. Crowl, D.A. and Louvar, J.F., Chemical Process Safety: Fundamentals with
Applications. 2nd ed. PTR Prentice Hall, Engelwood Cliffs, New Jersey, 2002
(Table 6.9, p. 267).
4. Louvar, J.F. and Schoeff, R.W., Dust Explosion Control. New York: Center for
Chemical Process Safety, American Institute of Chemical Engineers, 1994.
5. Geyer, M., "Subject: A Halloween Story," http://www.thecatalyst.org/forum/
halloween/halloween1.html, July 22, 2003.
6. Flinn Scientific, Inc., "Lycopodium Powder: The Mini Grain Elevator
Explosion," http://www.thecatalyst.org/download/demos/lycopodium1.pdf, July
22, 2003
Figure 1. Materials Used for Dust Explosion Demonstration
Propagation (70ms) 140 ms 200 ms 270 ms 360 ms
Figure 2. Sequential photographs of explosion recorded during the demonstration.
About This Learning Resource Module
This module will look at how to identify &
control ignition sources
Identifying &Identifying &Why Why
Some Some Dusts Dusts
ExplodeExplode
Why Why Some Some Dusts Dusts IgniteIgnite
Page 1
Identifying & Identifying & Controlling Controlling
Ignition Ignition SourcesSources
ExplodeExplodeIgniteIgnite
Table of Contents
Contents Of This Module: Dust Ignition Sources & Their ControlA. Intro & Non-Electrical Ignition SourcesB. Electrically Generated Sparks & Electrical
Area Classification (Overview)C. Static Electricity
Page forward or click any section
title to jump to that section.
Page 2
y1. Electro-Static Charge Generation Process2. Meaning Of The Term “Relaxation Time”3. Basics of Grounding & Bonding4. Charge Generation In Dusts (Solids) & How
It Differs From Metals & Liquids5. Types of Dust Electro-Static Discharges6. Induction Charging
D. Module Summary
Clicking this icon will return you to this page.
Clicking this icon will jump you to the next section.
Section A
3
• Intro & Non-Electrical Ignition Sources
In the earlier modules, we talked about the Fire Triangle
And the Dust Explosion Pentagon
MixingConfine-mentIgnition
SourceOxygen
Page 4
One of the most important ways to prevent dust fires and explosions is by controlling the ignition source.
Fuel
IgnitionSourceOxygen
Fuel
Ignition sources can come in a variety of forms. For example:
fire, flames,
hot surfaceselectrically
generated sparks
Page 5
smoldering material
mechanically generated sparks
static electricity causing a spark type discharge
static electricity causing a brush type discharge
fire, flames, smoldering
material
For example:•• HousekeepingHousekeeping
• If the dust can be kept inside the equipment designed to safely contain it, the less chance there is for one of these ignition sources to cause a fire or explosion.
•• Safe Work PermittingSafe Work Permitting• Control situations which could introduce a flame, hot
These three types of ignition sources are often controlled by very familiar technologies and precautions.
Page 6
hot surfaces
mechanically generated sparks
surface or tool capable of generating a spark into a dust handling area
•• Insulation IntegrityInsulation Integrity• Insulate hot surfaces and then ensure that insulation is
kept in good shape. If insulation has been removed or damaged, fix it or get it fixed as soon as possible.
•• Design for Safety, Maintain for SafetyDesign for Safety, Maintain for Safety• Design facilities to eliminate, minimize and control these
ignition sources. Then maintain these safety features and the facility so that everything functions as designed.
static electricity causing a spark type discharge
static electricity causing a brush type discharge
electrically generated sparks
A
Page 7
But electrical sources of ignition often pose unique control problems & solutions …
… with static electricity posing particular challenges.
Section B
8
• Electrically Generated Sparks & Electrical Area Classification (Overview)
static electricity causing a spark type discharge
static electricity causing a brush type discharge
electrically generated sparks
B
Page 9
But before we look into static electricity as a dust ignition source, we’ll first look at electrically generated sparks.
These can cause problems either due to:• Dust collecting near the electrical equipment• Or dust collecting inside the electrical equipment
So electrical equipment installed in dusty areas is specially designed to prevent the equipment being an ignition source.
For example, the electrical equipment in your dust area probably looks something like this:
example example example exampleconduit junction
B
Page 10
exampleplug & cord that
has been tested & approved for use
in a dust area
examplelight fixture that
has been tested & approved for use in
a dust area
examplestarter switch that has been tested & approved for use
in a dust area
conduit junction box that has been tested & approved for use in a dust
area
These special, heavy-duty fixtures are designed to meet certain design standards that are, in part, based on how
close the equipment is to a dusty area. This is called the electrical Area Classification.
For example, assume that this is a piece of dust handling equipment. Under some circumstances, this equipment can release dust into the atmosphere
To prevent ignition, all electrical equipment installed within the dark blue area must meet a certain Area
Classification design standard.Equipment outside the dark blue area but inside the light blue area must meet another
B
Page 11
?
blue area must meet another Area Classification design
standard.Since the Area Classification is often set by government rules, the names given to the dark & light blue areas – as well as the design specifications for the electrical equipment -- can vary by country & region.
In North American, for example, the dark & light blue area would typically be called Class II, Division 1 & Class II, Division 2 respectively. In Europe, though, similar areas might be called Zone 21 & 22. If you’d like to know more about Area Classification, complete the Area Classification module available at the learning resource website.
If you look closely at electrical equipment in a classified area, you will see a label that has symbols & codes
that identify what standards the equipment meets.
This equipment has been very carefully designed & manufactured to meet these
design standards. So …
B
Page 12
When using or servicing this equipment, always follow the manufacturer’s use &
service requirements.
Never use or service this kind of equipment unless you know what you
are doing.
Section C & C1
13
• Static Electricity– Electro-Static Charge Generation Process
C
static electricity causing a spark type discharge
static electricity causing a brush type discharge
electrically generated sparks
Page 14
Static electricity can be a very challenging ignition source to control.
Next we’ll look at how static electricity can be an ignition source.
C1
Charge Generation
Charge Accumulation
Have you ever …
Walked across a wool or synthetic carpet in
leather-soled shoes on a dry day …
Then touched a metal d k b
Page 15
Ignition?
Dischargedoorknob
… then ignition could occur.
and gotten a shock?
If the discharge spark is strong enough and it occurs in a
combustible atmosphere …
C1
Charge Generation
Charge Accumulation
Dusts can also generate & accumulate charge.
You may remember how an earlier module mentioned that some
dusts are good insulators. The
module also introduced the term “volume resistivity”.
Page 16
If the dust is a good insulator (in other words, it has high volume resistivity), then that dust is likely to generate an electro-static
charge whenever the particles rub and bump against other particles or against process equipment.
C1
Charge Generation
Charge Accumulation
The faster the particles rub and bump
Page 17
The faster the particles rub and bump together, the faster a charge is generated and
the greater the total charge that can be generated.
C1
Charge Generation
Charge Accumulation
But if you can prevent, minimize or control any of
these … Charge Accumulation
Discharge
Charge Generation
Page 18
Then you can help prevent this …
Ignition?
Discharge
C1
Charge Accumulation
Discharge
So, for example…
… keeping flow rates within known safe limits helps prevent charge
generation & accumulation …
and helps breaks
Charge Generation
Page 19
Ignition?
Discharge… and helps breaks the chain of events that
can lead to ignition.
C1
Charge Accumulation
Discharge
Charge Generation
Another example would be…
… increasing the humidity of the dust
processing stream …
hi h h l li i
Page 20
Ignition?
Discharge
… and helps breaks the chain of events that
can lead to ignition.
… which helps limit charge generation &
accumulation …
C1
But some of the common methods used to stop the chain of events that can
lead to discharge & ignition …
Charge
Charge Generation
Charge Accumulation
… involve relaxation or dissipation of
the charge.
Page 21
Charge Relaxation or Dissipation
Ignition?
Discharge
Section C2
22
• Meaning Of The Term “Relaxation Time”
Have you ever brushed your hair, or groomed your pet with a plastic comb or brush on a very dry day?
If so, then something like this probably
happened …
How does charge relaxation work?C2
Page 23
But once you stopped combing, the hair returns
to normal in a few minutes.
The electrostatic charge created by the comb on
the hair relaxed over time.
If we graphed the struck ball’s speed against time, it would look something like this:
This can be further illustrated with billiard balls. When a billiard ball is first struck by the cue ball, the ball moves very fast.
But gradually the ball loses speed and comes to a complete stop.
C2
Page 24
0 time0
Spee
d (mp
h)
The white cue ball strikes the ball, imparting energy to the struck ball
The ball gradually slows down
And eventually stops
d (mp
h)
To see how a similar graph can apply to dusts, we’ll change “speed” …
As the dust particles bump against each other (or against other objects), they become electrically charged
Once the particles stop bumping against each other (or against other objects), then they begin to lose that electrical charge
… to “electrostatic charge”
atic C
harg
e
C2
If left alone long enough,
Page 25
0 time
0
Spee
d
The amount of time it takes to lose an accumulated charge …
… is called the Relaxation Time for that dust
Elec
trosta
It can take days for some non-conductive solids (such as polyethylene or polypropylene dusts) to relax!
i
g g ,the particles eventually lose that electrical charge
C2
Relaxation Time is sometimes used to help
prevent electro-static discharge and ignition.
Charge Generation
Charge Accumulation
ChargeFor example process control
Page 26
Ignition?
DischargeCharge
Relaxation or Dissipation
For example, process control systems or operating procedures
may limit how fast a dust is allowed to move through the
process.
AA. Dusts can generate static electrical charges when the dust particles __________________________
0 time0
Elec
trosta
tic C
harg
e
BB. The time it takes for a dust to dissipate static electricity it has built up is called the __________________________
Page 27
QUESTION: Can you correctly complete these sentences?
ANSWER A: Dusts can generate static electrical charges when the dust particles bump into each other or into other objects.
ANSWER B: The time it takes for a dust to dissipate static electrical charge it has built up is called the relaxation time.
Click to reveal the answers
Section C3
28
• Basics Of Grounding & Bonding
C3
Electrostatic charges can also be dissipated.
Charge Generation
Charge Accumulation
Charge Relaxation orDissipation
Charge dissipation is similar in principle to how a lightning rod works.
When lightning strikes a structure protected with a lightning rod …
…the charge is conducted away from th t t b th
Page 29
the structure by the metal rod and cable …
… and into the ground (earth)
where it dissipates without causing
harm.Such system are called “grounding”
or “earthing” systems
C3
As a grounding example in a dust or powder system, consider the following situation.
A plastic dust is being handled. This plastic dust has a high
“volume resistivity” (is a good insulator).
A dust is being pneumatically conveyed through piping into a metal bin.
0 time0
Elec
trosta
tic C
harg
e
Page 30
Do you see any potential static generation problems with this
set-up?
The bin and nozzle do not touch.
It also has a long relaxation time.
C3
But, in this top part of the process, this charge isn’t
being allowed to
Yes, there is a potential problem.
The dust moving through the piping is generating an
electro-static charge.Charge
Generation
Charge Accumulation
We’ll analyze the potential problem by first looking at the top part of the process.
Page 31
Charge Relaxation or Dissipation
being allowed to accumulate.
So this top part of the process is okay.
Rather, as the charge is generated, it is safely directed away and is
dissipated by grounding. But what about the bin?
? Typically, flanged connections provide adequate electrical continuity between piping sections. But check the design specifications for your dust for more details on this.
C3
But – since there isn’t any direct contact between
the grounded piping and the bin - this charge
doesn’t have a path to ground. So there is no way for the charge to
An electro-static charge is also being generated in the bin as dust shifts &
falls inside the bin.Charge
Generation
Charge Relaxation or Dissipation
Charge Accumulation
Page 32
way for the charge to dissipate (except by
relaxation).
So charge accumulates on the bin.
