ANALYSIS OF DISTILLATION FLASK EXPLOSION AT X LABORATORY, FACULTY OF ABC YZ UNIVERSITY ZULKIFLI DJUNAIDI

Transcription

1 ANALYSIS OF DISTILLATION FLASK EXPLOSION AT X LABORATORY, FACULTY OF ABC YZ UNIVERSITY ZULKIFLI DJUNAIDI Presented at The 2 nd Asian Conference on Safety and Education in Laboratory December 2 nd, 2015 Depok, Indoesia

2 Introduction Distillation is one of important competence that has to be achieved by under-graduated student at Faculty ABC. Chemicals, instrumentations and experiment activities involved in distillation experiment contain significant hazards that need to be assessed and controlled beforehand. Failure of identifying and treating the risk will lead to an unexpected event.

3 Objectives Analyze the incidence of distillation flask explosion in Qualitative Chemical Laboratory, Faculty of ABC Arrange recommendations of control measures, so the same accident will not occur in the future. Take lesson learned from the incident that occurred.

4 Methods Desk-top review Discussion and Site Visit Data Analysis Report and Recommendation Study the results of investigation that has been conducted by OHSE Team of YZ University Collect secondary data Held a meeting to discuss with management of faculty Conduct Laboratory visit Fault Tree Analysis (FTA) Event Tree Analysis (ETA) Bow Tie Analysis Report of analysis results Recommendation for improvements

5 Chronology of Event Group A5 has a mixture of benzoate acid, resorcinol, isopropanol, and water. The experimental procedure was performed as follows: The distillation flask which already containing the mixture boiled over asbestos gauze using a spirit lamp. Based on one of group member information, before distillation flask exploded, the contents of the flask was running out while the spirit lamp still on fire. That member does not inform the temperature of distillation flask before exploded. The distillation flask of Group A5 exploded, then the activity was stopped. Source: Press release of Faculty, 2015

6 Distillation Flask Explosion Fault Tree Analysis Over pressure (FTA) Over heating Heating time over the limit The procedure of experiment incompatible with the safety aspect The students and supervisors did not control the heating process according to specified time and temperature The heater is not equipped with the process temperature control proses The procedure has not prepared by considerin g the potential risks There is no hazard communicati on OHS induction has not been done before the experiment Lack of understanding of critical hazard The response of student is less than optimal The room capacity did not based on the number of students The condition of Lab environment not appropriate Poor lighting in the Laboratory Lack of supervision The number of supervisors incompatib le with the number of students Using an open flame to warm up There is no warning system at the time of hazardous process condition Performed a week before the experiment Safety briefing has not been done before the experiment There is no safety sign

7 Event Tree Analysis INJURY Serious: 2 person Minor: 13 person Hospital cost: (ETA) Facility Damage Flask distillation damage EXPLOSION Laboratory Damage The cessation of experiment activity The image of University dropped Media publication The experiment using open flame is stopped The activity of distillation is stopped The experiment activity suspended for 2 weeks Newspaper TV Internet

8 Bow Tie Method THREAT 1: Human Resources THREAT 2: Facilities and Infrastructure CONSEQUENCES 1: SPILL THREAT 3: Procedures Distillation Flask Explosion THREAT 4: Work Environment CONSEQUENCES 4: FIRE THREAT 5: Material PREVENTION MITIGATION

9 Bow Tie Analysis Threat T1.2 Lack of supervision as result of the ratio between the number of students and supervisors (experiment assistant, lab assistant, and lecturer) inadequate. Barrier B1.2 Ensure the presence of supervisors in the Laboratory. Ensure that supervisors conduct supervision. Ensure the ratio of students and supervisors.

10 Bow Tie Analysis (2) Threat T1.3 Unsafe act of Human Resources, such as lack of concentration during experiment, not follow Standard Operating Procedure (SOP), etc. Barrier B1.3 Develop and communicate Standard Operating Procedure (SOP) in the Laboratory.

11 Bow Tie Analysis (3) Threat T2.2 The heater is not comply with safety standards. Barrier B2.2 Ensure to use the heater that has a process temperature control.

12 Bow Tie Analysis (4) Threat T2.4 Human resources (students) do not use appropriate PPE. Barrier B2.4 Provide and ensure that HR use appropriate PPE. The PPE in distillation experiment are: 1. Lab coat 2. Safety gloves 3. Safety goggles 4. Chemical mask

13 Bow Tie Analysis (5) Threat T3.3 Emergency response procedure and hazard communication procedure are not available. Barrier B3.3 Ensure that safety procedure in the Laboratory is available and has been communicated through safety briefing or induction before conduct the experiment.

14 Bow Tie Analysis (6) Threat T4.3 Lack of housekeeping Barrier B4.3 Ensure that the chemicals are placed in the chemical storage room and the student bags are placed in the locker, etc.

15 Bow Tie Analysis (7) Consequences Recovery Measure/Mitigation C1 Chemical spills M1 Decontamination and handling spills procedure C2 Inhaled chemical/ poisoning M2 M3 M2 The availability of spill kits The availability of chemicals or contaminated materials disposal. Emergency response procedure in the Laboratory C3 Injury M3.1 The availability of first aid box in accordance with standard medicine M3.2 Emergency response procedure in the Laboratory C4 Fatality M4 Emergency response procedure in the Laboratory C5 Fire C5.1 The availability of fire extinguisher which appropriate to chemical in the Laboratory. C5.2 Emergency response procedure in the Laboratory

16 Recommendation Attention to the design of Laboratory, include: The spacious of Laboratory: <70 m 2 for <25 person 85 m 2 for 30 person The minimum of bench wide (lab table) per practitioner = 0.30 m 2, The minimum of table length per practitioner = 600 mm. There is a space under the table for the knee when the student works while sitting. The minimum of roof height = 2,7 m from floor

17 Recommendation (2) Have the locker to store bags, books, etc. The minimum of lighting = 300 lux There are eye and body shower There is a fire extinguisher according to the chemicals There is the spillage kit Well ventilated

18 Recommendation (3) Arrange and communicate: Safe work procedure in the Laboratory Chemical spills handling procedure Emergency response procedure

19 Recommendation (4) Improve the housekeeping : Store the chemicals in separated place Move the materials that are not used in the Laboratory

20 Recommendation (5) Implement chemical safety, such as: MSDS Proper labelling Waste disposal Chemical storage

21 Recommendation (6) Work procedure: Review of safety aspect List of the maximum temperature which is allowed during distillation.

22 Recommendation (7) Heating flame with bunsen/spirit lamp is not recommended. Use the ceramic cavity heater, steam coils, hot water, nonflammable liquid bath/ electric heating mantle. Ensure that the surface of coil on the heating mantle is not damaged. Do not use hot plates, unless spark-proof. The addition of boiling chips to ensure homogeneous heating and not bumping. Thermometer to measure the reaction of temperature, and installed near the solvent.

23 Recommendation (8) The materials should be used: Not to do the distillation of organic compounds, or evaporate dry organic compounds because organic compounds can form explosive peroxides. For example: alcohol compounds, unsaturated hydrocarbons can form peroxides compounds when heated.

24 Recommendation (9) Personal Protective Equipment (PPE) should be used: Laboratory coat Closed shoes Safety goggles Neoprene gloves Safety mask

25 Thank You