ACCIDENT PREVENTION BY USING HAZOP STUDY IN

NAPHTHA HANDLING
a*
Prabaharan. R, b*
Dharani. R ., a V. Arumugaprabu , b P. Amuthakkannan
a
Department of Mechanical Engineering
Kalasalingam University, Krishnankoil-626 126, Tamil Nadu
*Corresponding Author email: rajkalaharan@gmail.com ,
dhararam7@gmail.com

ABSTRACT

The chemicals are used in industrial facilities for various purpose of manufacturing the
products. Many hazards can occur due to chemical storage and handling that may affect both
man, material and environment. The chemical hazards might cause injuries, explosion and
also leads to death within unsafe condition and unsafe act. It is vital to analyse hazards and
take some precautionary steps to minimize chemical hazards. This paper outlines hazop study
of chemical hazards (NAPHTHA) during handling and storage with its safety control
methods which verify the requirements of international standards and safety regulations as
NFPA, Factories Act, Underground storage act, HMCSAH Act to be checked on safety
requirements to be developed. The Paper presents safe arrangement of chemical tanks and its
components in a sample design to achieve functional Safety requirements.

KEYWORDS ─ Hazop study, NFPA 30, P & I diagram, Accident Chart, Underground
storage act.

1.INTRODUCTION

This paper deals with the control of hazards in storage and handling of naphtha. This hazop
study describes storing naphtha in underground tank, transporting, handling in workplace. The
brief information of naphtha MSDS is useful for understanding naphtha control procedures.

1.1 HAZARD AND OPERABILITY STUDY:

A hazard and operability study (HAZOP) is a systematic, critical examination by a team of

engineering and operating intensions of a process to assess the potential of the hazard.

The reason for carrying out hazop study are;

i. To identify the hazard

ii. To resolve the hazard
Hazardous chemical used in Tyre industry :

i. Naphtha
ii. Toluene
iii. Hexane
iv. Zinc oxide
v. Sulphur

These are the chemicals used in tyre manufacturing industry. Among these chemicals
NAPHTHA is one of the most flammable and toxic chemical. So hazop study was done on
storage and handling of naphtha.

NAPHTHA

The word NAPHTHA came from Greek and LATIN. It is a general term that has been
used for over two thousand years to refer to flammable liquid hydro carbon mixture. Mixtures
labelled NAPTHA have been produced from natural gas condensates, petroleum distillates,
and the distillation of coal, tar, peat. It is used differently in different industries and regions to
refer to gross products like crude oil or refined products such as kerosene.

APLLICATION OF NAPHTHA IN TYRE INDUSTRY

1) Paint shop
2) Export tyre plants

HEALTH HAZARD INFORMATION’S :

Acute Health Effects

The following acute (short term) health effects may occur immediately or shortly after
exposure to naphtha :

 Contact can irritate and burn the skin and eyes.

 Breathing naphtha can irritate the nose and throat
 Exposure to naphtha can cause headache, dizziness, nausea and vomiting.
 High exposure can cause fatigue,lightheadness and passingout.

Chronic Health Effects

The following chronic (longterm) health effects can occur at sometime after explosure to
naphtha and can last for months or years:

Cancer Hazard

 Naphtha may contain Benzene, a CARCINOGEN.

 Many scientist s believe there is no safe level of exposure to a carcinogen.
Reproductive Hazard

 There is no evidence that Naphtha affects reproduction. This is based on test results
presently available to the new Jersey Department of health and senior services from
published studies.

Other long term effects

 Long term exposure can cause drying and cracking of the skin.
 Repeated exposure may damage the nervous system and may affect the kidneys.

NAPHTHA
UNDERGROUND
STORAGE

Fig 1 : Naphtha Storage Site Plan

NAPHTHA MSDS
ACCIDENT CHART

50

40
year
30
2011
20 2012
10 2013
2014
0
fatal % injury % nearmiss
%

Fig 2.accident chart

NAPHTHA P & I DIAGRAM

Fig 3.naphtha p&i diagram

EXISTING SAFETY MEASURES

1. AOD Pump was installed in storage area.

2. FIRE EXTINGUISHER (DCP) was fixed in required place.

3. Spark Arrester was installed in transporting vehicle.

4. Complete Elimination of electric supply around storage area.

5. Fencing was provided to avoid unauthorised person entry.

6. MSDS was mentioned in transporting vehicle.

7. SOP was maintained in naphtha working place.

8. Static energy Discharge chains are provide in entrance of paint shop.

9. PPE’s are provided as per standard.

SAFETY RECOMMENDATIONS

1. Sprinkler should be installed in storage area

2. Foam Type Extinguisher also needed to install

3. Gas leakage detector & Fire sensor should be installed

4. SCBA should be arranged for emergency situation in naphtha handling

5. Pipeline should be insulated by proper material

6. Fire proof wall should be arranged.

7. Static Discharge Meter should be provided.

8. Checklist should be maintained for underground storage, defined as follows.

CONCLUSION

This project focuses on identifying and preventing the accidents in naphtha storage and
handling by using hazop study.By using some engineering control accident ratio was reduced.
Study is carried out by visiting underground storage area, transporting and handling in
workplace in a tyre industry.

REFERENCES

1. A.R. Qureshi, “The role of hazard and operability study in

risk analysis of major hazard plan”t, Journal of Loss
Prevention in the Process Industries, Volume 1, Issue 2,
Pages 104-109, April 1988,
2. Diana M. Ceballos, MS, PhD,Scott E. Brueck, MS, CIH,
“Confined Space Program Recommendations for Dairy Plant
Inspectors – Nationwide” Health Hazard Evaluation
Report,HETA 2010-0175-3144,November 2011.
3. Jouko Suokas , “The role of safety analysis in accident
prevention”, Accident Analysis and Prevention, Volume
20, Issue 1, Pages 67-85, February 1988.
4. Liu Yinga, Hua Zhijiaa, Lei Lianbaob, Motivation
Mechanism of Accident Prevention in Coal Mine, Procedia
Engineering, Vol 43, Pages 174 – 179, 2012 .
5. Michael Booth, John D. Butler, “A new approach to permit
to work systems offshore”, Volume, Pages 309–
326 ,November 1992.
6. Mary Lynn Garcia, “Entry Control”, Design and Evaluation
of Physical Protection Systems (Second Edition), Pages 187–
217, 2008.
7. Paul A. Erickson, “Confined space entry and hot work”,
Practical Guide to Occupational Health and Safety, Pages
100–116, 1996.
8. R.E. Iliffe, P.W.H. Chung and T.A. Kletz, “More effective
permit-to-work systems” , Trans IChemE, Vol 77, Part B,
March 1999.
9. S. Matsuoka, M. Muraki, “Implementation of Transaction
Processing Technology in Permit-to-Work Systems”,
Volume 80, Issue 4, Pages 204–210, July 2002.
10. Trevor Kletz, “Entry to Vessels”, Case Histories of Process
Plant Disasters and How They Could Have Been Avoided,
Pages 207–219, 2009.
11. Trevor Kletz, “Entry into Confined Spaces”, Case Histories
of Process Plant Disasters and How They Could Have Been
Avoided, Pages 375–389, 2009.