C3Once a charge builds up in
the bin …
… something as simple as someone touching the bin …
Charge Generation
Charge Accumulation
Discharge
Ignition
Page 33
… could cause a discharge (spark)
that could be strong enough to ignite the
dust.
C3
So the bin needs to be grounded too.
Grounding the bin prevents charge accumulation by neutralizing the charge as it is
Charge Generation
Charge Accumulation
Discharge
Ignition
Page 34
generated.
Charge Relaxation or Dissipation
And so helps prevent a dangerous
discharge (spark) and ignition.
C3
Alternatively, the bin could be attached to a piece of grounded equipment – such as the pipe.
This is called a bond.
This is an example of a typical small-sized grounding
/ bonding clamp.
Page 35
This end would be permanently attached to a
ground or grounded equipment. (such as our
pipe flange).
This end would be clamped to the bin
before dumping into the bin
C3
This type of grounding / bonding clamp often has a very strong spring. So they can be hard to open.
But this strong spring serves an important design purpose -- the sharp points of the clamps need
to get a good “bite”.
Page 36
This helps ensure that a good metal-to-metal, electrically conductive
contact is made. Do not impair the clamp’s spring
just to make it easier to open.
C3
Likewise, when using a C-clamp type bond attachment, it needs to be screwed in tightly so that the point makes a good metal-to-metal contact.
Page 37
Grounds and bonds also need to be checked on a regular basis. If your role requires you to check the continuity of grounds and bonds, it is important to do it and do it well.
Mixer/agitator
Container B
This table mounted mixer is located in a lab. The process involves slowly pouring material in Container A into Container B while the mixer is on.NOTE: The table is electrically conductive ( t i l t l) i
Page 38
QUESTION: If asked to describe the purpose of the items highlighted in yellow and their significance to safe operation of the mixer, could you answer correctly?
Container A Mixer On/Off
Switch
(stainless steel), as is everything else shown (e.g., Containers A & B are metal).
Answer given on next page
Mixer/agitator
This is the grounding / bonding system for this equipment. The system conducts any static electrical charge produced during the pouring or mixing operation to a ground where the charge can safely dissipate. This helps prevent producing a charge in any component which could then spark when it came in contact with a component with a different electrical charge.
Grounding barBonding
Page 39
Container A
Container B
Mixer On/Off Switch
Ground
barBonding straps
Bonding clamps
• How control measures taken at various steps in the charge
Static Electricity Generation & Control Basics
In this section, you learned:
• The meaning of the term “Relaxation Time”,
0 time0
Elec
trosta
tic C
harg
eCharge Generation
Charge
Charge Accumulation
• The charge generation process,
Page 40
• The meaning of the terms “Grounding” and “Bonding”
generation process can help prevent uncontrolled discharge and ignition, and
In the next section, we’ll learn more about the various
types of electro-static discharges
Relaxation or Dissipation
Discharge
Ignition
Section C4
41
• Charge Dissipation In Dusts (Solids) & How It Differs From Charge Dissipation In Metals & Liquids
C4
Rubbing a metal rod with wool can produce a charge – but it is almost i t tl d i d
How charge generates and flows differs depending on whether the material is:
Metal Liquid
Page 42
instantly drained away through the ground
Or an insulating solid (such as a plastic dust)
C4
Likewise, falling liquid can sometimes produce a charge …
Metal Liquid
… but the static charge is usually quickly drained
Page 43
Or an insulating solid (such as a plastic dust)
usually quickly drained away & dissipated through
the ground
C4
This is not necessarily the case for solids though.
Metal Liquid
Insulating solid
Page 44
Just because a dust is in contact with a grounded surface doesn’t always mean the charge is quickly neutralized.
Even in contact with a ground, it may take some time for the charge on the dust to dissipate.
Electrostatic charges on plastic dusts are particularly hard to dissipate by
C4
Metals neutralize their static charge through a ground very quickly
Liquids also neutralize their static through a ground very quickly
Insulating Solids, though, can take a very long time to neutralize a static charge through a ground
time
Page 45
are particularly hard to dissipate by grounding. You may remember from an earlier modules that the higher
the volume resistivity, the longer it takes for the static charge to
neutralize.
Insulating solid
Plastic dusts often have very high resistivities – certainly when
compared to most metals and most common liquids.
C4
Assume that all the dust handling equipment below is properly grounded and bonded.
As dust is slowly dumped into the bin, the static charge generated is being
To illustrate this, consider the following example.
Page 46
g g gfully dissipated by a combination of
electrical charge relaxation and grounding / bonding.
So there is no (or very little) static electricity
hazard as shown here.
C4
But now we’ll increase the flow rate.
This increases the amount of static charge being generated.
This, in turn, overwhelms the ability to remove the static charge by relaxation and
grounding/bonding.
Page 47
So a static charge begins to accumulate.
g g g
C4
Now suppose an operating technician tries to level the pile in the bin with a
grounded metal rod.
… an electro-static discharge could
occur which, if strong h ld i it
Page 48
enough, could ignite the dust.
C4
If all five of the elements of the Dust Explosion Pentagon are present …
… then the dust might not only ignite, but could also explode …
MixingConfine-ment
Fuel
IgnitionSourceOxygen
Page 49
… even though the grounding & bonding
systems are functioning as
designed.
FSFL – Helpful Tip Grounding Filter Cages
• Filter bag cages should be grounded because they are generally made from conductive materials such as carbon steel and stainless steel.
• These conductive materials accumulate static charges easily if ungrounded. Static may accumulate due to the friction of the bag against the surface of the cage, but the primary cause is impact/adhesion of charged dust particles on the bag.
• Grounding of the cage is critical if the MIE is <30 mJ
Helpful Tips: Grounding Filter Cages
FF
Page 50
• Grounding of the cage is critical if the MIE is <30 mJ.• If the MIE is >100 mJ for the finest fraction collected it is probably
not necessary to ground the cages, i.e. there is very low probability of electrostatic ignition from the cage if the MIE is above 100 mJ, owing to the relatively small capacitance of bag cage assemblies. However, note that the “finest fraction collected” might be much finer than the sub-63 �m sample used for routine MIE measurements, and the MIE of particles collected by filters might therefore be much less than expected from a routine MIE test.
• See MET 1 for proper methods to ground filter cages.
FSFL - Helpful Tip Hand Pouring
Hand dumping of up to 50 lb. bags or small containers of dusts (having low toxicity) is permissible in air under the following conditions:
• The open area of the dump hopper is =/> the deflagration vent area required for the highest Kst dust being dumped.
• All conductive parts of the container are grounded, including the top metal chime of a fiber drum to the receiving hopper.
• The dump hopper has its own individual dust collector and exhaust f i i l t d f ll t b f t ti l
Helpful Tips: Hand Pouring Of Combustible Powders
FF
Page 51
fan, or is isolated from a common collector by a fast acting valve, or explosion suppression block.
• The person doing the dumping is grounded, such as by a grounding bracelet, if the MIE of the dust is unknown, or known to be less than 30 mJ.
• The person doing the dumping is wearing fire retardant personal protective equipment (FRPPE), face shield, and gloves.
Grounding/Bonding “Insulators”
Your local operating discipline is written to ensure the charge can be safely dissipated – by grounding
and bonding, by allowing the charge to dissipate through relaxation etc
Always ground & bond per local operating discipline.
Page 52
Just be aware that under some conditions it is possible for insulating dusts to
generate enough static charge to pose a hazard despite grounding & bonding.
through relaxation, etc.
That is why it is so important to follow your local operating
discipline to the letter.
QUESTION: Assume both of these bins start with the same amount of
Metal bin containing a metal dust
Metal bin containing a plastic dust
Bin A Bin B
Page 53
electrostatic charge. Which bin would neutralize (go to a uncharged state) first due solely to the flow of charge through the grounding/bonding system?
ANSWER: Metals typically neutralize their charge very quickly because they are more conductive (their resistivity is very low). Plastics typically neutralize their charge slowly (their volume resistivity is much higher). So Bin A would typically lose its electrostatic charge much faster than Bin A.
Click to reveal the answer
Section C5
54
• Types of Dust Electro-Static Discharges
When a static discharge occurs, it can be one of five types.
TT C5
Type #1: Capacitor (Spark)Type #1: Capacitor (Spark)
+
Spark type electro-static discharges are one of the most powerful types of static discharges.
But we’ll only review the few that are most important for your job.
Page 55
+For example, a baghouse cage is a large object. If the cage is improperly grounded it can produce a powerful spark.The larger the charged object, the more
energetic the spark.
The spark from even a small charged object is enough to ignite most flammable vapors and even some dusts.
When a static discharge occurs, it can be one of five types.
FSFL-C5
Type #1: Capacitor (Spark)Type #1: Capacitor (Spark)
+
Spark type electro-static discharges are one of the most powerful types of static discharges.
FF
Page 56
+For example, a baghouse cage is a large object. If the cage is improperly grounded it can produce a powerful spark.The larger the charged object, the more
energetic the spark.
The spark from even a small charged object is enough to ignite most flammable vapors and even some dusts.
+++++++++
FSFL-C5
Type #2: CoronaType #2: Corona This may happen if a conductor with sharp protrusions is given a high voltage. But it may also happen if a grounded, sharp conductor (at zero voltage) is brought near a charged object, like a piece of plastic that has been rubbed. This event demonstrates that it does not
FF
Page 57
+++++++++ This event demonstrates that it does not take a high voltage to cause a discharge, only a high field strength.A corona discharge is often called a silent discharge. It may be maintained as long as the breakdown field strength is exceeded in some region – that is, as long as the voltage of the electrode or the charge density of the charged insulator is high enough.
If the field strength in front of a sharp point of a conductor exceeds the breakdown field strength for the medium (e.g., air) a corona discharge will occur.
C5
Type #3: BrushType #3: Brush Brush discharges are a common type of discharge when insulators (such as many plastics and plastic dusts) are directly part of the discharge path.
Brush discharges crackle -- like the so nd o hear hen o p ll a s eater
Page 58
+++++++++
sound you hear when you pull a sweater over your head on a dry day.
FSFL-C5
Type #3: BrushType #3: BrushBrush discharges can be further divided into:
FF
3B. Bulking 3B. Bulking Brush (Cone)Brush (Cone)
3A. Propagating Brush3A. Propagating Brush
Page 59
A cone discharge seen from above as produced in a laboratory setting.
A propagating brush discharge as produced in a
laboratory setting.
FSFL-C5The maximum amount of energy which can be produced by these types of electrostatic discharges can vary – with sparks capable of producing the highest discharge energies, followed by propagating brush type discharges.
Of concern even for materials with a minimum ignition energy (MIE) >10 mJ. These are generally of issue in polyethylene, polypropylene & additives
Of concern for materials with an MIE of <10 mJ. These are of issue for additives
FF
Page 60
These types of discharges are not generally an issue unless a hybrid mixture is present (gas + dust)
C5To illustrate the difference between a capacitor (spark) type discharge and a brush type discharge, we’ll look again at the
operating technician trying to level a dust pile with a metal rod.
You may recall how the dust pile had accumulated a charge due to a high
flow rate. When the technician touched the dust pile with the rod, a brush type discharge was likely to
occur
Page 61
occur.
Now let’s change how the electro-static charge built up. This time, a charge has accumulated – even at normal flow rates - because the grounding strap between
the metal bin and the ground has broken.
C5To illustrate the difference between a capacitor (spark) type discharge and a brush type discharge, we’ll look again at the
operating technician trying to level a dust pile with a metal rod.
You may recall how the dust pile had accumulated a charge due to a high
flow rate. When the technician touched the dust pile with the rod, a brush type discharge was likely to
occur
Page 62
As the technician approaches the bin, the rod comes close to the
ungrounded metal bin …
… a capacitor (spark) type discharge occurs between the rod and the
metal bin.
occur.
