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Q1. Discuss occupational health hazards and industrial accidents in petrochemical industry and offer remedial measures for the same. Answer – Petrochemicals are chemical products made from raw materials of petroleum or other hydrocarbon origin. Although some of the chemical compounds that originate from petroleum may also be derived from other sources such as coal or natural gas, petroleum is a major source of many. The two main classes of petrochemical raw materials are olefins (including ethylene and propylene) and aromatics (including benzene and xylene isomers), both of which are produced in very large quantities. Petrochemical industries are involved in the production of several chemicals which fit into one or more of the following four categories: 1.Basic raw materials 2.Key intermediates 3.Minor intermediates 4. End products The Occupational Hazards in petrochemical industry are follows A Hazard is a situation which poses a level of threat to life, health, property or environment. Most hazards are dormant or potential, with only a theoretical risk of harm, however, once a hazard becomes 'active', it can create an emergency situation Accident hazards: Falls from ladders and other elevated platforms Falls of heavy objects on head (from overhead storage shelves) and feet Slips and falls on wet, uneven or damaged floors (esp. hazardous when hand-transporting dangerous materials, e.g. chemicals Entanglement of clothes, hair, fingers, arms in rotating and other moving equipment, in particular centrifuges, mixers, blenders, etc. "Freeze burns" or frostbite from skin contact with very cold surfaces or fluids, e.g., liquefied gases. Electrocution and electric shock Acute poisoning by a wide variety of poisonous gases, liquids and solids used as starting materials or released in chemical reactions Cuts and stabs from sharp edges, broken glass; Fire and explosions in work with flammable gases, liquids and solids Physical hazards: Radiation: Depending on types of equipment and processes employed in a particular laboratory, workers may be exposed to different kinds of radiation.

Chemical hazards: Exposure to an extremely wide variety of chemical substances (actually, chemical and biological laboratory workers may be exposed to any known chemical agents or combinations thereof) including substances that are corrosive, irritating, toxic, , asphyxiating, allergenic, carcinogenic, mutagenic, teratogenic, radioactive, etc. Biological hazards: Exposure to an extremely wide variety of biological agents ( biological laboratory workers may be exposed to any known biological agents or combinations thereof) including viruses, bacteria, fungi, parasites, etc., by way of inhalation, ingestion, skin or eye contact, transmission by laboratory animal bites or stings, accidental injection, etc. Noise hazards: They also face problems with the noise generated at the workplace and have a greater risk of hearing loss associated with hazardous noise levels, as there is functioning of large mechanical machinery which generates high levels of noise. Electricity hazards: They have danger from electricity, short circuits which may lead to fire. As the industry deals with flammable compounds a small spark in the electrical units may lead to big uncontrollable fire. Explosion hazards: Explosions due to leakage of volatile gases are a major concern for the petrochemical units. A sight leakage of the gas may lead to a huge explosion in the unit and can kill al the workers present in its vicinity. There are lots of chemical used by these industries to produce different substances from the crude oil and these chemicals are kept under pressure, which may lead to explosions if any damages occur to the storage units. The intensity of the explosion depends on the volume of gas, pressure on the gas stored in the containers. Vessel explosion are major concern for these industries. Boiling liquid expanding vapour explosion (BLEVE): occurs when a large amount of pressurized liquid is suddenly vented to the atmosphere as the result of a containment vessel rupture Dust explosion: suspensions of finely divided combustible solids (flammable dust) can explode in much the same fashion as flammable gas. It is significant that dust suspensions in air, small concentrations of flammable gas, even well below the lower flammable limit of the gas, can contribute to a more severe explosion than that of the dust alone

Fire hazards: Fires in petrochemical industries are most common hazard which lead to the deaths of hundreds of its workers. The small oil spills in the vicinity of the oil containers may cause partial or full burns to the workers. A small ignition or spark can lead to the volatile substances; oils to catch fire immediately and wide spread it in no time. Toxic hazards: Exposure to powerful toxins such as benzene, hydrocarbons, volatile organic compounds can lead to lung disease, and neurological problems with the workers working in these industries. The toxic effects depend on the time and length of exposure. In halation of invisible particle of volatile gases for a long term also pose a danger to the health of the worker. Gasoline vapours have been reported to have experienced respiratory, neurotoxic and allergic illness. Accidents in the petrochemical industries are mostly occurring due to negligence in maintenance of the old units, pipes not properly cleaned can have residue that mixes fatally with the next batch of chemicals. Water left in lines after a shutdown and testing can turn to steam, causing a blowout. Accidents are fire explosion, oil containers catching fire, and leakages of toxic gases / chemicals. Therefore abiding by the safety policy measure of the industries and maintaining the equipments machinery is highly important to avoid the accidents. When one of these elements is missing, or an employee or supervisor is negligent, things can go very badly. It is reported that petrochemical industries have the highest number of deaths of it works than compared to any other big scale industries and fall under maximum number of accidents. Therefore safety remedial measures become the integral part of the petrochemical industry’s policy. It is necessary to look for all the probabilities which would lead to accidents or explosions in the industry. Perhaps the most important reason for such a low accident rate is that, given its hazardous nature, the industry has to be safe to be viable. In addition, several other reasons contribute to the low accident rate in the oil and petrochemical industry. A special attention should be paid to accident prevention by this industry, because of the hazardous nature of this industry.

