Basic Industrial Processes

Pelatihan dan Sertifikasi Higienis Industri Madya (HIMa)

ASOSIASI HIPERKES DAN KESELAMATAN KERJA INDONESIA
 The degree of hazard
Arising in/from Industry

Industrial Work
Process Operation

Degree
of
hazard
Industrial Raw
Control Materials

Product
The degree of hazard arising in/from Industry

depend on :
• Industrial processes : Method & equipment
• Work operation : Human resources competency
& Standard Operating Procedure
• Raw materials : Chemical, physical, or biological
Agent.
• Product : intermediate, finished product, &
by- product
• Industrial control : Ventilation control; enclosure,
etc.
 Portland Cement Manufacturing
Process Flow

Dust
collector
Dry process Raw
Grinding Air
Material
Mill separator
proportioned

Primary Raw
Quarrying
and Materials
Raw
Secondary Storage
Materials
Crushing

Raw
Grinding
Material
Wet process mill
proportioned
Water
added
 Portland Cement Manufacturing
Process Flow

Dust
Collector Fuel Gypsum Dust
collector
Dry mixing
and Storage Clinker Air
lending Kiln Storage Storage
cooler separator

Grinder
Slurry mixing
And Storage
blending
 Petroleum Refining Processes
Source : IARC MONOGRAPHS 1989

Crude Oil

Crude Light hydrocarbon Middle distillate Heavy hydrocarbon

separation processing processing processing

1. Atmospheric distillation
2. Gas processing
3. Vacuum distillation 1. Chemical sweetening
2. Kerosene hydro desulfurization
3. Gas oil hydro desulfurization
1. Polymerization
4. Fluid-bed catalytic cracking
2. Alkylation
5. Moving-bed catalytic cracking
3. Naphtha hydro desulfurization
6. Catalytic hydro cracking
4. Catalytic isomerization
5. Catalytic reforming
6. Steam cracking 1. Deasphalting
2. Visbreaking
3. Coking
4. Residual oil hydro desulfurization
 Petroleum Refining Products
Source : IARC MONOGRAPHS 1989

1. Fuel Gas
2. Liquified Petroleum Gas
3. Aviation Gasoline
4. Automotive Gasoline
5 Solvents
6. Jet Fuel
7. Kerosene
8. Distillate Fuel Oils
9. Diesel Fuel Oil
10. Residual Fuel Oils
 Chemicals released to the Atmosphere

Due to :
1. Releases or leaks from joints, closures, and other part
of a closed system
2. Intentional releases of contaminants from vents or
process sampling points
3. Stack gases from combustion processes
4. Accidental or unintentional releases due to equipment
malfunction or failure.

Note :
Many valves leak even they are supposed to be shut,
and such leaks can build up the air concentration to
the higher level of TLV.
 Cleaning Operations

Purges, minor overpressure, and system breathing into the

atmosphere should be contained by :

• Collection
• Scrubbing
• Reaction
• Incineration
• Etc.
 Cleaning Methods

• Manual wiping of equipment with a solvent-

soaked rag
• Use of handheld or mechanical brushes
• Use of a scraper
• Wet mopping
• Use of a wet sponge
• Abrasive blasting and hydro blasting
• Steam cleaning
• Use of compressed air to blow off dust
• Use of vacuum cleaning devices
 Checklist
For Overall Process or Operation
1. List all hazardous chemical or physical agents used or formed in the
Process.
2. List the conditions necessary for the agent to be released into the
workroom atmosphere.

– Does it normally occur in the process as a dust, mist, gas, fume,

vapor, as a low-volatile liquid, or as a solid ?

– What process condition could cause material to be sprayed or

discharged into the workroom atmosphere as a liquid aerosol or
dust cloud?

– Have the consequences of the exposure of raw material or

intermediates to adjacent operations been considered?

– Are unstable materials properly stored?

– Has the process been laboratory-checked for runaway explosive

condition?

– Have provisions been made for the safe disposal of toxic materials?
Checklist….
3. List the Ambient airborne concentration levels in the workroom
atmosphere that would normally be present as a function of time.
List the peak airborne concentration levels as a function of event
duration. List permissible exposure limits (PELs) and TLV.

4. Are fire extinguishers, respiratory protective equipment,

stretchers, and other equipment required? Are fire extinguishing
agents compatible with the process materials? Are special
emergency procedures and alarm required?