C5
Even in a well-grounded bin or hopper, some low-conductivity (high volume- resistivity) dusts and powder can create significant
l t t ti h i l f th ti l
Another type of brush discharge - a “bulking brush” or “cone” discharge -can occur in large bins and hoppers.
Page 63
electro-static charges simply from the particles settling and shifting within the bin.
Compared to other brush type discharges, these can be
relatively powerful.
C5
Even in a well-grounded bin or hopper, some low-conductivity (high volume- resistivity) dusts and powder can create significant
l t t ti h i l f th ti l
A “bulking brush” or “cone”
discharge can occur in large bins
and hoppers.
Page 64
electro-static charges simply from the particles settling and shifting within the bin.
Compared to other brush type discharges, these can be
relatively powerful.
Cone discharges can also occur when filling flexible intermediate
bulk containers (FIBCs)
C5
The metal rods we’ve been using in our examples
are great conductors.
But so are humans.
Page 65
So in our earlier examples, if a grounded
person would have contacted the charged
object, then a discharge would also have
occurred.
C5These last two examples illustrated how a charge on a dust bin can cause a discharge.
How? We talked earlier in this module about how a person can generate an electrostatic charge -- by shuffling across a carpet, for example …
But a discharge can also occur even when the dust and dust bin don’t have an electro-static charge (are neutral).
… or by wearing clothes that can generate static (such as a wool or acrylic sweater).
Page 66
C5These last two examples illustrated how a charge on a dust bin can cause a discharge.
How? We talked earlier in this module about how a person can generate an electrostatic charge -- by shuffling across a carpet, for example …
But a discharge can also occur even when the dust and dust bin don’t have an electro-static charge.
… or by wearing clothes that can generate static (such as a wool or acrylic sweater).
Page 67
When that person then touches a grounded object (such as a grounded and neutrally charged bin of dust), then a discharge can occur.
During normal activities, the human body can reach a charge of up to 10 to 15 kiloVolts. This can produce a
spark of up to 20 to 30 mJ. This is greater than the minimum ignition energy (MIE) of many dusts.
i
There are many ways to reduce the hazard of “the human touch”. For example:
• Special static dissipative (“anti-static”) flooring materials may be installed
• Static dissipative floor or table mats may be used
• Special static dissipative shoes or clothing may be required
C5
Page 68
clothing may be required• Grounding/bonding straps are
attached to the person & a grounded/bonded object before proceeding with a task may be required (most effective)
• And so forth
Section C6
69
• Induction Charging
C6We have so far illustrated situations or implied how direct contact between objects (such as between dust particles) generates electrostatic charges.
There is also a less obvious way an electro-static charge can be generated. This is known as “induction charging”. By induction, a charge (voltage) can be
N S
Page 70
(voltage) can be generated on an object even without direct contact with another object.
To help visualize how this could happen, we’ll first look at a bar magnet. Almost everyone is familiar with how if you sift metal filings onto a bar magnet, the filings will form a pattern. The filings align themselves along the normally invisible magnetic force lines created by the North and South poles of the magnet.
C6
The force lines made visible by the metal filings on the bar magnet help illustrate how induction charging occurs.
Induction charging occurs when, under some conditions, a particular type of highly charged object (A)…
Page 71
By invisible lines of force similar to those a magnet generates, Object A can then “induce” a charge on Object B even though A and B aren’t touching.
… and particular type of object that doesn’t initially have a charge (B) are placed close to each other.
A B
For more information, see http://www.ce-mag.com/archive/2000/mayjune/mrstatic.html
FSFL-C6FF
Electromagnetic induction is described by Faraday’s Law of Induction. Electrostatic induction describe the static effect of an electric field on a conductor. For example:
Example 1: Insulated conductor in the field of a
charged insulator
An insulated, uncharged conductor B is in the field from a positively charged insulator A.The field from A will cause electrons in B to move to the side of B that faces A. These electrons make up the bound induced charge. This charge cannot be removed as long as B is in the field from A.The corresponding excess positive charge—
Page 72For more information, see http://www.ce-mag.com/archive/2000/mayjune/mrstatic.html
the free induced charge—is located on the opposite side of B. But the total charge on B is still zero, as is the field inside B. The free induced charge (positive) creates an electric field outside of B, with the field lines eventually terminating on some grounded object.If this field is integrated from B to a ground point, we will get a positive figure, which, by definition, is the voltage of B. Thus we have an uncharged conductor with a positive voltage.
FSFL-C6FF
Example 2: Grounded conductor in the field from a
charged insulator.In Example 2, we have the same situation as in Example 1, except that now the conductor is grounded. Consequently the voltage of B is zero.But because B still has the negative, bound induced charge we have a negatively
Page 73For more information, see http://www.ce-mag.com/archive/2000/mayjune/mrstatic.html
induced charge, we have a negatively charged conductor with zero voltage.If the ground connection is broken, and B is moved away from the neighborhood of A (in an insulated way), B will still have its negative charge, giving B a negative voltage.We describe this process as B having been charged by induction.
C6
A practical example is illustrated in this resin pouring operation.
• The technician is pouring resin powder into the tank.
• The movement of the resin creates a charge on the plastic lining of the resin bag.
• The charge on the plastic lining of the bag creates an electrical field around the bag
Resin powder in a plastic lined bag
Ungrounded technician
Page 74For more information, see http://www.ce-mag.com/archive/2000/mayjune/mrstatic.html
field around the bag.• The electrical field around the
bag induces a charge (voltage) on the technician.
• When the technician touches the tank, a spark discharge occurs, the acetone vapors ignite and injure the technician.
Tank containing acetone vapors
Even though the technician never directly touched the inner plastic liner of the resin bag, the technician acquired a charge (voltage) through induction.
C6
Other examples of induction charging include:
• Standing next to a “Type D” Flexible Intermediate Bulk Container (FIBC)
• Touching an ungrounded hopper containing
Page 75
pp gpolyethylene or additives
• Holding a large polyethylene sample in a plastic bag
• Moving a Portable Metal Container with insulating rubber wheels, containing CaSt
Section D
76
• Module Summary
FSFL-D
• The more conductive the better. Conductivity can be influenced by:
• Use of anti-static additives • Increasing humidity to >60%
To Reduce The Electrostatic HazardSummary - Designing
FF
Charge Charge GenerationGeneration
Charge Charge AccumulationAccumulation
DischargeCharge Charge
Dissipation orDissipation or
Page 77
Increasing humidity to >60%• You can also reduce generation &
accumulation by:• Reducing velocities• Allowing relaxation time
Discharge
Ignition?
Dissipation or Dissipation or RelaxationRelaxation
FSFL-D
Charge Charge GenerationGeneration
Charge Charge AccumulationAccumulation
DischargeCharge Charge
Dissipation or Dissipation or R l tiR l ti
To Reduce The Electrostatic HazardSummary - Designing
FF
You can also use static eliminators –although these are not always effective.Use grounding & bonding to dissipate charge. (But remember that contact with ground doesn’t automatically mean the charge is neutralized.)
• If the MIE <30 mJ remember that
Page 78
Ignition?
RelaxationRelaxation If the MIE <30 mJ, remember that personnel are to be grounded to hoppers or other grounded containers during hand pouring or other transfer operation.
Static eliminators remove static charges by creating an ionized atmosphere in close proximity to the charged surface, neutralizing the surface.
Types include static (ionizing) bars, ionizing blowers & guns, & eliminators that use nuclear
devices.
i
FSFL-DIf you’d like to know even more about dusts, powders and static electricity, you can access to these books through Knovel.
To open a book, click book cover image below. Internet access is
required.
FF
Page 79
Other references (including links to on-line journal articles) are available at the “For more information” link provided in the web-based learning plan containing this module.
Electro-Static Discharges
Spark type (capacitance)
discharges can be powerful sources of
ignition.
But spark discharges are not the only type of electrostatic discharge. Some sensitive dusts
can be ignited by other types of discharges
such as brush discharges.
Page 80
In a large bin or hopper containing a
high volume resistivity dust, the settling of a dust
alone can produce a static discharge.In some situations, a charge
can be induced in some situations without being in
direct contact with a charged object.
Identifying & Controlling Ignition Sources
That concludes this module. In this module, you have learned:
Fire, flame, smoldering material
Hot surfaces
& Key Prevention/Control Mechanisms
Proper design; use of safe work permit & similar well-known safety systems to control work involving these sources of ignition; proper maintenance & service of equipment capable of producing such ignition sources
The 6 Basic Kinds Of Ignition Sources
Page 81
Mechanically generated sparks
Electrically generated sparks
Static electricity (spark type)
Static electricity (brush type)
Same as above plus conformance to area classification requirements
Design & operate to reduce potential for generating & accumulating static charge; proper use of grounding / bonding & related static dissipation measures; local operating discipline based on properties of the dust handled & local process operating conditions
Identifying & Controlling Ignition Sources
You have also learned:
Charge Relaxation or Dissipation
Ignition?
Discharge
Charge Generation
Charge Accumulation The Electrostatic
Charge Generation Process
0time0
Elec
trosta
tic C
harg
e
Including the concept of Relaxation Time
Page 82
What grounding & bonding is and how it works
The ways a static charge can discharge & cause ignition of a dust
TechTech
Practice Good Operating Discipline!• Strictly follow your local operating discipline.• Use manually attached grounds & bonds when
required.• Wear anti-static clothing & personal protective
What can you do to help prevent ignition?
Page 83
ea a t stat c c ot g & pe so a p otect eequipment when required.
• Don’t deviate from local operating discipline without following Management of Change (MOC) requirements.
• Good housekeeping is critical
TechTechAnd don’t let these kinds of things cause a problem for you:
Leaving a bond or ground wire off
Allowing loose or missing bolts in flanges – those bolts may be
serving an important grounding function
Using a non-
Page 84
gconductive hose or
flexible joint to transfer combustible, static
prone dusts
Using thewrong type FIBC
(Supersack)
This concludes the module …
Page 85
Identifying & Identifying & Controlling Controlling
Ignition Ignition SourcesSources
This module used with permission from The Dow Chemical Company
LEGAL NOTICE AND DISCLAIMER
The Dow Chemical Company and its consolidated subsidiaries (“Dow”) make no representation or warranty with respect to the information contained in the accompanying document, “Static Electricity for SACHE". Each company and/or other person using this document or information contained therein remains solely and exclusively responsible for the health, safety, and environmental protection standards programs procedures and interpretations for its own facilities and
Page 86
standards, programs, procedures, and interpretations for its own facilities and operations and must reach its own conclusions as to legal and regulatory compliance and the safety of its operations without reliance upon any information contained herein. Dow does not assume any duty, responsibility, or liability resulting from use by any company and/or other person of any standards, programs, procedures, or interpretations contained in the document. Receipt and acceptance of the document constitutes acknowledgment and acceptance of this notice and disclaimer by the company and/or other person receiving a copy hereof.
1
200820082008 SACHE Faculty Workshop SACHE Faculty Workshop SACHE Faculty Workshop
ChemicalChemicalReactivityReactivityHazards:Hazards:
ChemicalChemicalChemicalReactivityReactivityReactivityHazards:Hazards:Hazards:
2005 SACHE Faculty Workshop2005 SACHE Faculty Workshop2005 SACHE Faculty Workshop
foreseeforeseeavoidavoidcontrolcontrol
2
IntroductionIntroduction
The worst process industry disasters worldwidehave involved uncontrolled chemical reactions
Thesis: Chemical reactivity hazards must beanticipated and recognized before controls canbe engineered• Reactivity hazards that are eliminated will not
need engineering and administrative controls• SACHE has many products that can help
educate engineers to understand and safeguardagainst uncontrolled reactions
SyllabusSyllabus
Course TextsPretestKey Concepts 1Midterm ExamKey Concepts 2Open-Book Final
Extra-Credit Activities
3
CourseCourseTextsTexts
TextsTexts
CCPS Safety Alert 2001.Reactive Material Hazards:What You Need to Know.New York: AIChE. 10 pages.
