Safety aspects in plant layout:

Most accidents follow a three-step sequence:

 Initiation – The event that starts the accident.
 Propagation – The event/ events that maintain or expand the accident.
 Termination – The event/ events that stop the accident or diminish it in size.
For example, the worker tripped to initiate the accident. The accident was propagated by the
shearing of the valve and the resulting explosion and growing fire. The event was terminated by
consumption of all flammable materials.
Initiation can be diminished by: Grounding and bonding, Inerting, Explosion proof electrical,
Guardrails and guards, Maintenance procedures, Hot work permits, Human factors design,
Process design and Awareness of dangerous properties of chemicals.
Propagation can be diminished by: Emergency material transfer, Reduce inventories of
flammable materials, Equipment spacing and layout, Non-flammable construction materials and
Installation of check and emergency shutoff valves.
Termination can be increased by: Firefighting equipment and procedures, Relief systems,
Sprinkler systems and Installation of check and emergency shutoff valves.

An inherently safe plant relies on chemistry and physics to prevent accidents rather than on
control systems, interlocks, redundancy, and special operating procedures to prevent accidents.
Inherently safer plants are tolerant of errors and are often the most cost effective. A process that
does not require complex safety interlocks and elaborate procedures is simpler, easier to operate,
and more reliable. Smaller equipment, operated at less severe temperatures and pressures, has
lower capital and operating costs.
In general, the safety of a process relies on multiple layers of protection. The first layer of
protection is the process design features. Subsequent layers include control systems, interlocks,
safety shutdown systems, protective systems, alarms, and emergency response plans. Inherent
safety is a part of all layers of protection; however, it is especially directed toward process design
features. The best approach to prevent accidents is to add process design features to prevent
hazardous situations. An inherently safer plant is more tolerant of operator errors and abnormal
conditions.
Although a process or plant can be modified to increase inherent safety at any time in its life
cycle, the potential for major improvements is the greatest at the earliest stages of process
development. At these early stages process engineers and chemists have the maximum degree of
freedom in the plant and process specifications, and they are free to consider basic process
alternatives, such as changes to the fundamental chemistry and technology.
The major approach to inherently safer process designs is divided into the following categories:
 Minimise (Intensification):
o Change from large batch reactor to a smaller continuous reactor
o Reduce storage inventory of raw materials
o Improve control to reduce inventory of hazardous intermediate chemicals
o Reduce process hold-up
 Substitution:
o Use mechanical pump seals vs. packing
o Use welded pipe vs. flanged
o Use solvents that are less toxic
o Use mechanical gauges vs. mercury
o Use chemicals with higher flash points, boiling points, and other less hazardous
properties
o Use water as a heat transfer fluid instead of hot oil
 Moderate (Attenuation and Limitation of effects):
o Use vacuum to reduce boiling point
o Reduce process temperatures and pressures
o Refrigerate storage vessels
o Dissolve hazardous material in safe solvent
o Operate at conditions where reactor runaway is not possible
o Place control rooms away from operations
o Separate pump rooms from other rooms
o Acoustically insulate noisy lines and equipment
o Barricade control rooms and tanks
 Simplification and error tolerance:
o Keep piping systems neat and visually easy to follow
o Design control panels that are easy to comprehend
o Design plants for easy and safe maintenance
o Pick equipment that requires less maintenance
o Pick equipment with low failure rates
o Add fire- and explosion-resistant barricades
o Separate systems and controls into blocks that arc easy to comprehend and understand
o Label pipes for easy "walking the line"
o Label vessels and controls to enhance understanding