5. For all raw materials used in the process, consider chemical

reactions that could take place to produce other toxic materials :
For example : the inadvertent mixing of acids and plating tank
liquids containing cyanides produces hydrogen cyanide (HCN). Is
there safe storage space for raw materials and finished products?

6. List the levels of those physical agents that may normally be

present (electromagnetic radiation, temperature extremes, noise,
etc).
 Checklists
For Process Equipment

1. List those pieces of equipment that contain sufficient hazardous

material that a hazard would be produced if their contents were
suddenly released to the environment.
2. List those pieces of equipment that could produced hazardous
levels of physical agents during normal or abnormal plant
operations.
3. List the machinery and equipment that could produce hazardous
concentrations of airborne contaminants. Indicate the control
measures installed to minimize the hazard. Is the health and
safety control measure adequate, failsafe, and reliable ?
4. List process equipment with components that are likely to leak
hazardous materials-such as valve, pump packing, and tank
vents. Is each safeguard adequate, failsafe, and reliable ?
5. Are labels provided for all valves and switches? Are all
containers of hazardous chemical labeled according to the
OSHA standard?
 Process Operation
Requiring Detail Study

1. What utilities are required? What could happen if one of these

utilities were suddenly and permanently or temporarily
interrupted?

2. What would happen if the flow of one or more of the process

streams entering or leaving the equipment was interrupted?
▪ What if the stream were twice the desired quantity?
▪ What would happen if the normal outlet connection from the
equipment became plugged?
▪ Can flammable fluids feeding production units be shut off from
a safe distance in case of fire or other emergency ?

3. In the case of a small leak, what would happen to the leaking

material ?
▪ Would it produce an environmental health hazard? How long
might it leak before being detected? Would the leak hasten
the corrosion and failure of the vessel or equipment?
Process ……

4. If the vessel is no longer functional, how would the

contents be contained?
▪ If the contents are volatile, what would be done to
diminish and control their vaporization?

5. What would be the effect of overpressure?

▪ If the vessel is protected by overpressure release devices,
▪ where would the material be vented?
▪ What would be the effect
of overheating? Of overcooling?
▪ Would the vessel be surrounded by burning material if other
equipment in the area failed?
▪ If so, what would happen?

6. What instrument failure or operator error could result in the

accidental release of vessel contents?
 Checklists
For Instrumentation

1. What would happen to one instrument or to a group of

instruments following a power loss or motive force
failure?
▪ To all instruments?
▪ What position would control valves assume?
▪ Is this be best failsafe position to minimize hazard ?

2. For each instrument, what can happen in case of

sensor failure?
▪ In case of control valve seizing, would the operator
receive warning in time to take corrective action?
▪ In an emergency situation, would it be clear to the
operator what corrective action is needed, or can the
situation be handled with built-in automatic overrides?
 Checklists
For Material-Collection Systems

Such as Industrial Ventilation and Pollution-Prevention Equipment

(scrubbers, hoods, ducts, blowers, dust collectors, condensers, flares,
combustion incinerators, etc).
1. Under normal operation conditions, is the capacity of the system
adequate to prevent hazardous concentrations of harmful air
contaminants in the workroom air ?
▪ What abnormal plant conditions can impose the greatest load on
this equipment?
▪ How long can these abnormal condition persist?
▪ What would be the effect on the system under these conditions
of increased or decreased flow?
▪ Would the system be adequate ?
2. What would happen in the case of utility failure or flow stoppage
to the collection device?
3. What would happen to the collection device if it were surrounded
by fire ? Could it suffer an internal fire? What would happen then?
 Operation and Maintenance
Personal

Operation and Maintenance Personal should set

up a routine procedure for testing the industrial
hygiene and safety control measures that are not
used in normal, ordinary plant operations.
 INITIAL JUDGMENT

Estimation of the potential health hazard to

employees requires that an initial judgment be
made. The initial determination is a simple one
that is based on factors such as the chemical,
physical, and toxic properties of the substance
being processed, the size of the workplace, the
amount and type of ventilation, and the proximity
of the employee to the source of contamination
 Initial Determination of Health Hazards

1. Date of Report
2. Name and social security number of each employee at a work
operation
3. Work operations performed by the employee at the time of the
report
4. Location of work operations within the worksite
5. Chemical substances to which the employee may be exposed at
each work operation
6. Any information, observations, and estimates that may indicate
exposure of this employee to a chemical substances; list any
exposure measurement data and calculations
7. Federal permissible exposure limits and TLV established by ACGIH
for each chemical
8. Complaints or symptoms that may be attributable to chemical
exposure
9. Type and effectiveness of any control measures used; for
mechanical ventilation controls, list measurements taken to
demonstrate system effectiveness
10. Operating condition ranges for production, process, and control
measures for which the determination applies
 Worst Case
1. When variation in job operation make it difficult to define
typical exposure, a “worst case” exposure pattern can be
used to represent the longest exposure time to the highest
expected air contaminant concentration. This exposure
pattern provides a convenient starting point for comparing
employee exposures.