Major accidents occurring in petrochemical industries – Vessel explosion: a) Deflagration a detonation of pure gas not mixed with oxidants: acetylene is an example of a gas that would undergo a self-sustaining decomposition that releases energy. Acetylene can burn with oxygen in the air as either a deflagration or a detonation. However acetylene alone, with no oxygen, can also deflagrate or detonate.

b) Combustion, deflagration and detonation in enclosure: - these can be fuelled by gaseous, liquid or dust particle fuels. If an enclosure is too weak to sustain the pressure resulting from combustion, it will explode. c) Runaway exothermic chemical reaction: many industrial chemical reactions are exothermic. Certain reaction can go in a accelerated manner. If released energy is not removed fast. If pressure exceeds the pressure capability of the vessel, it explodes. d) Simple overpressure of equipment with non reactive gaseous contents: these are also called mechanical explosions. Rupture of pressure vessels due to overpressure may occur, if human error or ancillary equipment allows too high an internal pressure to accumulate. Some of the recommended safety measures would be: Workers training in safety measures should be compulsory as these factors contributed to the good safety performance of the oil and petrochemical industry. It has also been noted that a large percentage of other accidents involved contract workers; hence the safety of contract workers cannot be ignored. Thus introducing a safety orientation training course for contract workers should be implemented. The oil and petrochemical industry needs to step up their vigilance in the supervision of contract workers as they carry out their work. This effort minimizes occurrence of "processrelated" accidents. It is necessary to identify, evaluate and control petrochemical hazards and review operating procedures to ensure accuracy. Developing and implementing safety practices in the use of flammable gas meters, sensors and alarms should be installed and follow inspection and maintenance procedures on mechanical equipment should be from time to time. Hazardous materials should be contained and stored mostly in closed systems as this facilitates control and reduces exposure. Safety body equipments should be worn by the workers working on site. Wearing helmets, fire resistant body aprons, gloves, eye and face protection equipments should worn. Thus personal care equipments should be made compulsory where the probability of danger can be maximum. A holistic safety management approach should be focused to minimize the occurrences of the accidents in the industrial units. A modern process technology and operation should be carried out to ensure safety from use of old techniques which can lead to accidents. The approach towards the materials used in the industry should be on the safer side and their handling should be taken care of. Maintenance, alteration and quality assurance of equipment and facilities should be done after short period of time and there should be an emergency preparedness among the workers. This approach will ensure immediate safety if an accident occurs. Safety operations. 1. Training and supervision of personnel

2. Maintenance, alteration and quality assurance of equipment and facilities 3. Emergency preparedness. 4. Company must follow permissible exposure limits for hazardous chemicals. 5. Eye Contact: Flush eyes thoroughly with sterile wash solution. Seek medical attention if irritation persists 6. Eye Contact: Flush eyes thoroughly with sterile wash solution. Seek medical attention if irritation persists. 7. Skin Contact: Wash skin with soap and water. Seek medical attention if irritation persists. 8. Inhalation: Remove to fresh air if breathing is difficult. Seek medical attention if difficulty persists. 9. Ingestion: Ingestion is considered to be unlikely route of exposure. However, if ingestion occurs, seek medical attention 7. Apply water spray to cool exposed containers containing combustible chemicals. 8. temperature must be maintained below flash points of flammable chemicals. 9. in case of accidents Clean up with absorbent material. Transfer to appropriate containers for disposal. 10. Storage: Store in closed containers away from direct source of heat. 11. Ventilation: The use of local exhaust is desirable Personal Protection: If prolonged contact is anticipated, use barrier skin cream.

Q2. Discuss International Legislation for OSHAS Regulation and code federal regulation. Answer:-The United States Occupational Safety and Health Administration (OSHA) is an agency of the United States Department of Labor. It was created by Congress under the Occupational Safety and Health Act, on December 29, 1970. Its mission is to prevent work-related injuries, illnesses, and deaths by issuing and enforcing rules (called standards) for workplace safety and health. OHSAS (Occupational Health and Safety Management System) is an international occupational health and safety management system specification. The (OHSAS) specification gives clearer direction to an occupational health and safety management system. OHSAS is an audit/certification specification, not a legislative requirement or a guide to implementation. It should be noted that OHSAS does not state specific performance criteria, or give detailed specifications for the design of a management system. Instead, the system is geared towards reducing and preventing accidents and accident-related loss of lives, resources, and time. Any Occupational Health and Safety Management system specifies processes to continuously improve the performance and at the same time, comply with legislation. It provides the framework to seamlessly integrate the OH&S management system with your overall business plan. OSHAS standards fall into four major categories: • • • • •

General Industry Maritime Construction Agriculture. Provide for the development, analysis, evaluation and approval of state occupational health The Elements of OHSAS 18001:2007 include:

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Policy and commitment Hazard identification, risk assessment & risk controls Legal requirements Objectives and Programs Organization and personnel Training, Communication and Consultation Documentation and records Operational Controls Emergency Readiness Measurement and monitoring Accident and incident investigation, corrective and preventive action Audit and Review Application and Relevance in the Industry

Objectives of OSHA: • • • • • •

Encourage employers and employees to reduce workplace hazards and to implement new or improve existing safety and health programs Provide for research to develop innovative ways of dealing with occupational safety and health problems Establish "separate but dependent responsibilities and rights" for employers and employees for the achievement of better safety and health conditions Maintain a reporting and recordkeeping system to monitor job-related injuries and illnesses Establish training programs to increase the number and competence of occupational safety and health personnel Develop mandatory job safety and health standards and enforce them effectively Benefits of Implementing an OH&S management system include:

OHSAS 18001:2007 has established itself as the ‘international certification standard’ for OH&S management systems. Implementing OHSAS ensures: • • • • • • • • • •

Improve efficiency and consequently reduce accident and production time loss Increase control and reduction of hazards through the setting of objectives, targets and evolved responsibility Demonstrate your commitment to the protection of staff, property and plant Demonstrate legal compliance Increase your reputation for safety and occupational health Reduce insurance premiums Is an integral part of a sustainability strategy Encourage more effective internal and external communication Improve your safety culture Reduced costs associated with accidents and illness

The OSHA Act applies to employers and employees in such varied fields as: • • • • • • •

Manufacturing Construction Long shoring Agriculture Law and medicine Charity and disaster relief Organized labor and private education.

Occupational Safety and Health Administration (OSHA) Regulations: The Code of Federal Regulations (CFR) is the codification of the general and permanent rules published in the Federal Register by the executive departments and agencies of the Federal Government. It is divided into 50 titles that represent broad areas subject to Federal regulation. OSHA's mission is to assure the safety and health of workers by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual improvement in workplace safety and health. OSHA and its state partners have inspectors, plus complaint discrimination investigators, engineers, physicians, educators, standards writers. This staff establishes protective standards, enforces those standards, and reaches out to employers and employees through technical assistance and consultation programs. The passage of the Williams-Steiger Occupational Safety and Health Act of 1970 clearly defined the regulations governed by OSHA. The Occupational Safety and Health Act of 1970 was passed to assure safe and healthful working conditions for working men and women; by authorizing enforcement of the standards developed under the Act; by assisting and encouraging the United States in their efforts to assure safe and healthful working conditions; by providing research, information, education, and training in the field of occupational safety and health; and for other purposes. The regulations under the act are covered in 29 CFR. They are further divided into 52 PARTS, each part containing Chapters on Regulation and Standards set by the CFR for different sectors. For example PART 1926 deals with Safety Regulations for Construction, PART 1915 deals with Safety Regulations for Ship yard Employment, PART 1918 for Long shoring, PART 1928 for Agriculture and so on. 29 CFR PART 1903 states that: •

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Every employer covered under the Williams-Steiger Occupational Safety and Health Act of 1970 furnish to his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees. Employers comply with occupational safety and health standards promulgated under the Act, and that employees comply with standards, rules, regulations and orders issued under the Act which are applicable to their own actions and conduct. The Department of Labor is authorized to conduct inspections, and to issue citations and proposed penalties for alleged violations.

29CFR Part 1904 requires employers to record and report work-related fatalities, injuries and illnesses. Under the act, companies are required to use OSHA 300, 300-A, and 301 forms, or equivalent forms, for recording work-related injuries and illnesses.

The Code of Federal Regulations (CFR) is the codification of the general and permanent rules published in the Federal Register by the executive departments and agencies of the Federal Government. It is divided into 50 titles that represent broad areas subject to Federal regulation. Each volume of the CFR is updated once each calendar year and is issued on a quarterly basis. • • • •

Titles 1-16 are updated as of January 1st Titles 17-27 are updated as of April 1st Titles 28-41 are updated as of July 1st Titles 42-50 are updated as of October 1st

Each title is divided into chapters, which usually bear the name of the issuing agency. Each chapter is further subdivided into parts that cover specific regulatory areas. Large parts may be subdivided into subparts. All parts are organized in sections, and most citations in the CFR are provided at the section level. A list of agencies and where they appear in the CFR may be found in Appendix C of the U.S. Government Manual. There are about 50 chapters dealing with different sectors like health, environment, roads, construction, industry, transportation and so many other fields. Each title is again divided into many sub chapters like introduction, rules, regulations, authorities, regulatory bodies, punishments, documentation, records, etc. Thus it is a very wide database of US laws and regulation dealing with almost all the sectors. Chapter 41 deals with Environmental rules and regulations. Subchapter of this title deal with Forest, air, pesticide, water and many of the environmental programmes. The online CFR is a joint project authorized by the publisher, the National Archives and Records Administration's (NARA) Office of the Federal Register (OFR), and the Government Printing Office (GPO) to provide the public with enhanced access to Government information.