Introduction to Plant Design and Safety

1
Introduction to Plant Design and Safety

• Presented to ES-317y at UWO in fall of 1999
• By Dick Hawrelak

2
Reasons for Adding Safety to Plant Design
(ES-317y)

• Industry demands safety awareness.
• Government wants correct application of
• Often confusing guidelines,
• Numerous codes and complex regulations.
• Academia needs to retain accreditation.

3
Course Objectives

• Sensitize the students to safety.
  (Case Studies)
• Introduce safety in plant design. (Where
  We Go Wrong).
• Introduce safety tools used in plant design
  (Plant Design Hazard Analysis spreadsheet
  software given to UWO).

4
Three Laws of Loss Prevention

• He who ignores the past is condemned to repeat
  it.
• Success in preventing loss is in anticipating the
  future.
• You are not in control if a loss has to occur
  before you measure it.

5
A Word of Caution From Albert Einstein

• Concern for man himself and his fate must always
  form the chief interest of all technical
  endeavor. Never forget this in the midst of your
  diagrams and equations.

6
Some Safety Statistics

• A general perspective to set the tone.
• Comparison to other industries.
• Comparison to other activities.

7
Fatal Accident Frequency Rate (FAFR)
8
FAFR For Other Activities
9
CMA Safety Data
10
Case Studies - Lessons Learned

• Flixborough - VCE
• Bhopal - Continuous Toxic Release
• Potchefstroom - Instantaneous Toxic Rel.
• PEMEX, Mexico City - Domino BLEVEs
• Norco - Largest Refinery VCE
• Phillips - Largest Insurable Loss VCE
• Mississauga - Train Wreck - Toxic Release

11
Where We Go Wrong

• Marsh McLennan Protection Consultants.
• Based on 150 major losses to January 1989.

12
Percent of Losses
13
Equipment Involved
14
Average Trended Loss
15
Contributing Factors
16
Final Exam

• One hour exam during the last session.
• Example exam questions will be given during each
  presentation.
• Example - What are the Three Laws of Loss
  Prevention?
• Example - The greatest percentage of losses come
  from (operational error, engineering design,
  mechanical failure)?
• Example - The greatest equipment losses come from
  (piping, exchangers, tanks)?