The three phases in any industrial safety project are identification, evaluation, and control:
Identification: determination of the presence or possibility of workplace exposures.
Evaluation: determination of the magnitude of the exposure.
Control: application of appropriate technology to reduce workplace exposures to acceptable
levels.
Ventilation and lighting:
Proper ventilation and lighting play very crucial role in the safety
Ventilation plays a crucial role in ensuring plant safety. It helps to maintain a safe and healthy
working environment by controlling the concentration of hazardous gases, vapors, dust, and
fumes that can accumulate in enclosed spaces. Without proper ventilation, these substances can
reach harmful levels, leading to various health risks and potential accidents. Here are a few key
reasons why:
1. Maintaining air quality: Adequate ventilation helps to ensure that the air inside the plant
remains clean and safe to breathe. This is especially important in industrial plants that may
produce pollutants or contaminants that could be harmful to workers or the environment.
2. Preventing the buildup of hazardous materials: Proper ventilation can help to prevent the
buildup of flammable, explosive, or toxic gases, fumes, or dust that can pose a serious threat
to plant safety. This is particularly important in manufacturing plants, where the use of
chemicals and other hazardous materials is common.
3. Controlling temperature and humidity: Proper ventilation can help to regulate the
temperature and humidity inside the plant, which can improve working conditions and
prevent the growth of mold or other harmful microorganisms.
4. Reducing the risk of fire: In addition to preventing the buildup of flammable materials,
adequate ventilation can also help to reduce the risk of fire by removing heat and combustion
byproducts from the plant.
Overall, ventilation is an essential component of plant safety, and it is important to ensure that it
is properly designed, installed, and maintained in order to minimize risks and protect workers
and the environment.
Lighting is an essential aspect of plant safety. Proper lighting can help prevent accidents, reduce
the risk of injury, and improve productivity. Here are some of the key reasons why lighting is
important in plant safety:
1. Improved visibility: Proper lighting can improve visibility in the workplace, making it easier
for workers to identify hazards and avoid accidents. Good lighting can also reduce eye strain
and fatigue, which can improve worker productivity.
2. Prevention of slips, trips, and falls: Adequate lighting can help prevent slips, trips, and falls
by providing better visibility of walking surfaces, stairs, and other potential hazards.
3. Emergency preparedness: In the event of an emergency, such as a power outage or a fire,
good lighting can help workers evacuate safely and quickly.
4. Compliance with regulations: Many industrial plants are required by law to maintain a
certain level of lighting to ensure worker safety.
5. Improved security: Proper lighting can also improve security by deterring theft and other
criminal activity.
6. Visual inspections: In certain industries, such as manufacturing and quality control, proper
lighting is critical to performing accurate visual inspections of products, parts, and
equipment.
Overall, lighting is a critical aspect of plant safety. It is important for plant managers and
workers to understand the risks associated with poor lighting and take the necessary steps to
ensure that adequate lighting is provided at all times. This may include installing additional
lighting, replacing bulbs and fixtures, and conducting regular maintenance and inspections.

Colour codes and Symbols for safety in chemical plants:

In chemical plants, safety is of utmost importance. One way to ensure safety is using colour
codes and symbols to indicate potential hazards and safety measures. Safety signs in the
workplace are an indispensable way of protecting employees from accidents. Their purpose is to
convey information in a comprehensive way about objects and situations that can be dangerous.
In case of a fire, for instance, well placed signs can speed up the evacuation of a building and
help those giving first aid.
Common dangerous situations are:
• Exposure to harmful substances, gases or vapours.
• Machines being repaired or being in maintenance.
• Marked-out danger zones.
• Danger of falling objects.
• Trip hazards and slippery floors.
• Fast evacuation of contaminated places, etc.

Chemical plants use a variety of color codes and symbols to communicate safety information to
workers and visitors. Here are some common examples:
1. Hazard warning labels: These labels are used to identify the hazards associated with a
particular chemical or substance. The labels typically include a pictogram, hazard statement,
precautionary statement, and product identifier. The colors and symbols used on the label
may vary depending on the country or region.
2. Safety signs: Safety signs are used to communicate important safety information, such as the
location of emergency exits, the location of first aid stations, and the location of safety
equipment. The colors and symbols used on safety signs are standardized and may vary
depending on the type of information being conveyed.
3. Pipe marking: In chemical plants, pipes are often used to transport hazardous materials. To
identify the contents of the pipes, color codes are used. For example, yellow is used for pipes
carrying flammable gases, while red is used for pipes carrying fire-quenching fluids.
4. Emergency stop buttons: Emergency stop buttons are used to quickly shut down equipment
in the event of an emergency. These buttons are typically red in color and may be labeled
with the word "STOP" or a symbol of a hand pressing a button.
5. Personal protective equipment (PPE): In chemical plants, PPE is often required to protect
workers from exposure to hazardous substances. The colors and symbols used on PPE may
vary depending on the type of equipment, but often include a symbol of a person wearing the
equipment and may include a color code to indicate the level of protection provided.
Here are some common color codes and symbols used in chemical plants:
1. Red - indicates a potential danger or hazard, such as fire, high temperature, or corrosive
materials.
2. Yellow - indicates caution or warning, such as a potential trip hazard, or materials that can
cause moderate harm.
3. Orange - indicates warning of dangerous equipment or processes, such as electrical or
radiation hazards.
4. Green - indicates safety or emergency equipment, such as safety showers or eyewash stations.
5. Blue - indicates information or mandatory requirements, such as personal protective
equipment (PPE) requirements.
6. Black and white - indicates a specific action, such as start or stop.

Overall, color codes and symbols play an important role in chemical plant safety. They help to
ensure that workers and visitors can quickly and easily identify potential hazards and take
appropriate precautions to protect themselves.

