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Thursday, June 21, 2007
How To Detect and Handle Hazardous Chemical/Gases Leakage and Spillage
The following was written by Mr.Chang Miau Sin, Principal Consultant (ESQ Consultancy Services SDN. BHD). It was presented at the APHOSO-20 Conference.
Abstract Hazardous chemicals and gases are used as raw materials in the chemical, petrochemical, and other types of industries around the world. Although the risks and hazards of hazardous chemicals and gases have been assessed, audited and analyzed by many EHS experts, accidents continue to occur in many industries around the world. The writer would like to share his experiences in the latest technologies, methodology, management guidelines and instrumentation in regard to the topic of this paper "How To Detect and Handle Hazardous Chemical/ Gases leakage and Spillage" with the participants in the APHOSO-20 Conference.
Hazardous chemical and gases have potential risks and hazards. They can be disastrous to people in the workplace and the surrounding manufacturing or residential areas. In addition, hazardous chemicals and gases can cause death, cancer, illness, and long term or short term poisoning. They can also caused fire and explosion in the facilities and environment.
This paper provides details and information about the latest technologies, methodologies, management guidelines and instrumentation knowledge, which have been used in many multinational companies in developed countries around the world. The paper will also discuss preventive measures, protective equipments, equipments, detective equipments and the necessary control systems that need to be in place. The author will share the practical experiences and knowledge in handing emergency response and disaster with the participants.
In order to control the risks and hazards for usage, storage, transporting and handling hazardous chemical and gases, the company should:
In addition, an effective chemical / gases detection system should be implemented for the preservation of lives and property. The writer will also introduce various types of risk assessment systems for the production process, which provideact as an advance warning to prevent potential disasters from happening.
1. Introduction
Although the EHS management system has been well developed and implemented in industries to prevent hazardous chemical and gases leakage and spillage, many hazardous chemicals/gases disasters and incidents happen around the world. In order to preserve human life, it is important for top management to understand the latest technologies, methodology and system on how to detect and handle hazardous chemicals & gas leaks and spillage.
2. Prevention of hazardous chemical/ gas leakage and spillage
The commitment from top management of the company or organization is the key factor to prevent accidents. The preventive measures for hazardous chemical/gas leakage and spillage includes:
3. EHS Management System
The EHS management system should include hazard identification that determines the potential hazard of a facility that uses chemicals/gas. Depending on the risk level and the type of operation at the workplace, the EHS management system may include:
4. The Hazardous Chemical/Gas Detection System
In the event of hazardous chemical or gas leakage and spillage, the response time for the emergency response team to react or active is normally less than 3-5 minutes. It is impossible to activate emergency response plan, if the hazardous chemical/gas is not detected during the incident. One of the key elements to prevent such incident/disaster is "How to detect the hazardous chemical / gas leakage and spillage?"
The presence of Hazardous chemical / gas at in incident location or other emergency situation adds a new dimension of risk to residents and to those who are handling and treating casualties and providing emergency services. Therefore the selection and installation of the chemical / gas detection system is the fundamental element in accident prevention program.
4.1 Hazardous Chemical / Gas Detection System
Before purchase and installation of chemical / gas detection system, evaluation process need to be carried out. Suggested evaluation steps are as follow:
(1) Identity the potential risk, hazard and danger points
(2) Understand the application
(3) Selection of the detection system
(4) Profile the potential chemical / gas release scenarios
4.1.1 Identity the potential risk, hazard and danger point
The design of detection system should be linked to the type of risk and hazard of the chemical and gas . The hazard identification can asses the level of the level of hazard of the chemical and gas. The hazard identification can asses the level of hazard on-site. The method of hazard identification has been well established, such as Job Safety Analysis, Fault Tree Analysis, Hazard study, QRA and Safety Integrity Levels, etc.
When the hazard has been identified, the location of the leakage and spillage of hazardous chemical / gas could pose a danger to human life should be determined. In general, the gas detector or sensor used to monitor potential release point should be positioned close to potential leak point.
With regards to the environment of work place, various type of sensor or detector should be considered, such as explosion-proof, weatherproof type, etc.
4.1.2 Understand the application
Before purchase hazardous chemical / gas detection system, the person-in-charge should decide the type of hazardous material should monitor. Reference need to make to the local legislations and industrial safety requirement; the type of sensor, response time of sensor and accuracy of sensor should be identified. Depend on the level of hazards, the detection system should be able to activate immediately upon leakage incident through automatically shut down the valve, initiate the alarms or sirens and other application.
4.1.3 Selection of the Detection System
The key point of selection of the detection system is the high quality and reliability of system. In general, most of the company or person-in-charge only consider the cost of the detection system. Using the wrong type and not reliable detection system may result in heavy lawsuit, Compensation or medical bill that costs thousand times higher than the cost the detection system.