2. If the initial judgment or determination indicates that exposure

in the worst case is not hazardous to health, then it may be
that no problems should be expected to develop with other,
lesser exposures.

3. If the worst case exposure pattern does exceed the TLV or

OSHA standards, separate initial determination reports
should be prepared for each of the individual exposure
patterns that may be encountered.
 Typical Procedures

When investigating a situation in which solvents are used in the

workplace, the health and safety professional should ascertain :
▪ the circumstances of use, the surface area of the exposed solvent,
the air and solvent temperatures, the control measures in use, the
proximity of workers, and other conditions that might affect
employee exposure.

The professional should determine the relative volatility and the toxic,
irritating, and narcotic properties of the solvent.

Based on these fact and previous experience, a judgment can be made as

to whether further investigation is necessary. Many exposures can be
classified as non hazardous simply by inspection.

The initial determination ensures that exposure to the contaminant has

been investigated in a detailed way. Common sense must be used in
the assumptions made in the initial evaluation
 Field Survey

A survey of work operation is performed to identify

actual and potential health hazards under normal
and abnormal conditions.

Survey and studies are conducted to determine

levels of exposure among workers to various
atmospheric contaminants and physical agents;
to determine the effectiveness of control
measures; to investigate complaints; and to
determine compliance with regulation.
 Walk-Through Survey

A walk-through survey is performed to pinpoint the location of

existing health hazards so that proper corrective action can
be taken.
The initial survey is used to establish a baseline from which
future conditions can be compare and evaluated.
Prior to the walk-through survey, the OHS professional should
review the process to become familiar with the raw
materials, equipment, by-products, and products. The
process flows, pressure, and temperature conditions should
also be reviewed.
Processes and job operations that are run only intermittently
may present some of the greatest potential health hazards.
 Industrial Processes or Operation :
Nature and Description of Hazards

1. Abrasive Blasting
• Operation : Automatic or manually
• Use : sand, steel, shot, or artificial abrasives.
• The Dust level of workroom air must be examined to make
sure that the level are not above the TLV and the operator
are not overexposed.
2. Abrasive machining
• Operation : The material is removed in the from of small
particles. Whenever the operation is performed dry, these
particles are projected into the air in the vicinity of the
operation.
3. Assembly Operation
• Improper positioning of equipment and handling of work
parts may present ergonomic hazards due to repeated
awkward motion and resulting in excessive stresses.
4. Ceramic Coating
• Operation : present the hazard of airborne dispersion of
toxic pigments and heat stress from the furnaces and hot
ware.
Industrial Processes …..

5. Bagging and handling of dry materials

• Process : the bagging of powdered material (such as
plastic resins, paint pigments pesticides, cement, etc) is
accompanied by generation of airborne dusts.
• Airborne dusts as a result of the displacement of air from
the bag, spillage, and motions of the bagging machine
and the worker
• The conveying, sifting, sieving, screening, packaging, or
bagging of any dry material present a dust hazards.
• The transfer of dry powder may result in the formation of
airborne dust.
6. Dry Mixing
• Operation : present a dust hazard, should take place in enclosed
mixer
Industrial Processes …..

7. Coating Operation
Operation : A substance containing volatile constituents is
applied to a surface in an industrial workplace, there is
potential for any vapors evolved to enter the breathing zone
of workers.
8. Crushing and Grinding

9. Drying Ovens

10.Electron-beam Welding

11.Fabric and Paper Coating

12. Forming and Forging
Industrial Processes ….

13. Gas Furnace

14. Grinding Operation
15. High Temperature from hot casting
16. Materials handling, Warehousing
17.Metalizing
18. Microwave and Radio-frequency heating operation
19. Molten Metals
20. Open surface tanks
21. Paint spraying
22. Plating
23. Pouring stations for liquids.
24. Punch press, press brake
Industrial Processes …..

25. Vapor degreasing

26. Welding-gas Electric arc.
27. Wet Grinding
28. Wet Mixing