Classification of colour codes and symbols:

Color codes and symbols are essential tools for plant safety management, and they are commonly
used to indicate potential hazards and promote safety in various industries. Warning colors:
These colors are used to indicate potential hazards or danger. For example, red and yellow are
often used to indicate fire, explosion, or chemical hazards.
It can be categorised as:
 Safety colors: These colors are used to indicate the location of safety equipment or to
mark areas of safe passage or exit. For example, green is often used to indicate
emergency exits or safety showers.
 Instructional colors: These colors are used to provide information or instructions. For
example, blue might be used to indicate the location of safety equipment or to provide
directions.
 Hazard symbols: These symbols are used to indicate the type of hazard associated with a
substance or area. For example, a skull and crossbones symbol is used to indicate a
substance that is toxic or poisonous, while a flame symbol is used to indicate a substance
that is flammable or explosive.
  Prohibition symbols: These symbols are used to indicate actions that are prohibited or
dangerous. For example, a circle with a line through it might be used to indicate that
smoking is prohibited in a certain area.
 Mandatory symbols: These symbols are used to indicate actions that are required or
necessary. For example, a symbol might indicate that workers are required to wear
protective equipment in a certain area.
Overall, color codes and symbols play a crucial role in plant safety. By understanding the
meaning and applications of these codes and symbols, workers can better identify potential
hazards and take appropriate precautions to prevent accidents and injuries.
Safety Signs are the information or instructions about health and safety on labels or on
signboards with a specific colour, an illuminated sign or acoustic signal. The companies must
provide and cater safety signs to employees where there is considerable risk to health and safety.
Signs are self- descriptive, illuminated, and deliver safety messages at a glimpse. Specific
colours, shapes, and symbols can appropriately convey information and alerts. Safety signs are
independent of languages. Mostly universal graphical images are used.
There are two types of Chemical Safety Signs:
1. Signs for Hazard Communication
2. Informative Signs for Safety Instructions.
Hazard pictograms alert us to the presence of a hazardous chemical. The pictograms help us to
know that the chemicals we are using might cause harm to people or the environment.
Colour codes for gas cylinder:
Colour codes for gas cylinders are used to indicate the type of gas contained in the cylinder and
any potential hazards associated with handling the cylinder. Here are some common color codes
used for gas cylinders:
Colour coding is helpful in identification of gas cylinders and lines even by laymen provided
they are familiarised with such colour codes. Almost all countries follow their own guidelines
but efforts have been made to prescribe universal colour coding. British Compressed Gases
Association introduced cylinder identification and colour coding scheme through BS EN 1089 –
3
which has been harmonised in the European Union. The colours used for medical gases are
harmonised on the basis of ISO 32 standard. The colour coding is applied to the shoulder or the
curved portion of the cylinder and it identifies the property of the gas inside the cylinder.
Yellow – toxic
Red – flammable
Light blue – oxidising
Bright Green – inert
A gas cylinder having two concentric colour bands indicates a combination of properties. The
body of the cylinder can be of any colour of manufacturer’s choice but it should not lead to
confusion regarding risk associated with the gas as indicated by the shoulder colour.
For the purpose of easy identification and the shoulder colours can refer to the gas inside the
cylinder. Some typical examples are:
Hydrogen - Red
Nitrous oxide - Blue
Nitrogen - Black
Oxidant - White
Compressed air: The color of a compressed air cylinder is usually plain aluminum or stainless
steel, with no color coding required.
Oxygen: Oxygen cylinders are typically green or white with a green band.
Nitrogen: Nitrogen cylinders are typically black or blue with a green band.
Carbon Dioxide: Carbon dioxide cylinders are typically gray with a green band.
Argon: Argon cylinders are typically light green or gray with a brown band.
Helium: Helium cylinders are typically brown with a green band.
Acetylene: Acetylene cylinders are typically maroon with a white band.
Propane: Propane cylinders are typically orange with a white band.

Colour codes for pipelines:

In the chemical industry, pipelines are used to transport a wide range of fluids and gases, some of
which can be hazardous or dangerous if not handled properly. To promote safe handling and
identification of these pipelines, specific color codes are used.
This Indian standard (IS 2379-1990 PIPELINES -IDENTIFICATION – COLOUR CODE)
covers the colour scheme for the identification of the contents of pipelines carrying fluids in
domestic and public buildings and such industrial installations where a specific colour code
does not exist. For the purpose of this standard, piping systems shall include pipes of any kind
and in addition fittings, valves, and pipe coverings. Supports, brackets or other accessories are
specifically excluded from application of this standard. This standard is not applicable to
pipelines buried underground or used for electrical services.
Lettering is painting, labelling, stencilling or otherwise indicating the contents of a pipeline.
PAINTS:
Appropriate quality of paints conforming to relevant Indian Standards, shall be used for colour
marking. It is recommended that the paints used should produce a glossy finish.
COLOURS:
In order to identify the contents of the pipelines, a large number of colour shades are required.
The system of colour coding consists of a ground colour and colour bands superimposed on it.
Ground Colours: The ground colour identifies the basic nature of the fluid carried (see Fig. 1)
and also distinguishes one fluid from another, for example water from oil.

The various ground colours (also called basic identification colour) are indicated in Table 1.
Colour Bands: Colour bands are superimposed on the ground colour (see Fig. 2) to distinguish:
a) One kind or condition of a fluid from another kind or condition of the same fluid, or
b) One fluid from another but belonging to the same group, for example carbon monoxide from
coke oven gas or diesel fuel from furnace fuel.