The decision of selecting the detection system should be made by a team of EHS operation and engineering committee. The specification, standard and guide on the selection of the detection system should be discussed and finalized before purchase. Understanding of the detection system is the most important issue before consideration of purchase. Other important factors to be considered for example the supplier’s company background, their customer’s reference and feedback can used as important reference to the reputation of the supplier. The supplier should provide detail presentation explaining the product specification, additional value added service for example after sales service, backup facilities and maintenance training, etc.
4.1.4 The Potential Chemical / Gas Release
Depend on the scenarios of the potential Chemical / gas leakage, the response time of the detection system and the time to active emergency response plan will be the important issue. If the plant or operation is located near the residential area, city or school, the decision to shut down the operation / process / plant should be depend on the level of the hazardous chemical / gas. For example in the Bhopal – Methyl – Iscyanides underground storage tank automatically ignited during the critical moment, this will substantially reduced the number of death by the incidents.
In a vapor cloud explosion, unconfined vapor cloud explosion or boiling liquid expanding vapor explosion, the time for people to escape could be less than 3 minutes. It is important to determine the situation, the timer for the explosion might be occurred. In general, while the atmosphere reach 10% of LEL, the detection system should be able to active alarm to alert the operation personal to take necessary action ti prevent fire & explosion. Although the reliability of detector or meter is the most important factor, easy operation and calibration of the detection system should be the additional key points to consider during evaluation.
Conclusion
As refer to the hazardous chemical / gas leakage and spillage incident & disasters, no one in the organization, industries or companies can afford to compromise on Environmental, Health and Safety issue. The top management or person-in charge should work out the financial budget that the company can afford to purchase, rent or lease the detection system.
However, EHS management system, hazard identification, detection system, emergency response / evacuation plans and personal protective equipment can prevent and mitigate the risk of handle hazardous chemical and gases.
The author is pleasure to share his experiences and knowledge on the design and installation of the high quality hazardous chemical and gas detection system in various industries / operations. He can reached at esqcssb@streamyx.com or esqcssb@tm.net.my.
Abstract Hazardous chemicals and gases are used as raw materials in the chemical, petrochemical, and other types of industries around the world. Although the risks and hazards of hazardous chemicals and gases have been assessed, audited and analyzed by many EHS experts, accidents continue to occur in many industries around the world. The writer would like to share his experiences in the latest technologies, methodology, management guidelines and instrumentation in regard to the topic of this paper "How To Detect and Handle Hazardous Chemical/ Gases leakage and Spillage" with the participants in the APHOSO-20 Conference.
Hazardous chemical and gases have potential risks and hazards. They can be disastrous to people in the workplace and the surrounding manufacturing or residential areas. In addition, hazardous chemicals and gases can cause death, cancer, illness, and long term or short term poisoning. They can also caused fire and explosion in the facilities and environment.
This paper provides details and information about the latest technologies, methodologies, management guidelines and instrumentation knowledge, which have been used in many multinational companies in developed countries around the world. The paper will also discuss preventive measures, protective equipments, equipments, detective equipments and the necessary control systems that need to be in place. The author will share the practical experiences and knowledge in handing emergency response and disaster with the participants.
In order to control the risks and hazards for usage, storage, transporting and handling hazardous chemical and gases, the company should:
- Implement the best practices of an effective EHS management system
- Have an on-site and off-site emergency response plan (ERP) and Emergency Response Drill.
In addition, an effective chemical / gases detection system should be implemented for the preservation of lives and property. The writer will also introduce various types of risk assessment systems for the production process, which provideact as an advance warning to prevent potential disasters from happening.
1. Introduction
Although the EHS management system has been well developed and implemented in industries to prevent hazardous chemical and gases leakage and spillage, many hazardous chemicals/gases disasters and incidents happen around the world. In order to preserve human life, it is important for top management to understand the latest technologies, methodology and system on how to detect and handle hazardous chemicals & gas leaks and spillage.
2. Prevention of hazardous chemical/ gas leakage and spillage
The commitment from top management of the company or organization is the key factor to prevent accidents. The preventive measures for hazardous chemical/gas leakage and spillage includes:
- an EHS management system
- a chemical/gas detection system
- on-site emergency response & evacuation plans
- public awareness
- personal protective equipment
- emergency and rescue equipment.
