Chemical Industry: A Risky Workplace
India has seen many major industrial safety mishaps, including chemical leaks, explosions, and fires:
- Bhopal Gas Tragedy: In 1984, a chemical leak at the Union Carbide plant in Bhopal released 45 tons of methyl isocyanate gas into the air. The gas drifted over nearby neighborhoods, killing an estimated over 10,000 people and causing panic. Tens of thousands of others fled the city, and half a million survivors suffered respiratory problems, eye irritation, or blindness. At the time, it was considered the worst industrial accident in history.
- Chasnala Mining Disaster: In 1975, a malfunctioning piece of equipment ignited a pocket of methane gas in a coal mine in Jharkhand, causing an explosion that collapsed the mine.
- Visakhapatnam Gas Leak: In 2020, a gas leak occurred in Visakhapatnam.
- Chennai Oil Spill: In 2017, an oil spill occurred in Chennai.
- Neyveli Boiler Blast: In 2020, a boiler blast occurred in Neyveli.
- Dombivli Explosion: In May 2024, an explosion occurred at a chemical factory in the Dombivli Maharashtra Industrial Development Corporation (MIDC) area, resulting in injuries, loss of life, and damage to nearby property.
Critical Safety Points in Chemical Industry
Chemical/process industry is largely considered a risky workplace. There can be multiple hazards intrinsic to operations that cannot be eliminated. However, safety awareness can be created, and strict protocols can be adhered to. This requires scientific and systematic workplace management, which is often missed, resulting in accidents and heavy damage. Here are some critical safety points that should be considered:
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Hazard Identification and Risk Assessment (HIRA)
- Identify Potential Hazards: Regularly identify and evaluate all chemical, physical, biological, and ergonomic hazards associated with processes and materials.
- Risk Assessment: Quantify and prioritize risks based on their potential impact and likelihood, and implement appropriate control measures.
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Process Safety Management (PSM)
- Process Hazard Analysis (PHA): Conduct systematic reviews to identify potential hazards and the effectiveness of existing safety measures.
- Safety Instrumented Systems (SIS): Implement automated systems to monitor and control critical processes, ensuring safe operation.
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Chemical Handling and Storage
- Proper Labelling: Ensure all chemicals are correctly labeled according to safety standards.
- Storage Conditions: Store chemicals in appropriate conditions (e.g., temperature, humidity) and in compliance with compatibility requirements.
- Secondary Containment: Use secondary containment systems to prevent spills or leaks from reaching the environment.
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Personal Protective Equipment (PPE)
- PPE Provision: Provide adequate PPE such as gloves, goggles, respirators, and protective clothing based on the chemical hazards involved.
- Training: Ensure that all personnel are trained in the correct use and maintenance of PPE.
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Emergency Preparedness and Response
- Emergency Plans: Develop and regularly update emergency response plans, including evacuation procedures and spill response.
- Fire Safety: Install fire detection and suppression systems, and ensure regular fire drills.
- First Aid: Maintain well-equipped first aid stations and train employees in basic first aid and emergency procedures.
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Process Control and Monitoring
- Automation and Controls: Use automated systems for monitoring critical process parameters (temperature, pressure, flow rate) to prevent deviations that could lead to unsafe conditions.
- Regular Inspections: Conduct regular inspections and maintenance of equipment to prevent failures and accidents.
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Training and Competency
- Ongoing Training: Provide regular safety training to all employees, covering topics like chemical hazards, safe handling practices, and emergency procedures.
- Competency Assessment: Assess and certify the competency of employees, especially those involved in high-risk operations.
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Incident Investigation and Reporting
- Incident Reporting: Encourage reporting of all safety incidents, near-misses, and unsafe conditions.
- Root Cause Analysis: Investigate incidents thoroughly to identify root causes and implement corrective actions to prevent recurrence.
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Environmental Protection
- Waste Management: Properly manage and dispose of chemical waste to prevent environmental contamination.
- Emissions Control: Implement measures to control air and water emissions, ensuring compliance with environmental regulations.
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Regulatory Compliance
- Adherence to Standards: Ensure compliance with local, national, and international safety regulations and standards.
- Audits and Inspections: Regularly conduct internal audits and be prepared for external inspections to ensure ongoing compliance.
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Management of Change (MOC)
- Change Control: Implement strict procedures for managing changes to processes, equipment, and personnel to ensure safety is maintained.
- Review and Approval: Ensure all changes are reviewed and approved by qualified personnel before implementation.
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Community and Public Safety
- Communication: Maintain open communication with the local community about potential hazards and emergency procedures.
- Emergency Coordination: Coordinate with local emergency services and authorities to ensure a rapid and effective response in case of an incident.
Visual Management: An Effective Technique for Building a Safe Workplace
Visual management is recognized as a highly effective tool to develop a culture adhering to safety and other compliances throughout the company. It also helps in enhanced material management and plant performance monitoring.
Visual management plays a vital role in creating safety awareness as visuals are easy to understand, especially since 65% of the population are visual learners. It is also stated that visual memory is 60,000 times better and more effective than auditory memory.
A well-designed visual management solution at a chemical site will bring a change that might not be achieved through regular training sessions and regular instructions being given to individuals.
VisualMitra has worked extensively and developed visual management kits for chemical sites. The kits are developed by industry experts, taking references and guidelines from safety standards such as ISO 45001 (OHSAS). All the critical aspects of safety and better workplace management have been considered while developing the visual management kit. The kit comprises various effective displays. The size of the kit can be decided based on the area of the site, and accordingly, a specific kit can be selected. VisualMitra has been serving the chemical industry for the past two decades.