Download for free athttp://www.aiche.org/CCPS/Resources/SafetyAlerts/index.aspx
4
TextsTexts
Johnson, Rudy, Unwin 2003.Essential Practices forManaging ChemicalReactivity Hazards.New York: AIChE. 193 p.
Register for free access atwww.knovel.com/ccps
TextsTexts
CCPS 1995.Guidelines for ChemicalReactivity Evaluation andApplication to ProcessDesign.New York: AIChE. 210 p.
AIChE members can accessfor free at www.knovel.com
5
TextsTexts
CCPS 1995.Guidelines for SafeStorage and Handling ofReactive Materials.New York: AIChE. 364 p.
AIChE members can accessfor free at www.knovel.com
TextsTexts
CCPS 1999.Guidelines forProcess Safety inBatch Reaction Systems.New York: AIChE. 171 p.
Available fromwww.wiley.com
6
TextsTexts
Hazard Investigation 2002.Improving ReactiveHazard Management.Washington, D.C.: U.S.Chemical Safety and HazardInvestigation Board. 150 p.
Download for free atwww.csb.gov
TextsTexts
HarsBook: A technicalguide for the assessment ofthermal hazards in highlyreactive chemical systems.HarsNet Thematic Network onHazard Assessment of HighlyReactive Systems. 143 p.
Download for free atwww.harsnet.net
7
TextsTexts
P.G. Urben (ed.) 2006.Bretherick’s Handbookof Reactive ChemicalHazards (2 vols).Academic Press. 2,680 pages
~$400 from Amazon.com;also available electronically
SoftwareSoftware
CCPS 2006.Chemical ReactivityTraining CD-ROM.New York: AIChE.
$265.50 from wiley.com;free to all SACHE members
8
PretestPretest
PretestPretest
On the NFPA ‘diamond’,which color(s) or position(s)are associated with chemicalreactivity hazards?
WOXWOX
0334
Q1
9
Flammability
WOXWOX
0334
Special Hazards
InstabilityToxicity
A1
PretestPretest
PretestPretest
Your new research calls for thepiloting of a process involvingacetone cyanohydrin.
What should you do first?
Q2
10
PretestPretest
First, find out the inherent hazardsof acetone cyanohydrin.
A2
C4H7NO
PretestPretest
First, find out the inherent hazardsof acetone cyanohydrin.
A2
CH3 C O + HCNCH3
11
PretestPretest
First, find out the inherent hazardsof acetone cyanohydrin.
A2
COHCH3
C NCH3
Acetone CyanohydrinAcetone Cyanohydrin
2113
NFPA 49NFPA 49
Severe health hazard; combustible;readily decomposes, producingHCN; no “special hazards”;reacts with acids, alkalis,oxidizing materials,reducing agents
12
Acetone CyanohydrinAcetone Cyanohydrin
1224
International Chemical Safety CardInternational Chemical Safety Card
Extremely toxic, Class IIIB combustible,unstable at elevated temp,decomposes in water
Acetone CyanohydrinAcetone Cyanohydrin
2224
WISER (WISER (http://wiser.nlm.nih.gov)
• HIGHLY FLAMMABLE: Easily ignited byheat, sparks or flames
• DO NOT GET WATER on spilledsubstance or inside containers
13
Acetone CyanohydrinAcetone Cyanohydrin
DOTDOT
Class 6.1 Poisonous material
Acetone CyanohydrinAcetone Cyanohydrin
DOT DOT Emergency Response Guidebook 2004Emergency Response Guidebook 2004A water-reactivematerial that produceslarge amounts of HCNwhen spilled in water
14
Acetone CyanohydrinAcetone Cyanohydrin
NOAA Chemical Reactivity WorksheetNOAA Chemical Reactivity WorksheetSpecial Hazards· Water-ReactiveNo rapid reaction with Air
Air and Water ReactionsSoluble in water. Readily decomposes oncontact with water to form acetone andpoisonous hydrogen cyanide.
General Description
Chemical ProfileReadily decomposes to acetone
and poisonous hydrogencyanide gas on contact withwater, acids (sulfuric acid) orwhen exposed to heat.Should be kept cool andslightly acidic (pH 4-5) [Sax,2nd ed., 1965, p. 388].Slowly dissociates to acetone,a flammable liquid, andhydrogen cyanide, aflammable poisonous gas,under normal storage andtransportation conditions.Rate of dissociationincreased by contact withalkalis and/or heat.
A colorless liquid. Flash point 165°F.Lethal by inhalation and highly toxic orlethal by skin absorption. Density 7.8 lb /gal (less dense than water). Vapors heavierthan air. Produces toxic oxides of nitrogenduring combustion (© AAR, 1999).
Acetone CyanohydrinAcetone Cyanohydrin
NIOSH NIOSH Pocket Guide to Chemical HazardsPocket Guide to Chemical HazardsIncompatibilities & Reactivities:Sulfuric acid, caustics
Note: Slowly decomposes to acetone & HCN atroom temperatures; rate is accelerated by anincrease in pH, water content, or temperature.
15
Acetone CyanohydrinAcetone Cyanohydrin
CHRISCHRIS
Acetone CyanohydrinAcetone Cyanohydrin
CHRISCHRIS
16
Acetone CyanohydrinAcetone Cyanohydrin
SIDS: Stability in Water
0
10
20
30
40
50
60
4.5 5 5.5 6 6.5 7 7.5
pH
T½ (
min
)
Acetone CyanohydrinAcetone Cyanohydrin
ConclusionsConclusions
Extremely toxic; must keep containedand avoid all contactCombustible; must avoid flame, ignitionDissociates to produce highly toxic andflammable gases; dissociation increaseswith heat, moisture, alkalinityMust prevent spills into drains, etc.Must avoid incompatible materials
17
KeyKeyConceptsConcepts
Key ConceptsKey Concepts
From 2005 SACHE module onChemical Reactivity Hazards
18
19
(etc.)
20
The NOAA Chemical ReactivityWorksheet predicts the results ofmixing any binary combination ofthe 6,080 chemicals in the CAMEOdatabase, including manycommon mixtures and solutions.
For each substance, a generaldescription and chemical profileare given, along with specialhazards such as air and waterreactivity.
21
CRWorksheetCRWorksheet Limitations Limitations
Only binary combinations considered
Consequences predicted only forambient temperature, atmosphericpressure
Possible effects of confinement,catalysts, contaminants, or materials ofconstruction not included
Reaction products not predicted, thoughflammable or toxic gas generation maybe suggested
PreliminaryPreliminaryScreen forScreen forChemicalChemicalReactivityReactivityHazardsHazards
Source: Johnson et al. 2003
SummaryFlowchart
22
IncidentIncident
April 21, 1995April 21, 19955 workerfatalities~300evacuatedFacilitydestroyedSurroundingbusinessesdamaged
Ed Hill, The Bergen RecordUsed with permission
WHY?Those hazards that are not eliminated orreduced to insignificance must be managedthroughout the lifetime of the facility,to avoid uncontrolled chemical reactions thatcan result directly or indirectly in seriousharm to people, property or the environment.
23
Inherently Cleaner
Processes
Inherently Inherently CleanerCleaner
Processes Processes
Pollution Prevention Pollution Pollution Prevention Prevention
Waste Management
Waste Waste Management Management
Environ- mental
Restoration
Environ- Environ- mental mental
Restoration Restoration
InherentlySafer
Processes
Inherently InherentlySafer Safer
Processes Processes Prevention Prevention Prevention Mitigation Mitigation Mitigation
AccidentRecovery Accident AccidentRecovery Recovery
Inherently Cleaner, Safer PlantsInherently Cleaner, Safer Plants
AFTERMATHAFTERMATHRELEASERELEASEPOTENTIALPOTENTIAL
24
Safe OperationSafe Operation
Contain and control all chemicalreactivity hazards throughout entirefacility lifetime
Reduce hazards or design safeguardssuch that even if hazard containment orcontrol were lost, no injuries, propertydamage, environmental damage orbusiness interruption would occur
Eliminate chemical reactivity hazards
(with respect to Chemical Reactivity Hazards)(with respect to Chemical Reactivity Hazards)
Inherently Safer StrategiesInherently Safer Strategies
MINIMIZE
SUBSTITUTE
MODERATE
SIMPLIFY
25
Foresee, Avoid, ControlForesee, Avoid, Control
Anticipate chemical reactivity hazards
Identify all reactive materials andall possible reactive interactions
Do whatever it takes to fully understandintended and unintended reactions• Boundaries of safe operation• Calculations, literature, testing, experts
Design and operate to avoid unintendedreactions and control intended reactions
26
STARTSTART Section 4.1Develop/Document System to Manage Chemical Reactivity Hazards
4.8Communicate and Train onChemical Reactivity Hazards
4.5Assess ChemicalReactivity Risks
4.6Identify ProcessControls and RiskManagement Options
4.7Document Chemical ReactivityRisks and Management Decisions
4.9InvestigateChemicalReactivityIncidents
4.10Review, Audit,Manage Change,Improve HazardManagementPractices/Program
4.2Collect ReactivityHazard Information
4.4Test for ChemicalReactivity
NO
YES
Sufficientinformation to evaluate
hazard?
4.3Identify ChemicalReactivity Hazards
IMPLEMENT; OPERATE FACILITYIMPLEMENT; OPERATE FACILITY
ManagingManagingChemicalChemicalReactivityReactivityHazardsHazards
27
4.8Communicate and Train onChemical Reactivity Hazards
4.5Assess ChemicalReactivity Risks
4.6Identify ProcessControls and RiskManagement Options
4.7Document Chemical ReactivityRisks and Management Decisions
4.9InvestigateChemicalReactivityIncidents
4.10Review, Audit,Manage Change,Improve HazardManagementPractices/Program
4.2Collect ReactivityHazard Information
4.4Test for ChemicalReactivity
NO
YES
Sufficientinformation to evaluate
hazard?
4.3Identify ChemicalReactivity Hazards
IMPLEMENT; OPERATE FACILITYIMPLEMENT; OPERATE FACILITY
Identify,Identify,CharacterizeCharacterize
HazardsHazards
Chemical Reaction Hazard IdentificationChemical Reaction Hazard IdentificationD.C. Hendershot 2002. “A Checklist for Inherently SaferChemical Reaction Process Design and Operation.” CCPSInternational Symposium on Risk, Reliability and Security.
28
Reaction Hazard IdentificationReaction Hazard Identification
1 Know the heat of reaction for theintended and other potential chemicalreactions.
There are a number of techniques for measuring orestimating heat of reaction, including variouscalorimeters, plant heat and energy balances forprocesses already in operation, analogy with similarchemistry (confirmed by a chemist who is familiar withthe chemistry), literature resources, supplier contacts,and thermodynamic estimation techniques. You shouldidentify all potential reactions that could occur in thereaction mixture and understand the heat of reaction ofthese reactions.
2 Calculate the maximum adiabatictemperature for the reaction mixture.
Use the measured or estimated heat of reaction,assume no heat removal, and that 100% of thereactants actually react. Compare this temperature tothe boiling point of the reaction mixture. If themaximum adiabatic reaction temperature exceeds thereaction mixture boiling point, the reaction is capableof generating pressure in a closed vessel and you willhave to evaluate safeguards to prevent uncontrolledreaction and consider the need for emergencypressure relief systems.
Reaction Hazard IdentificationReaction Hazard Identification
29
Reaction Hazard IdentificationReaction Hazard Identification
3 Determine the stability of all individualcomponents of the reaction mixture atthe maximum adiabatic reactiontemperature.
This might be done through literature searching,supplier contacts, or experimentation. Note that thisdoes not ensure the stability of the reaction mixturebecause it does not account for any reaction amongcomponents, or decomposition promoted bycombinations of components. It will tell you if any ofthe individual components of the reaction mixture candecompose at temperatures which are theoreticallyattainable.
