Plant & Process Safety Assessments

When handling materials that produce dusty conditions, such as foodstuffs, powders, grain and sugar, an explosion can occur if the mixture is ignited. This can happen during processing or storage, for example in silos. Plant layout and construction should prevent explosions and accidents to protect people and processes.

For example, explosion protection must be taken into account when deciding on the type of storage and the use of special floor coatings. In dusty environments, such as grain mills and powder conveyors, explosion-proof electric motors should be used. Damp environments, such as canning environments, require the use of moisture-proof motors. Steam boilers should be located in a separate boiler house.

Plant and process safety in a chemical plant is imperative, as explosions are not uncommon. When such explosions occur, they can frequently lead to serious injuries and even death, and they can affect not only employees, but also local communities and the environment.

The causes of explosions are diverse and range from infrequent maintenance of equipment and improper storage or transportation of hazardous chemicals to insufficient training of personnel and human error in the operation of equipment. Another major cause of chemical plant explosions is a product malfunction such as a defective safety valve or warning system.

Explosions, especially relating to dust, pose a significant potential hazard in the manufacture, handling, storage and processing of pharmaceuticals. Many pharmaceutical products are in the form of fine powders and chemically rich for combustion. It is advisable to have these powders/dusts tested.

Furthermore, it is essential to implement adequate measures for explosion prevention and protection. Besides that, the very nature of substances in the pharmaceutical industry can pose a toxic risk and cause harmful effects to employees, either during processing or if the substances escape into the atmosphere.

Effective process safety management is critical in the oil and gas industry. Workers may face the risk of fire or explosion, especially due to ignition of flammable vapors or gases which may be released from wells, trucks, production equipment or surface equipment such as tanks and shale shakers. Ignition sources can include static, electrical energy sources, open flames, lightning, cutting and welding tools, hot surfaces and frictional heat.

In recent years, many explosions and accidents have occurred in automotive plants and repair shops worldwide. One was caused when sparks ignited a highly flammable aluminum powder when workers were polishing hubcaps. On another occasion, gas leaking from valves in a reheating furnace caused an explosion in a plant of a steel component supplier. Toxic fumes in a paint shop can cause an explosion when ignition occurs.