1. Chapter 11 & 12 Engineering & Administrative Controls

2. Risk Evaluation Hazardous materials Chemical process
Physical operations
Equipment design
Plant location and layout
Operator practices and training

3. Objectives
Learn to implement systems to eliminate or prevent/control hazards.
Learn about different types of hazard controls:
Preventive maintenance and managing change
Emergency planning, occupational health programs, and contractor safety
Reminder: Hazard Prevention and Control is one of the four major components of an SHMS.

4. Hazard Control
The first consideration for controlling hazards is to eliminate the hazard or substitute a less hazardous material or process.
An example of this method is utilizing a water- based paint rather than a solvent-based paint.
This control measure minimizes flammable vapors as well as eliminates health concerns associated with solvent-based paints.

5. Hazard Control
When it is not possible to eliminate a hazard, you should control the hazard using the following methods (in order):
Engineering controls
Administrative controls
Personal Protective Equipment
Applying this hierarchy is a systematic approach to identify the most effective method of risk reduction. You want to select the highest-level feasible control.

6. Hazard Control - Engineering
If hazard elimination or substitution is not feasible, engineering controls should be considered next.
Engineering controls are physical changes to the work area or process that effectively minimize a worker's exposure to hazards.

7. Hazard Control - Engineering
Enclosed Hazard
Enclosure of the hazard, such as enclosures for noisy equipment.
Isolate Hazard
Isolation of the hazard with interlocks, machine guarding, welding curtains, and other mechanisms.
Remove / Redirect Hazard
Removal or redirection of the hazard such as with local and exhaust ventilation.
Redesign Workplace
Redesign of workstation to minimize ergonomic injuries.

8. #1 POLL QUESTION
All of the following are examples of engineering controls except
A. adjustable workstation to accommodate various employee sizes. B. elimination of lead-based paint. C. installation of welding curtains during hot work. D. installation of sound-dampening shields on noisy equipment
B is Correct - This is an example of hazard elimination, and therefore engineering controls may not be necessary

9. Dusting Heat transfer Pressure Vaporization Spaying Mixing Separation
Chemical Process Evaluation
Physical Operations Evaluations
Analyzes the hazardous properties of reactants, which are products that might be formed under certain conditions, and the environmental effects of those products.
Dusting
Heat transfer
Pressure
Vaporization
Spaying
Mixing
Separation
Generation

10. Equipment Design Evaluation
Plant Location and Layout Evaluation
Drainage and runoff control
Climatic conditions
Effects of uncontrolled release
Community capability and emergency response
Plant accessibility
Available utilities
Gate security
Hazardous unit placement
Spacing of equipment
Equipment systems are designed so that the failure of one or more devices will not result in a disaster.

11. Operator Practices and Training Evaluation
Hazardous Materials Evaluation
A detailed analysis of all the properties of the materials handled, stored, and processed in the plant:
Quantities
Physical properties
Toxicity
Stability hazards
Corrosiveness
Impurities
Operational failures have been identified as the most frequent cause of industrial disasters.

12. Design and Operation of Plants for Safety
There must be adequate spacing between process equipment, specific storage, and loading facilities.
Evaluate and limit the storage of hazardous material.
Evaluate the use of open structures and will recommend new designs for total storage containment.

13. Figure 11-1 Triangular Equipment Placement

14. Alarms and Indicators
The most effective tool used by process technicians in the operation of a large chemical facility are alarms and indicators.

15. Fire Alarms and Detection Systems
Automatic fire alarm systems come in three types:
Fixed-temperature type
Rate-of-rise type
Nuclear detector type

16. Redundant Alarm and Shutdown Devices
Operating a large chemical complex requires the use of redundant systems that provide emergency warning and shutdown protection. Redundancy is a process that uses two or more devices to shut down a system.

17. Interlocks and Automatic Shutdown Devices
An interlock is a device that will prevent an operational action unless a specific condition has been satisfied
Software
Hardwire
A permissive is a special type of interlock that contains a set of conditions that must be satisfied before a piece of equipment can be started.

18. Process Containment and Upset Control
There are a number of elements in controlling process containment and in the design of upset control:
Reduction in hazardous material storage inventory
Storage of liquefied gases and the conditions under which these should be stored
Plan for a design that provides total containment

19. Figure 11-3 Traditional and Nontraditional Diking Systems (Totally Self-Contained).

20. Closed System/Closed-Loop Sampling
Closed systems/closed-loop sampling is a procedure where a bypass loop is installed that allow a small part of the system to be diverted from the main flow.