Reaction Hazard IdentificationReaction Hazard Identification
3 (continued)
If any components can decompose at the maximumadiabatic reaction temperature, you will have tounder-stand the nature of this decomposition andevaluate the need for safeguards including emergencypressure relief systems.
30
Reaction Hazard IdentificationReaction Hazard Identification
4 Understand the stability of the reactionmixture at the maximum adiabaticreaction temperature.
Are there any chemical reactions, other than theintended reaction, which can occur at the maximumadiabatic reaction temperature? Consider possibledecomposition reactions, particularly those whichgenerate gaseous products. These are a particularconcern because a small mass of reacting condensedliquid can generate a very large volume of gas from thereaction products, resulting in rapid pressuregeneration in a closed vessel.
Reaction Hazard IdentificationReaction Hazard Identification
4 (continued)
Again, if this is possible, you will have to understandhow these reactions will impact the need for safeguards,including emergency pressure relief systems.Understanding the stability of a mixture of componentsmay require laboratory testing.
31
Reaction Hazard IdentificationReaction Hazard Identification
5 Determine the heat addition and heatremoval capabilities of the pilot plantor production reactor.
Don’t forget to consider the reactor agitator as asource of energy – about 2550 Btu/hour/horsepower.Understand the impact of variation in conditions onheat transfer capability. Consider factors such asreactor fill level, agitation, fouling of internal andexternal heat transfer surfaces, variation in thetemperature of heating and cooling media, variation inflow rate of heating and cooling fluids.
Reaction Hazard IdentificationReaction Hazard Identification
6 Identify potential reaction contaminants.
In particular, consider possible contaminants which areubiquitous in a plant environment, such as air, water,rust, oil and grease. Think about possible catalyticeffects of trace metal ions such as sodium, calcium, andothers commonly present in process water. These mayalso be left behind from cleaning operations such ascleaning equipment with aqueous sodium hydroxide.Determine if these materials will catalyze anydecomposition or other reactions, either at normalconditions or at the maximum adiabatic reactiontemperature.
32
Reaction Hazard IdentificationReaction Hazard Identification
7 Consider the impact of possible deviationsfrom intended reactant charges andoperating conditions.
For example, is a double charge of one of the reactants apossible deviation, and, if so, what is the impact? This kindof deviation might affect the chemistry which occurs in thereactor – for example, the excess material charged may reactwith the product of the intended reaction or with a reactionsolvent. The resulting unanticipated chemical reactionscould be energetic, generate gases, or produce unstableproducts. Consider the impact of loss of cooling, agitation,and temperature control, insufficient solvent or fluidizingmedia, and reverse flow into feed piping or storage tanks.
Reaction Hazard IdentificationReaction Hazard Identification
8 Identify all heat sources connected tothe reaction vessel and determine theirmaximum temperature.
Assume all control systems on the reactor heatingsystems fail to the maximum temperature. If thistemperature is higher than the maximum adiabaticreaction temperature, review the stability andreactivity information with respect to the maximumtemperature to which the reactor contents could beheated by the vessel heat sources.
33
Reaction Hazard IdentificationReaction Hazard Identification
9 Determine the minimum temperature towhich the reactor cooling sourcescould cool the reaction mixture.
Consider potential hazards resulting from too muchcooling, such as freezing of reaction mixturecomponents, fouling of heat transfer surfaces, increasein reaction mixture viscosity reducing mixing and heattransfer, precipitation of dissolved solids from thereaction mixture, and a reduced rate of reactionresulting in a hazardous accumulation of unreactedmaterial.
Reaction Hazard IdentificationReaction Hazard Identification
10 Consider the impact of highertemperature gradients in plant scaleequipment compared to a laboratory orpilot plant reactor.
Agitation is almost certain to be less effective in aplant reactor, and the temperature of the reactionmixture near heat transfer surfaces may be higher (forsystems being heated) or lower (for systems beingcooled) than the bulk mixture temperature. Forexothermic reactions, the temperature may also behigher near the point of introduction of reactantsbecause of poor mixing and localized reaction at thepoint of reactant contact.
34
Reaction Hazard IdentificationReaction Hazard Identification
10 (continued)
The location of the reactor temperature sensor relativeto the agitator, and to heating and cooling surfaces mayimpact its ability to provide good information about theactual average reactor temperature. These problems willbe more severe for very viscous systems, or if thereaction mixture includes solids which can foultemperature measurement devices or heat transfersurfaces. Either a local high temperature or a local lowtemperature could cause a problem. A high temperature,for example, near a heating surface, could result in adifferent chemical reaction or decomposition at thehigher temperature.
Reaction Hazard IdentificationReaction Hazard Identification
10 (continued)
A low temperature near a cooling coil could result inslower reaction and a buildup of unreacted material,increasing the potential chemical energy of reactionavailable in the reactor. If this material is subsequentlyreacted because of an increase in temperature or otherchange in reactor conditions, there is a possibility of anuncontrolled reaction due to the unexpectedly highquantity of unreacted material available.
35
Reaction Hazard IdentificationReaction Hazard Identification
11 Understand the rate of all chemicalreactions.
It is not necessary to develop complete kineticmodels with rate constants and other details, butyou should understand how fast reactants areconsumed and generally how the rate of reactionincreases with temperature. Thermal hazardcalorimetry testing can provide useful kinetic data.
Reaction Hazard IdentificationReaction Hazard Identification
12 Consider possible vapor phasereactions.
These might include combustion reactions, other vaporphase reactions such as the reaction of organic vaporswith a chlorine atmosphere, and vapor phasedecomposition of materials such as ethylene oxide ororganic peroxide.
36
Reaction Hazard IdentificationReaction Hazard Identification
13 Understand the hazards of the productsof both intended and unintended reactions.
For example, does the intended reaction, or a possibleunintended reaction, form viscous materials, solids, gases,corrosive products, highly toxic products, or materialswhich will swell or degrade gaskets, pipe linings, or otherpolymer components of a system? If you find anunexpected material in reaction equipment, determine whatit is and what impact it might have on system hazards. Forexample, in an oxidation reactor, solids were known to bepresent, but nobody knew what they were. It turned out thatthe solids were pyrophoric, and they caused a fire in thereactor.
Reaction Hazard IdentificationReaction Hazard Identification
14 Consider doing a Chemical InteractionMatrix and/or a Chemistry HazardAnalysis.
These techniques can be applied at any stage in theprocess life cycle, from early research through anoperating plant (Mosley et al. 2000). They are intendedto provide a systematic method to identify chemicalinteraction hazards and hazards resulting fromdeviations from intended operating conditions.
37
ASTM E 2012-00ASTM E 2012-00
“Standard Guide for the Preparation of a“Standard Guide for the Preparation of aBinary Chemical Compatibility Chart”Binary Chemical Compatibility Chart”
Scenario-based
Inadvertent Mixing ScenariosInadvertent Mixing Scenarios
SCENARIO CONDITIONS NORMAL?1
R, NRor ?2 INFORMATION SOURCES; COMMENTS
1 Mix one liter of household ammoniacleaner into four liters of household chlorinebleach in an open bucket, with intention ofimmediate use
Yes R Based on sodium hypochlorite solutionMSDS. Generates heat and toxicvapors; can form explosive nitrogentrichloride under certain conditions
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C
No ? Compatibility information only known forambient conditions; no reaction withcyclohexane expected, but may be hotenough to increase dimer formation andpossibly initiate polymerization
1 Does the contact/mixing occur at ambient temperature, atmospheric pressure, 21% oxygen atmosphere, and unconfined? (IF NOT, DO NOT ASSUME THAT PUBLISHED DATA FOR AMBIENT CONDITIONS APPLY) 2 R = Reactive (incompatible) under the stated scenario and conditions NR = Non-reactive (compatible) under the stated scenario and conditions ? = Unknown; assume incompatible until further information is obtained
Johnson and Lodal, "Screen Your Facilities forChemical Reactivity Hazards," CEP, Aug. 2003
38
SCENARIO
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C
Inadvertent Mixing ScenariosInadvertent Mixing Scenarios
SCENARIO CONDITIONS NORMAL?1
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C1 Does the contact/mixing occur at ambient temperature, atmospheric pressure, 21% oxygen atmosphere, and unconfined? (IF NOT, DO NOT ASSUME THAT PUBLISHED DATA FOR AMBIENT CONDITIONS APPLY)
No
Inadvertent Mixing ScenariosInadvertent Mixing Scenarios
39
SCENARIO CONDITIONS NORMAL?1
R, NRor ?2
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C
No
2 R = Reactive (incompatible) under the stated scenario and conditions NR = Non-reactive (compatible) under the stated scenario and conditions ? = Unknown; assume incompatible until further information is obtained
?
Inadvertent Mixing ScenariosInadvertent Mixing Scenarios
SCENARIO CONDITIONS NORMAL?1
R, NRor ?2 INFORMATION SOURCES; COMMENTS
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C
No ? Compatibility information only known forambient conditions; no reaction withcyclohexane expected, but may be hotenough to increase dimer formation andpossibly initiate polymerization
Compatibility information only known forambient conditions; no reaction withcyclohexane expected, but may be hotenough to increase dimer formation andpossibly initiate polymerization
Inadvertent Mixing ScenariosInadvertent Mixing Scenarios
40
SCENARIO CONDITIONS NORMAL?1
R, NRor ?2 INFORMATION SOURCES; COMMENTS
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C
No ? Compatibility information only known forambient conditions; no reaction withcyclohexane expected, but may be hotenough to increase dimer formation andpossibly initiate polymerization
G.W. Boicourt, “Experimental Safety: What YouNeed for Effective Process Safety Evaluation,”Proceed. 30th Annual Loss Prev. Symp., 2/96.
Inadvertent Mixing ScenariosInadvertent Mixing Scenarios
SCENARIO CONDITIONS NORMAL?1
R, NRor ?2 INFORMATION SOURCES; COMMENTS
2 Inadvertently pump up to 1400 kg of 38°Ccyclohexane at 0.3 kg/s into closed,temperature-controlled storage tank ofbetween 700 and 2800 kg of acrylic acid with200 ppm MEHQ inhibitor, maintained at 20°C
No ? Compatibility information only known forambient conditions; no reaction withcyclohexane expected, but may be hotenough to increase dimer formation andpossibly initiate polymerization
SeveritOn Off
Containment rupture explosionFireToxic reaction products release
Cause ConsequencesGuideWord/Deviation Freq
AS WELL ASCyclohexaneAdded
Connecting valveleft open
Inadvertent Mixing ScenariosInadvertent Mixing Scenarios
41
Chemistry Hazard Analysis ScenariosChemistry Hazard Analysis ScenariosGuideword Deviation Consequences Comments/Actions
No No Catalyst Cadded
No reaction when Reactants Aand B are mixed; if Catalyst Cis added after the entire chargeof Reactants A and B has beencompleted, a rapid and violentreaction can occur
Develop kinetic andthermodynamic data onthis reaction
More Hightemperature;greater than70°C
Side reactions have beenobserved in similar systemsabove 70°C, and may alsooccur with this chemistry
Investigate thebehavior of the reactionat elevated temperature
As well as Rust, as wellas normalmaterials
The effect of contaminationwith iron or rust is unknown
Determine the effect ofiron/rust contamination
Mosley, Ness, and Hendershot, "Screen Reactive ChemicalHazards Early in Process Development," CEP, Nov. 2000
4.8Communicate and Train onChemical Reactivity Hazards
4.5Assess ChemicalReactivity Risks
4.6Identify ProcessControls and RiskManagement Options
4.7Document Chemical ReactivityRisks and Management Decisions
4.9InvestigateChemicalReactivityIncidents
4.10Review, Audit,Manage Change,Improve HazardManagementPractices/Program
4.2Collect ReactivityHazard Information
4.4Test for ChemicalReactivity
NO
YES
Sufficientinformation to evaluate
hazard?
