WSHCCaseStudiesChemicalIndustryCover.indd127/5/1311:01AMWorkplacesafetyandhealth(WSH)playsakeyroleinachemicalplantinachievingbetterproductivityandgoodreputation.Hence,everychemicalplantshouldbedesignedtobesafeandeasytomanageandoperate.However,accidentscanstilloccurduetootherfactorssuchastechnicalandengineeringfailures,humanerrorsormanagement/proceduralfaults.Aspartofourcontinuousefforttosupportthechemicalindustry,theWSHCouncil(ChemicalIndustries)Committeehasformedaworkgrouptoputtogetheracompilationoflocalcasestudies.ThecasestudieswillbeausefulreferencetoManagers,SupervisorsandWSHProfessionalsinthechemicalindustry,particularlythosewithmanufacturingoroperationsportfolioandworkinginSmall-andMedium-sizedEnterprises(SMEs).Thisbookletoffersinsightstopastaccidents/incidentsthathavetakenplaceinSingapore.Thecasestudiesnotonlyprovidelessonslearntfortheindustry,butmoreimportantly,theyremindustoactivelyreviewourcurrentpracticesandcontinuallyfindwaystomakeourworkplacessafer.Readersareencouragedtocarefullythinkthrougheachcase,reviewitsrelevancyandcontexttospecificworkplacesituations,andincorporatethelessonslearntwhereappropriate.Thisbookletisdividedintovarioussectionsaccordingtotypeofincidentforeasyreference.The5M(Mission,Man,MachineandManagement,Medium)Model(seeAppendixB)isusedtoanalysethecontributingfactorsofeachcase.Attheendofthebookletisasectiononoccupationalhealthhazards.Unlikesafetyhazards,consequencesposedbyoccupationalhealthhazardsmaynotbeasobviousandimmediate.Adversehealtheffectsmaybechronicinnatureandcantakealongtimefortheoccupationaldiseasetomanifest.Thissectionwillshowinnovativeapproachesusedinaddressingexposuretooccupationalhealthhazardsinvolvingnoise,ergonomicsandchemicals.Ihopethatthecasestudieswillbeusefultoyouincreatingasaferandhealthierworkplaceforyourorganisation.MrKarthikeyans/oR.KrishnamurthyChairmanWorkplaceSafetyandHealthCouncil(ChemicalIndustries)CommitteeFOREWORDFORWARDCONTACTWITHHAZARDOUSSUBSTANCESCase1Chemicalsplashatprocessplant06Case2Chemicalburnsduringblendingoperation09Case3Hydrogensulphidepoisoningduringplant12shutdownoperationCase4Exposuretochlorinegasduringelectrolysershutdown15Case5Contactwithhydrofluoricacidduringdecommissioning18ofpressurisedtankFIREANDEXPLOSIONCase6Lossofcontainmentatelevatedflaretower23Case7Fireduetosightglassleak26Case8Flashfireduringchargingofflammablepowder28Case9Explosionandfireatchemicalmanufacturingplant30Case10Explosionofreactorandsettlertankduringprocess33troubleshootingCase11Explosionofcondenserduringchemicalprocess36Case12Boilerexplosionduringplantcommissioning39Case13Furnaceexplosionduringtemperingprocess42CONTACTWITHHOTSUBSTANCES/OBJECTSCase14Scaldedbysteamcondensateinprocessplantarea46Case15Scaldedbyhotliquidfromincinerator48CONTENTSFALLSFROMHEIGHTCase16Fallfromheightwhileclimbingropeladder52CAUGHTIN/BETWEENOBJECTSCase17Trappedin/betweenprimemovercabinandcabindoor55OCCUPATIONALHEALTHHAZARDSCase18PreventingNID:Acousticenclosureforshreddermachine60Case19Improvingworkergonomics:Push-pullattachmentforforklift62Case20Eliminatingexposuretohazardouschemical:63AutomaticdosingsystemCase21Eliminatingexposuretohazardouschemical:64InflightsolidsamplerACKNOWLEDGEMENTS65GLOSSARY66APPENDIXA.ProcessSafetyinSingaporeStandardSS506:70Part3OSHManagementSystemB.Overviewof5M(Mission,Man,Management,Machine,Medium)Model73C.CaseListingbyOSH...
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