3. EHS Management System
The EHS management system should include hazard identification that determines the potential hazard of a facility that uses chemicals/gas. Depending on the risk level and the type of operation at the workplace, the EHS management system may include:
- EHS Policy
- EHS organization structure
- EHS duty/responsiblility
- EHS process control
- EHS program
- EHS training/awarenes
- EHS work permits
- contractor EHS program
- EHS audit/inspection
- EHS committee/meetings
4. The Hazardous Chemical/Gas Detection System
In the event of hazardous chemical or gas leakage and spillage, the response time for the emergency response team to react or active is normally less than 3-5 minutes. It is impossible to activate emergency response plan, if the hazardous chemical/gas is not detected during the incident. One of the key elements to prevent such incident/disaster is "How to detect the hazardous chemical / gas leakage and spillage?"
The presence of Hazardous chemical / gas at in incident location or other emergency situation adds a new dimension of risk to residents and to those who are handling and treating casualties and providing emergency services. Therefore the selection and installation of the chemical / gas detection system is the fundamental element in accident prevention program.
4.1 Hazardous Chemical / Gas Detection System
Before purchase and installation of chemical / gas detection system, evaluation process need to be carried out. Suggested evaluation steps are as follow:
(1) Identity the potential risk, hazard and danger points
(2) Understand the application
(3) Selection of the detection system
(4) Profile the potential chemical / gas release scenarios
4.1.1 Identity the potential risk, hazard and danger point
The design of detection system should be linked to the type of risk and hazard of the chemical and gas . The hazard identification can asses the level of the level of hazard of the chemical and gas. The hazard identification can asses the level of hazard on-site. The method of hazard identification has been well established, such as Job Safety Analysis, Fault Tree Analysis, Hazard study, QRA and Safety Integrity Levels, etc.
When the hazard has been identified, the location of the leakage and spillage of hazardous chemical / gas could pose a danger to human life should be determined. In general, the gas detector or sensor used to monitor potential release point should be positioned close to potential leak point.
With regards to the environment of work place, various type of sensor or detector should be considered, such as explosion-proof, weatherproof type, etc.
4.1.2 Understand the application
Before purchase hazardous chemical / gas detection system, the person-in-charge should decide the type of hazardous material should monitor. Reference need to make to the local legislations and industrial safety requirement; the type of sensor, response time of sensor and accuracy of sensor should be identified. Depend on the level of hazards, the detection system should be able to activate immediately upon leakage incident through automatically shut down the valve, initiate the alarms or sirens and other application.
4.1.3 Selection of the Detection System
The key point of selection of the detection system is the high quality and reliability of system. In general, most of the company or person-in-charge only consider the cost of the detection system. Using the wrong type and not reliable detection system may result in heavy lawsuit, Compensation or medical bill that costs thousand times higher than the cost the detection system.
The decision of selecting the detection system should be made by a team of EHS operation and engineering committee. The specification, standard and guide on the selection of the detection system should be discussed and finalized before purchase. Understanding of the detection system is the most important issue before consideration of purchase. Other important factors to be considered for example the supplier’s company background, their customer’s reference and feedback can used as important reference to the reputation of the supplier. The supplier should provide detail presentation explaining the product specification, additional value added service for example after sales service, backup facilities and maintenance training, etc.
4.1.4 The Potential Chemical / Gas Release
Depend on the scenarios of the potential Chemical / gas leakage, the response time of the detection system and the time to active emergency response plan will be the important issue. If the plant or operation is located near the residential area, city or school, the decision to shut down the operation / process / plant should be depend on the level of the hazardous chemical / gas. For example in the Bhopal – Methyl – Iscyanides underground storage tank automatically ignited during the critical moment, this will substantially reduced the number of death by the incidents.
In a vapor cloud explosion, unconfined vapor cloud explosion or boiling liquid expanding vapor explosion, the time for people to escape could be less than 3 minutes. It is important to determine the situation, the timer for the explosion might be occurred. In general, while the atmosphere reach 10% of LEL, the detection system should be able to active alarm to alert the operation personal to take necessary action ti prevent fire & explosion. Although the reliability of detector or meter is the most important factor, easy operation and calibration of the detection system should be the additional key points to consider during evaluation.
Conclusion
As refer to the hazardous chemical / gas leakage and spillage incident & disasters, no one in the organization, industries or companies can afford to compromise on Environmental, Health and Safety issue. The top management or person-in charge should work out the financial budget that the company can afford to purchase, rent or lease the detection system.
However, EHS management system, hazard identification, detection system, emergency response / evacuation plans and personal protective equipment can prevent and mitigate the risk of handle hazardous chemical and gases.
The author is pleasure to share his experiences and knowledge on the design and installation of the high quality hazardous chemical and gas detection system in various industries / operations. He can reached at esqcssb@streamyx.com or esqcssb@tm.net.my.
posted by Steve Hudgik |
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