4.3Identify ChemicalReactivity Hazards
IMPLEMENT; OPERATE FACILITYIMPLEMENT; OPERATE FACILITY
PHAs; Ensure Risk ControlPHAs; Ensure Risk Control
42
ChemicalReactivityHazards
Intentional ChemistryUnintentional Chemistry• Materials Reactive with
Ubiquitous Substances– Spontaneously Combustible– Peroxide Forming– Water Reactive– Oxidizing
• Self-Reactive Materials– Polymerizing– Decomposing– Rearranging
• Reactive Interactions– Incompatibilities– Abnormal Conditions
Identify,Identify,characterizecharacterize
hazardshazards
ChemicalReactivityHazards
Impacts• People• Property• Environment
Potential Loss Event
Normal Situation - Normal Situation - ReactivesReactives
Reactive materials contained
Reactive interactions (incompatibilities) avoided
Intended reactions controlled
43
ChemicalReactivityHazards Deviation
Abnormal Situation - Abnormal Situation - ReactivesReactives
Cause
Loss of containment
Reactive interaction (incompatibility)Loss of reaction control
Chemical ReactivityChemical Reactivity:: Loss Events Loss Events
Loss Event• Fire• Explosion• Release
Johnson and Unwin, “Addressing Chemical ReactivityHazards in Process Hazard Analysis,” 18th AnnualInternational CCPS Conference, NY: AIChE, Sept. 2003.
44
Loss Events Associated with Reactivity HazardsLoss Events Associated with Reactivity HazardsHazard Type Typical Uncontrolled Chemical Reaction Consequences
IntentionalChemistry
Containment rupture explosion (uncontrolled reaction resulting inliquid/vapor heating or gas generation inside inadequately relievedvessel or enclosure that is incapable of withstanding peak pressure)
Fire (e.g., excess heating or loss of cooling in unconfinedconfiguration allows autoignition temperature to be attained)
Toxic reaction products release (e.g., off-gas treatment system fails)
SpontaneouslyCombustibleMaterials
Containment rupture explosion (self-ignition of vapor, dust or mistinside inadequately relieved vessel or enclosure that is incapable ofwithstanding peak pressure)
Fire (e.g., self-ignition of flash fire, jet fire, pool fire, pile fire, orbuilding fire)
Toxic combustion gases release
PeroxideFormers
Condensed-phase explosion (e.g., explosive decomposition ofunstable peroxide initiated by heat, friction, spark, or mechanicalshock)
Fire (e.g., follow-on effects from condensed-phase explosion, such asflammable liquid containment rupture and ignition)
Hazard Type Typical Uncontrolled Chemical Reaction Consequences
Water-ReactiveMaterials
Explosively violent reaction (e.g., reaction of sodium with water)
Containment rupture explosion (reaction with water resulting inliquid/vapor heating or gas generation inside inadequately relievedvessel or enclosure that is incapable of withstanding peak pressure, orflammable vapors generated by reaction with water ignited insideinadequately relieved vessel or enclosure that is incapable ofwithstanding peak pressure)
Flash fire (e.g., ignition of unconfined flammable vapors generatedby reaction with water)
Toxic vapor release (toxic vapors generated by reaction with water,or decomposition reaction initiated by heat of reaction with water)
Oxidizers Fire (initiated or accelerated by presence of oxidizer)
Condensed-phase explosion (initiation of detonable mixture ofoxidizer with reducing substance)
Containment rupture explosion (ignition or spontaneous ignition ofoxidation reaction inside inadequately relieved vessel or enclosure thatis incapable of withstanding peak pressure)
Toxic combustion gases release
• Note that many oxidizers are subject to decomposition, so also havepossible Self-Reactive Material consequences
45
Hazard Type Typical Uncontrolled Chemical Reaction Consequences
Self-ReactiveMaterials(Polymerizing,Decomposing,Rearranging)
Condensed-phase explosion (e.g., heat, friction, spark, or mechanicalshock initiation of decomposition proceeding at detonation velocity)
Containment rupture explosion (e.g., by self-reaction resulting inliquid/vapor heating, gas generation, or evolution and ignition offlammable vapors inside inadequately relieved vessel or enclosure thatis incapable of withstanding peak pressure)
Toxic vapor release (e.g., from toxic decomposition products or heatfrom self-reaction resulting in vaporization of toxic component)
Flash fire (e.g., by ignition of flammable off-gases)
Pile fire (e.g., by self-heating to autoignition temperature)
IncompatibleMaterials
Condensed-phase explosion (e.g., by initiation of detonable mixture)
Containment rupture explosion (e.g., by liquid/vapor heating, gasgeneration, or evolution and ignition of flammable vapors insideinadequately relieved vessel or enclosure that is incapable ofwithstanding peak pressure)
Toxic vapor release (e.g., from toxic reaction products or fromheating and vaporization of toxic component)
Flash fire (e.g., by ignition of flammable off-gases)
Hazardous material spill (e.g., loss of containment due to reactionwith wrong material of construction)
Extra-Extra-CreditCreditActivitiesActivities
46
SACHE SACHE Case HistoriesCase Histories
Batch Polystyrene Reactor Runaway
The Bhopal Disaster
Methacrylic Acid Tankcar Explosion -video
Explosion and Fire Caused By a RunawayDecomposition
Rupture of a Nitroaniline Reactor
Seveso Accidental Release
Mini Case Histories
SACHE Reactivity ProductsSACHE Reactivity Products
Hazards Awareness and ReductionAn Introduction to Reactive andExplosive Materials (video)
Acrylic Monomers Handling
The Hazards of Hydroxylamine
Chemical Reactivity Hazards (web-based)
Introduction to Inherently Safer Design
47
SACHE Reactivity ProductsSACHE Reactivity Products
Emergency Relief SystemsDesign for Overpressure andUnderpressure Protection
Unit Operations Laboratory Experimentfor Runaway Reactions and Vent Sizing
Relief System Design for Single- andTwo-Phase Flow
Runaway Reactions -- ExperimentalCharacterization and Vent Sizing
RMRRMR
Reactivity Management RoundtableKickoff Meeting
Las Vegas, NevadaOctober 23, 2003
Most Recent Activities
• NOAA CRW updating• Warehousing matrix• TurboTax®-type chemical
reactivity hazard identification
48
DIERS Users GroupDIERS Users Group
AIChE Design Institute for EmergencyRelief SystemsDIERS Users Group Meetings
See http://www.diers.net/diersweb/home.aspxfor schedule and information
DIERS ConferenceDIERS Conference
3rd International Symposium onRunaway Reactions andPressure Relief Design
Cincinnati, OhioOctober 31 - November 4, 2005
Held in conjunction with2005 AIChE Annual Meeting
49
DIERS Conference TopicsDIERS Conference Topics
11 Theoretical and Experimental Reactivity Screening
2 2 Best Practices and Standards for ManagingChemical Reactivity
ERS Design for Reactive Systems3 3 – Computational Methods44 – Experimental Methods5 5 – Fire Exposure
66 Effluent Handling Design for Reactive Systems
Loss Prevention SymposiumLoss Prevention Symposium
43rd43rd Annual Loss Prevention Symposium Annual Loss Prevention Symposium
Tampa, FloridaApril 27-29, 2009
Fires, Explosions and Reactive HazardsCase Histories and Lessons Learned
50
Continuing Education CoursesContinuing Education Courses
AIChE / ASME on-site: “Identifying andManaging Chemical Reactivity Hazards”
Mary Kay O’Connor Process Safety Ctr
200820082008 SACHE Faculty Workshop SACHE Faculty Workshop SACHE Faculty Workshop
ChemicalChemicalReactivityReactivityHazardsHazards
51
Contact InformationContact Information
Robert W. JohnsonRobert W. JohnsonUnwin Company
1920 Northwest Blvd, Suite 201Columbus, OH 43212-1197 USA
(614) [email protected]
www.unwin-co.com
1
1
Emergency Relief
Gary Van Sciver September 16, 2008
·
2
Gary Van Sciver
Process Engineer – 8 years
Risk Analyst – 22 years
ETC – 2 ½ years
3
Presentation Overview
2
4
Terminology (ERS)
Emergency Relief System
5
1. Normal Vent
6
What is the difference between the normal vent & the
emergency vent?
3
7
What are the differences? (between the normal & emergency vents)
• No blocking devices in ERS • No flame arresters in ERS • ERS usually bigger • Normal vent also handles vacuum • Pollution abatement for normal vent • Normal vent opens first • Manifolding for normal vent .
8
VPRV (conservation vent)
9
VPRV (vacuum pressure relief valve)
4
10
Manifolds One pollution abatement device will normally
handle the discharge of multiple vessels
11
VPRV (vacuum pressure relief valve)
12
Storage Tank Under Vacuum
5
13
Plastic Bag Over Vent
14
2. Design Basis
15
Upset Scenario...
Series of events leading to high vessel pressure
6
16
What do we want the ERS to protect against?...
17
Concept Sciences 1999 Allentown, PA 5 fatalities hydroxylamine
18
Concept Sciences
• The plant was designed to concentrate hydroxylamine (HA) up to 50%
• HA is known to be explosive above 70% concentration
• Due to startup problems, the actual concentration was 86% HA .
7
19
Concept Sciences
20
Flammable Discharge
21
BP - 2005
Texas City, Texas 15 fatalities
Vapor cloud explosion of hexane/heptane (44ºC)
7700 gallons released < 2 minutes from 35 m height
8
22
BP - 2005 Tower – 170 feet tall Blowdown drum – 115 feet tall
23
BP - 2005 Truck parked,
but idling about 25 feet from
blowdown drum
Eyewitness saw engine over-revving and
backfiring sparks
24
BP - 2005
9
25
Toxic Discharge
26
Bhopal - 1984
>2000 off-site fatalities due to toxic relief valve discharge
27
Bhopal
10
28
Bhopal 1984
• Relief valve on an MIC storage tank lifted in the middle of the night releasing 80,000 lbs
• >2,000 people died within a short period
• ~30,000 people were permanently or totally disabled
• MIC reacted with water, source of contamination uncertain
• Incident had long-term ramifications for Union Carbide and the chemical industry as a whole .
29
Bhopal - 1984
30
Design Basis Procedure
1. Identification 2. Sizing 3. Selection
11
31
How do we identify upsets?
32
2 important upsets
33
Fire Exposure
12
34
Runaway reaction
35
Some other non-reactive upsets
36
Excessive heating (steam valve failures, coil leaks)
13
37
Pressurized liquid addition
38
Pressurized gas addition (line blowing, pressure transfers, pads or purges)
39
Some reactive upsets
14
40
Inadequate cooling
41
Inadequate heat sink
42
Excessive reactant
15
43
Poor reactivity
44
Design Basis Procedure
1. Identification 2. Sizing
45
Sizing vents is straightforward but we do need kinetics
data for reactive scenarios
16
46
Types of runaway reaction
• Vapor Pressure • Gas Generating .
47
Vapor Pressure Runaway Reaction
• Pressure related to temperature • Control temperature by
evaporative cooling .
48
Emulsion Runaway
• 1995, one-shot emulsion process • Water charging system failed • New operator being trained, batch not stopped • 2,000-gallon, 120-psig reactor • Broke 35-psig, 18-inch rupture disk
• ~1200 lbs ethyl acrylate released.
17
49
Emulsion Runaway
50
Emulsion Runaway
Odor complaints 13 miles away in
Karlsruhe, Germany
51
Gas Generating Runaway Reaction
• Pressure related to amount of gas • Can’t control temperature by
venting • Only control is depletion of
reactants .