21. Figure 11-4 Closed-Loop Sampling System

22. Floating Roof Tank and Ventilation Systems
Floating roof storage tanks are used for storing materials at atmospheric pressure.
Ventilation systems are usually designed to protect process technicians from organic vapors, harmful additive dusts, and fumes.

23. Figure 11-5 Floating Tank Designs

24. Effluent Control and waste Water Treatment
New technicians are typically assigned to this area in order to train on a variety of complex systems.

25. Figure 11-6 Clarifier

26. Figure 11-7 Settling Basin

27. Noise Abatement
Noise abatement is an engineering procedure designed to reduce or limit noise through the use of modern technology.

28. Flares
Flares are used to burn waste gases and control pressure generated by process upsets.

29. Figure 11-8 Flare System

30. Pressure Relief Devices
Safety valves for gases
Relief valves for liquids
Rupture discs for both

31. Figure 11-9 Pressure Relief Devices

32. Chapter 12 Administrative Controls

33. Introduction to Administrative Controls
Administrative controls can be described as the programs and activities used to control industrial hazards.
Mutual aid agreements are written agreements between industry and outside emergency response organizations in the event of a catastrophic release or situation.

34. Hazard Control
If engineering controls are not feasible you must then consider implementing administrative controls.
Administrative controls
No physical changes
Limits daily exposure to hazards by
Adjusting work tasks or schedules.
If engineering controls are not feasible or do not provide adequate control of the identified hazard, you must then consider implementing administrative controls.

35. Hazard Control - Administrative
Examples of administrative controls include:
Limited time exposure to hazards
Written operating procedures,
Work practices, and
Safety and health rules for employees.
Examples of administrative controls include:
Limited time exposure to hazards such as noise, radiation, temperature or repetitive motion (an ergonomic hazard).
Written operating procedures, work practices, and safety and health rules that employees must follow to complete the job safely, such as a company policy on the safe lifting of loads.

36. #2 POLL QUESTION
Which of the following is an example of an administrative control?
A. Rotating jobs to minimize exposure to noise. B. Enclosing loud equipment to reduce noise exposure. C. Training employees to properly wear hearing protection to minimize noise exposure. D. A and C, only.
D is Correct - A and C are both examples of administrative controls

37. Hazard Control - Administrative
Alarms, signs and warnings
Buddy system
Training
Stretching exercises and break policies

38. CAER guiding principles include:
Respond to community concerns about chemicals and operations.
Produce chemicals that can be disposed of safely.
Report health, chemical, and environmental hazards and require PPE.
Incorporate safety, health, and environmental research on products.
Work with customers on the transportation, storage, and disposal of chemicals.
Resolve handling and disposal problems.
Create responsible laws, regulations, safeguards, and standards
Promote the principle of Responsible Care®

39. Job safety Analysis Observe the people doing the job.
The primary steps used in this procedure are:
Observe the people doing the job.
Document the steps in the procedure.
Validate the procedure with subject matter experts.

40. Hazards and Operability Study
HAZOP is a comprehensive process hazards analysis system designed to identify hazards to technicians, equipment, operations, and environment.

41. Training and Mandated Training
Government-mandated training for process technicians covers a variety of topics and includes formal classroom and hands-on training that takes place upon assignment to a process unit, and training that takes place annually, every two years, or every third year.

42. Housekeeping Prevents accidents and increases productivity.
Good housekeeping improves the image of the company and the moral of plant employees.

43. Safety Inspections and Audits
The primary objective is to identify unsafe work conditions and to ensure compliance with plant and government regulations.
Inspections are conducted by local personnel.
Audits are conducted by outside groups from corporate or regulatory agencies.

44. Monitoring Equipment
There are two monitoring systems: industrial hygiene and fugitive emissions.
Industrial hygienists collect samples from the work environment to determine hazardous conditions.
Fugitive emission monitoring compares samples taken in the field to company, EPA, and government regulation.

45. A short list of detecting devices:
Mercury vapor monitor
Direct-reading colorimetric tubes and badges
Flame ionization detectors
Photonionization detectors
Infrared analyzers
Gas chromatographs
Ion mobility spectrometers
Particulate monitors

46. Figure 12-2 Combustible Gas Indicator

47. First Aid
OSHA’s General Industry Standard, CFR Medical Services and First Aid, is used by the CPI to establish a first aid program
A qualified first aid provider is described as an employee qualified by a certified medical group to administer first aid.