Complex Assignment Mohd Fazlieman 45688.docx

Department of Chemical Engineering and Energy Sustainability Faculty of Engineering

KNC 4253: OPERATIONAL SAFETY AND HEALTH

OSHA Assignment

MOHD FAZLIEMAN BIN GURAHMAN (45688)

Bachelor of Engineering with Honours (Chemical Engineering) 2017

Complex Assignment KNC 4253 Sem-1/2017-2018 Marks 10 Question: The following paragraph describes one of the accidents happened in the past. Evaluate the causes of accident, and recommend two (2) important actions t hat will reduce the  possibility of a similar accident from happening again and state the reasons.

Zoalene is one of the materials used at the Dow Chemical Company at King’s Lynn,  Norfolk. On 25 June 1976 at 3 pm, a batch of zoalene was charged to a dryer. The steam supply to dryer was shut off at 2 pm on 26 June. The material was left in the dryer with temperature of approximately (120 –  (120 –  130)  130) oC. The following day, on 27 June at 5.07 pm, the shift foreman on duty heard odd sound came from the dryer, and immediately activated the emergency alarm. Unfortunately an explosion occurred at 5.10 pm killed one man, and caused extensive damage on the plant (Lees, 1996).

Answer On 27 June 1976 at 5.07 pm, an explosion occurred at the Dow Chemical Company at King’s Lynn, Norfolk. The explosion killed one man and cause extensive damage to the plant. An investigation has been made to identify the causes of the explosion. The explosion involved a detonation of Zoalene. Zoalene is a poultry feed additive that used at the Dow Chemical Company. After the drying process had been completed, the Zoalene had been left inside a closed dryer vessel for a period of twentyseven hours. The insulation of the dryer maintained the Zoalene at a temperature  between (120-130)°C. The Zoalene began to decompose under that condition. The evolution of heat causing self-accelerating decomposition of Zoalene which led to detonation. It appears that materials could have been left in dryer for twenty four hours and more before being transfer to the holding hopper. The Clopidol plant that use t o dry the Zoalene is been fitted with dust explosion suppression equipment. When it comes to Zoalene processing, it show that an appreciable leakage of dust which necessitated fitting exhaust ventilation to the elevator and hopper. It was discover that the stock of Zoalene were low in infrared assay, being only 96-98 percent of purity. The minimum standard for purity that has been demanded is 98 percent whi ch doesn’t followed by the 2

company. The low assay maybe caused by the presence of impurities. This factor may disturbed the drying process involving the Zoalene that can cause accident. Some of action should be taken to prevent this accident from occur again. The company should conduct a training in handling hazardous and explosive chemical to their employee. This is to reduce the risk of accident during the process that involve the chemical and the increase the awareness of the employee on the safety when handling hazardous chemical. The company should also hire a safet y officer to monitoring changes in plant  processes. The safety officer can make a good decision whether the process or the chemical are safe to use. The company should also improve the safety and emergency response in their plant. This can help them to prepare themselves if any accident occur. The company should do risk and hazard assessment before conducting a process. This method can help them to identify any possible hazard that can cause by the operation or process and some control measure can be taken to avoid the accident.

3