18
52
MAA Rail Car
July 1988 (R&H) Deer Park, Texas
53
VSP (Vent Sizing Package)
54
VSP
19
55
Temperature vs time
56
P vs T
57
Design Basis Procedure
1. Identification 2. Sizing 3. Selection
20
58
List the scenarios in order of
increasing relief device size requirement
59
Example Scenario List
2” 1.Liquid filling 3” 2.Fire case 12” 3.Half charge runaway 18” 4.Full charge runaway 24” 5.Full charge runaway, no water heel .
60
Selection Approaches
1. Codes 2. Tradition 3. Risk .
21
61
NFPA 30 requires ERS protection against fire for
aboveground storage tanks of flammables &
combustibles
Codes
62
Fire Case Requirement
63
Tradition
22
64
Take advantage of our previous experience
65
For example: batch reactor ERS sized for a full-charge
runaway
66
Risk
23
67
Risk Management Services (RMS)
68
Rohm and Haas Risk Criteria
Community 1 in 100,000 per year
Employees 1 in 40,000 per year
69
3. Mechanical
24
70
Vessel Failure
71
Vessel Failure With increasing pressure, flat surfaces become rounded,
vessel resembles a sphere.
72
Bottom Seam Failure
25
73
Hold Down Lug - Older
74
Hold Down Lug - Newer
75
Hold Down Lug - Newer
26
76
Failure Pressure
77
Relief Devices
78
Rupture Disk
27
79
Tension-loaded RD
80
Tension-loaded RD
Vacuum support goes under the RD
81
Compression-loaded RD (Reverse Buckling)
Knife blade (if necessary) goes on top of the RD
28
82
Relief Valves
83
Weak Seam Roof (part of API 650)
84
Weak Seam Roof Weak seam roof should prevent this
29
85
Weak Seam Roof
Install with relief device to protect the roof
86
Design Temperature
87
Thrust forces
30
88
Thrust forces
89
Thrust forces
For 24” RD, Area = 452 sq in
Pmax = 165 psi
Thrust = 2 Pmax A = 150,000 lbs
90
Piping – Thrust forces (initial & established)
31
91
4. Discharge
92
Dispersion Zones 1. High momentum 2. Less momentum 3. Gravity 4. Atmospheric
turbulence
93
2-phase Flow
32
94
2-phase Flow
95
PHAST – Emulsion Reactor RD
96
Gooseneck
33
97
Toll Incident • Wisconsin - 2002 • Leaky steam valve heated a completed
batch from 40C to 150C in 3 hours • Resulting decomposition (>200 psig) • MSDS: “This material is considered
stable” • No fatalities or injuries .
98
Toll Incident
2002 runaway
99
Toll Incident
2002 runaway
34
100
Toll Incident 2002 runaway
101
TNP (Thrust Neutralization Plate)
102
TNP Thrust Neutralization Plate
35
103
TNP or Gooseneck
104
Catch Tank Gravity Separator
Vapors still escape from a separator,
but at a lower
velocity.
105
Catch Tank
From reactor Cyclone separator
36
106
Catch Tank Incident
107
Catch Tank Incident • Illinois 2001 • Runaway reaction
broke 135 psi RD • Blew off catch tank
top & damaged piping
• No injuries or fatalities .
108
Catch Tank Incident
Catch tank roof failed
Low-pressure vessel with
insufficient vent
37
109
Catch Tank Incident
110
Quench Tank
111
Straight up
38
112
Rain Protection - Cover
113
5. MOC
114
Why document?
• Required by OSHA PSM (Process Safety Mgmt) • Required by EHS 536 (Process Safety Mgmt) • For future Management of Change (MOCs) • For future HAZOPs • Avoid reconstructing the design • Information can be used on other systems .
39
115
Vent System Analysis
Follow the ERS procedure for every vessel & every relief device
Store the results in a safe place
116
Questions?
9/4/08
1
Rohm and Haas At A Glance
We are a specialty materials company with an excellent reputation among our customers, our suppliers and our communities.
We are a responsible company that operates at the highest levels of integrity and ethics. The people who work for us are among the most qualified in the industry.
We measure our progress by how well we perform in the eyes of five key stakeholder groups, each of whom have a strong voice in determining our success – the customer, the employee, the owner, the community, and the process.
Vision
• Inventor of specialty materials which improve the quality and functionality of everything from semiconductor chips to house paint.
• Global manufacturer – more than 100 plant and research locations in 27 countries.
• Contributor to our customers’ success – talented workforce of 16,500 people who bring technology, and more, to serve customer and market needs.
• We imagine the possibilities℠ – we work with our customers to ensure we provide them with the right technologies for their products and market needs.
Who we are
9/4/08
2
• A specialty materials company with annual sales of $8 billion
• Focused on delivering technically advanced products and services to customers in more than 100 countries
• Approximately 16,500 employees
• More than 100 manufacturing sites and technical centers around the world
Key Statistics
• United States • Canada • Bahamas
• France • Germany • Italy • Netherlands • South Africa
• Sweden • Switzerland • Spain • Turkey • United Kingdom
• Argentina • Brazil
• Australia • China • India • Indonesia
• Japan • New Zealand • Philippines • Singapore
• South Korea • Taiwan • Thailand • Colombia
• Mexico
Geographic Reach
53% 25%
18%
4%
of sales
of sales
of sales
of sales
• Building and Construction
• Electronics and Electronic Devices
• Packaging
• Household and Personal Care
• Industrial
• Water
• Automotive
• Food and Retail
The markets we serve
9/4/08
3
• Coatings
• Electronic Materials
• Adhesives and Sealants
• Performance Chemicals
• Morton Salt
• Monomers
Businesses
Polyurethanes
Amines
Sodium Chloride
Borohydrides
SiC, ZnSe, ZnS Structures
MgO Acrylic, Styrenic & Vinyl Acetate Copolymers and Multipolymers
Biocides Acrylic Monomers
Mercaptans & Sulfides
Polyesters
Photoactive Materials
Organometallics
Plating Systems
Water Soluble Polymers Abrasives
Pigment Dispersions
Photoactive Materials Functionalized Polymers
Polybutadiene, PVDC Organic Synthesis
Inorganics Radical
Polymerization
Condensation Polymerization
Technology
Bristol Plant • Otto Haas’ First Greenfield Site • Broke Ground in April 1917, First Batch December 1917 • Tanning Agents -- WWI • Ag Chemicals – Insecticides F • Monomers & Pre-cursors – MMA • Solution Resins • Oil-additives – Pour-point Depressants • Plexiglas -- WWII • Emulsions – Latex Emulsions, Plastics Additives • Imaging – Toners & Inks • At peak, over 3,000 employees • Research
9/4/08
4
9/4/08
1
Rohm and Haas Bristol Polymers
Process Safety Systems
Discussion
9/16/2008
Overview • Conference is focusing on Emergency Relief
• This discussion will review items/systems in place to prevent use of emergency relief and other health, safety, or environmental problems
Bristol Polymers • Terminal For Acrylic Monomers
• Unloading, Storage, Loading of Flammable & Hazardous Raw Materials
• Solution Polymerization Reactors
• Polyurethane Reactors (Isocyanates)
• Packaging & Shipping
9/4/08
2
Relief Systems • Thermal Expansion
• Tank Breathing
• Vacuum Relief
• Pump Pressure
• Emergency Relief (Heating/Fire)
• Emergency Relief Hazardous Reaction
• Mitigation of Relief Hazards
Facility Safety Systems • Electrical Classification/Design
• Fire Suppression
• Flammable Vapor Hazards
• Explosion Relief (Blow-out Panel Buildings)
• Spill Control
• Siting/Location of People & Equipment
Process Control Systems • DCS
• PLC
• Local/Hardwire
• Alarm
• Interlocking
• Level of Protection/Redundancy
• Maintenance
9/4/08
3
Procedures • Preparation • Start-up • Normal Operation • Shut-down • Abnormal Conditions • Emergency Shut-down • Lock & Tag/Remove Hazardous Energy • Maintenance, Calibration, & Dismantlement • Control, Accessibility, & Periodic Review
Training • Operations
• Maintenance
• Procedure
• Permitting
• LOTO
• Materials
• Emergencies
Materials • Hazards – R/T/F/Special • Environment/Control/Permitting/Reporting • Process Design • Engineering Controls • Administrative Controls • Protective Equipment • Right to Know • Industrial Hygiene/Monitoring • Medical/Records/Access
9/4/08
4
Maintenance • Design Documentation
• Procedure
• Emergency Repair
• Preventive Maintenance
• Inspection – Relief/Vessel/Piping/Calib
• Parts/Spares
• Maintenance Excellence
Design, Construction, and Operation Codes • OSHA PSM
• BOCA/Fire/NFPA/NEC
• Boiler Codes/Piping Codes/ANSI/ASME
• Corporate Standards
• EHS Management/Responsible Care
• R&H COSMP, R&H MCSP
• ISO 9000
Management of Change • Direct Replacement
• Replacement in Kind
• Basic Change
• Major Change
• New Facilities
• Personnel
• Ensuring Completeness of Change
9/4/08
5
Incident Response • Injury/Illness • Fire • Environmental/spill/release • Hazardous Reaction • Quality Loss • Business or Financial Loss • Reporting/Near-miss/SCCA • RCA/Corrective Action/Documentation
Compliance Auditing • Internal & External • OSHA PSM • Corp EHS • Responsible Care • EPA/DEP/Permitting Authorities • ISO • Local Township, Fire, Insurance • Sarbanes-Oxley
1
Safety Indoctrination for Visitors to the
Rohm and Haas Bristol Plant
Welcome to Our Plant
Your safety, and the safety of our employees is very important to Rohm and Haas.
Because of this, all Visitors and Contractors must receive the Plant Safety Indoctrination
This information will help you understand and comply with the
Rules and Regulations of the Bristol Plant.
VISITOR SIGN IN
Please Sign the Visitor Log when you enter or leave the plant. This allows plant personnel to account for everyone in the event of an emergency.
Visitor’s Log Book is located in the Gatehouse
2
• No Drugs, Alcohol, or Weapons • No one under 18 years old • No cell phones, or electronic devices
in areas where PPE is required • Minimum Standard PPE
– Hard Hat - Safety Glasses w/Side Shields - Sturdy Shoes.
– Shorts, Tank Tops, and Sandals are prohibited.
• When walking through the plant, please stay within the painted lines. – Plant policy requires people not
wearing PPE to stay within the lines
General Plant Rules
No Smoking For the health and safety of everyone at
our plant, there is no smoking on the Rohm and Haas, Bristol Plant property.
This includes all grounds, roadways, parking lots, commercial and private vehicles, and structures.
Safety Indoctrination
Only authorized vehicles may enter the plant
Vehicles and Packages entering or leaving the plant are subject to search at any time.
Plant Security
Home Land Security The Bristol Plant has a Security Plan in place which includes Home Land Security issues
3
Safety Indoctrination
• Evacuation Alarm – Continuous Bell • Evacuation Procedures
– Listen to the direction of your Host or other R&H Employee – Evacuate immediately OUTDOORS by the nearest emergency
exit – Proceed to Headcount Area with your Host – Do not leave the Headcount Area – Do not re-enter the plant until an all clear is given – Report any illness, injury, or safety concern to the Evacuation
Coordinator
Report all incidents of illness or injury, any safety or security concerns, or any at-risk condition to your Rohm and Haas contact.
• For Non-life Threatening Emergencies First Aid Injuries DIAL 4000.
• For Chemical related incident Spill, Odor, Leak DIAL 4000
• For Life Threatening Emergencies Medical Trauma or Fire DIAL *9911
• Copies of any medical records generated on your behalf
will be made available to you.
Safety Indoctrination
• The Bristol Plant is covered by and complies with OSHA’s Hazard Communication Standard.
• All chemicals brought on site must – be approved – have proper labeling & hazard information – have proper training for those handling the material
• Consult your Rohm and Haas contact for more information.
OSHA’s
Hazard Communication Standard
4
Safety Indoctrination Process Safety Management
• OSHA has identified materials as Highly Hazardous above certain thresholds.
• Areas where these materials are stored, transferred, processed or produced are covered by the OSHA Process Safety Management Standard (PSM)
• PSM requires close monitoring of persons & activities in these areas.
PSM
Process Safety Management
Your Guide will inform you of PSM Systems and Locations and whether there are specific requirements for touring or working in these locations
PSM Systems & Locations
PSM
Consult your Rohm and Haas contact for more information.
Use of RED Tape
• RED Tape is used:
– to DENY entry to a designated area
– as an absolute boundary & may not be crossed
DANGER
5
Permit Required Confined Spaces
Large enough to enter but not meant to be occupied Limited Means of Entry and Egress One or more Hazards:
Atmospheric Mechanical Engulfment or Entrapment
Require a formal permit and specialized training to enter Never place any part of your body into a confined space opening Open Confined Spaces are controlled by a Safety Watch or Red
Tape
Confined Spaces are uniquely hazardous locations which OSHA and Rohm & Haas carefully regulate
HAVE A SAFE VISIT
Safety Indoctrination
9/4/08
1
Rohm and Haas Bristol Polymers
Polymers Plant Tour
Agenda
9/16/2008
Overview • Conference Room & Plant Tour Areas
• Tour Safety Discussion
• Process Discussion
• #7 Kettle Reactor & Charging
• #10 Kettle Reactor & Charging
• Continuous Reactor Area
• Outside Control Room
Tour Safety Discussion
• Stick with Team Leader
• Working Unit Shut-down/Starting-up
• Avoid Contact With Material
• Avoid Touching/Operating Equipment
• Listen Carefully to Instructions
• Observe and Ask Questions
9/4/08
2
Process Discussion
• Solution Polymerization Reactors -- Kettles
• Flammability/Toxicity
• Monomer/Initiator Reactivity
• Heat of Polymerization
• Environmental
• Operation of Typical Process
Process Discussion • Continuous Reactor Area • Smaller equipment • Possible because of smaller heat of polymerization • Feed of materials • Mixing/dissolving • Polyurethane ingredients • Pressures/temperatures
#7 Kettle Reactor • Relief valves
• Rupture Disks • Vent sizing/thrust
• Mitigation of relief hazards (modelling indicates evaporates)
• Blow-out walls • Classified area
• Remote location/cell • Static/grounding/inertion
• Process Energy
• Fire protection/safety showers/eyewashes
9/4/08
3
#7 Kettle Charge Area • Ventilation
• Floor Loading Access • Material Handling
• Ergonomics – valve handle extensions, drum lifter, catalyst hose balancer
• Spill control • Open Vessel Mitigation – closed vessels
• Labeling • Static/grounding/inertion
• Fire protection/safety showers/eyewashes
#10 Kettle Reactor • Relief valves • Rupture Disks • Vent sizing/thrust • Mitigation of relief hazards (modelling indicates evaporates) • Blow-out walls • Classified area • Special maintenance/training/test procedures • Static/grounding/inertion • Process Energy – Kettle is smaller for pressure • Fire protection/safety showers/eyewashes • Pressure operation/access control
#10 Kettle Charge Area • Ventilation • Floor Loading Access • Material Handling/Labeling • Ergonomics – valve handle extensions, drum lifter,
catalyst hose balancer • Spill control/cleaning station • Open Vessel Mitigation – closed vessels • Local DCS access • Static/grounding/inertion • Fire protection/safety showers/eyewashes
9/4/08
4
Continuous Reactor Area
• Equipment size/Capacity • Relief • Interlocking/pressure switch • Scale of equipment much smaller • Process intensity • Ventilation • Remote operation, splash hazard for key operation • Fire protection/safety showers/eyewashes
Outside Control Room • Distributed Control Systems – Remote Operation, Alarming, Data • PLC – Programmable Logic Controllers • Local/Hardwire (Relays) • Alarm/Panel alarm • Interlocking • Manually Operated Remote Control • Data Trending & Alarm History • Sequence Operation • Recipe Operation • Standard operation procedures, charge/react/package/integrity
Post Tour Review • Questions
• Observations
• Thank You for Visiting!!
1
“The Value of an EHS Education”
Looking at the program grid, I congratulate you on the time
you’ve spent in understanding more about how to advance
process safety.
I have been asked to talk about the value of an EHS
education and I realized this morning how difficult that is
for me. Because I am so convinced of the need for such,
that it is difficult for me to see it all from the vantage point
of the unconvinced.
Not that you are the unconvinced, but—here we go.
Whether it’s looking at the disasters of BP or Arco or
Phillips, or even the problems of Merrill Lynch and AIG,
the advantage of an EHS education should be clear.
Let me explain.
The impact of a Texas City disaster or Bhopal is immediate
and far reaching.
First, imagine yourself as the victim of a chemical process
accident. Consider your pain and anguish in having lost a
son, daughter, brother, sister, mother or father to fire,
explosion or toxic release from a chemical process. How
would you feel? Whom would you blame? What would
you be tempted to do?
2
Additionally then there is the pain of being the one to have
to call a family member to tell them you are responsible for
the death of their loved one.
While forgiveness is possible and you can generally
recover from such a thing, I guarantee you it’s something
you will never want to do. And every one of your students
will thank you for having given them the knowledge to
spare them such an experience.
In terms of affect on an enterprise, consider the billions BP
will spend to deal with Texas City or the reasonable
conclusion that, in the end, it was Bhopal that brought
down Union Carbide and the value of an EHS education
should be clear.
Now let’s talk about what any of this has to do with AIG.
There are fewer enterprises than there should be who are
going to look at an applicant’s resume for signs that they
have a good basic EHS education.
So it is important to remind students and ourselves that the
most important value of anything is that it allows us to
better perceive and act on truth.
AIG, Merril Lynch, Bear Stearns, Lehman Brothers all
seemed to have gotten into trouble by allowing the fads of
the moment to dissuade them from acting on the truth they
knew.
3
The idea that housing prices would always rise should have
been seen as false no matter what the fashion of the
moment. Just as building and operating safe robust
processes should never be sacrificed on the altar of the race
for profits.
The value of an EHS education is allowing us to understand
the truths of how businesses and processes are to operate
and to have the knowledge and courage to leave if the
enterprise begins to stray; allowing us to understand that all
the value of an enterprise can not be immediately
monetized.
I teach a module on environmental medicine to medical
residents and one of the things I point out is you have to
always be prepared to leave an enterprise when it persists in
following a path that while legal is unsafe and unwise.
Because staying around while short term profits are
realized at the expense of health, safety and environmental
performance, performance which can not be immediately
monetized, will get you when you least expect it and in
ways that you least want.
These inherent and metaphysical aspects of an EHS
education are played out in the connections with
sustainable development and the next evolution of
capitalism.
4
As many of you know Rohm and Haas has been a
champion of sustainable development since the mid 80’s
and we have done more than most in moving toward a
sustainable state.
Most recently, we have engaged with The Natural Step
from Sweden to move sustainable development to the next
level of strategic focus in the company.
Within the four system conditions that are the basis of The
Natural Step approach the value of an EHS education is
seen again.
System condition #4 is about not doing things that will
prevent people from being able to satisfy their own needs.
Blowing up their house or killing their children would
certainly seem to qualify as preventing people from being
able to satisfy their own needs.
More positively, within the 110 to 120 years of life that our
bodies are built for, success needs to happen on many
dimensions. Not to make too much of being in the Franklin
Institute, I think we would agree we want to be healthy,
wealthy and wise.
Health is in part determined by our genes, but is more
determined by the choices we make every day—to exercise
or not, to eat to many or the wrong calories or not, to
smoke or not.
5
Wisdom is determined by our ability and willingness to
learn and live in truth.
And wealth is determined by the will of God or what you
might call luck and the decisions we make that will allow
us to sustain enterprises that bring value to society over the
long haul.
EHS is the blocking and tackling, the basic requirement of
sustainable wealth production. It is the vantage point from
which processes that continual produce high value products
may continue to do so time, after time, after time.
If you were unconvinced a moment ago, I hope you are
convinced now about the value of an EHS education in
protecting the lives and livelihoods of you, me, your
students our families and society.
So continue in the good work you have started and know
that it will be helpful and valuable to you and your students
now and forever.
Atmospheric Storage Tank Atmospheric Storage Tank Fire Protection Fire Protection
September 19, 2008September 19, 2008
Jeffrey Oland, P.E., Fire Protection Engineer
Main Types of Atmospheric Storage Tanks
Fixed Roof– Roof does not move– Typical for smaller tanks (<50 ft. diameter)
Floating Roof– Roof floats on liquid surface– External
Area above roof open to atmosphere
– InternalFixed roof over floating roof
Tank Fire Scenarios
Fighting Fires in Atmospheric Storage Tanks
Foam/water is required for hydrocarbon fires– Forms layer of foam “bubbles” on surface of burning
liquid to extinguish fireLarger tanks = more foamLargest Sunoco crude storage tank requires 11,000 gpm of foam/water solution (330 gallons of foam concentrate at 3%)20 minutes of application requires 220,000 gallons of water and 6,600 gallons of foam concentrate
Foam Proportioning Systems
Seal Foam Application
Full Surface Foam Application
“Over the Top” Foam Application
Case Study
Tank 15
Xylene at the 26’ level (36,000 bbls)Cone Roof 100’ diameter40’ height
Operating & Service DataOperating & Service Data
Full surface fire with roof blown off and slightly hinged to the East
Strategy was offensive with a one point of application non aspirating nozzle utilized
Incident Emergency ResponseIncident Emergency Response
STA 6-1 ThorofareSTA 6-2 VergaSTA 6-3 Colonial ManorSTA 6-6 GreenfieldsSTA 15-1 Woodbury HeightsSTA 21-1 GibbstownSTA 9-2 Deptford (Tacoma Blvd station)
STA 13-1 WenonahSTA 22-2 MantuaSTA 17-1 PaulsboroSTA 18-1 BridgeportDeptford Canteen 1Cherry Hill FD Canteen
Volunteer Organizations
Participating Companies: Staging outside of West gate
Industry Mutual AidSTA 21-4 Valero Refinery
Fire Department
Incident Emergency ResponseIncident Emergency Response
Eagle Point RefineryPipeline 1Tanker 67Engine 9
Philadelphia RefineryEngine 4Truck 7Tanker 9NER Fieldcom 1
Marcus Hook RefineryTAC 80Tanker 80Engine 10Rehabilitation 1
Sunoco NER Fire Department Response “Tank Taskforce”
New Jersey Division of Fire/SafetyState Fire Marshal (Larry Petrillo)Captain Mike GallagherGloucester County Mobile Communications (Fieldcom 1)Gloucester County OEMNew Jersey DEPNew Jersey State Police
Incident Emergency ResponseIncident Emergency ResponseState/Local Agencies
Tactical unit at the 6 O’ clock position capable of delivering 5,000 GPM
Engine 9- 6,000 GPM pump which supplied the Water and foam proportioning for the appliances and apparatus at the tank
Tank 15Tank 16
E-9
TAC-80
TAC-
67
Apparatus-NER-
Appliances-5.00”hose-7.25” hose-
69
123
T-16
T- 80 Tanker
Tanker614613
2111
663
9111312
1518
621
Community-
Escape
Total time from ignition to fire out 3.5 hours, with actual 20 minute foam time
Replenishing of the foam blanket continued until the tank was emptied by operations.
A great portion of the tank and product were savedSunoco NER facilities participated with suppression
activitiesManning 12 response vehicles65 trained personnel15 additional providing coverage in the event of an
emergency within NER
The Next DayThe Next DayThe Next Day
What made it safe and efficient?
NER tank fire task force General OrderFrequent EOC drills Frequent ERT training Frequent interaction with Local and State emergency response agenciesPre-plansSpecific tank training seminars/schoolsOrganized Communication Center“Around-the-pump” delivery technology
QuestionsQuestions