Module 7 – Safety & Emergency Response

Objective:
By the end of this module, a trainee will be able to:

1. Identify potential hazards in a butadiene/petrochemical plant.

2. Understand the purpose and operation of emergency response systems.

3. Apply basic fire, gas, and toxic exposure safety practices.

4. Recognize the steps for safe evacuation and emergency shutdown.

5. Integrate safety principles into routine operator work.

7.1 – Introduction to Safety in Petrochemical Plants

Definition:

• Safety = preventing accidents, injuries, environmental harm, and damage to equipment.

• Operators are first line of defense in hazard detection and response.

Key Principles:

1. Hazard Awareness: recognize flammable, toxic, reactive, or high-pressure chemicals.

2. Prevention: follow SOPs, interlocks, alarms, and PPE requirements.

3. Preparedness: know emergency procedures, exits, and response hierarchy.

4. Communication: alert control room and other personnel immediately.

Analogy:

• Safety is like seat belts, airbags, and smoke detectors: preventing accidents and reducing consequences.

7.2 – Common Hazards in Butadiene Plants

• Flammable Chemicals

Butadiene, hydrocarbons

Avoid sparks, follow grounding, inert tanks if needed

• Toxic Exposure

VOCs, hydrogen sulfide (trace)

Use PPE, monitor gas detectors, avoid confined spaces

• High Pressure

Reactors, compressors, storage tanks

Never open pressurized lines, monitor relief valves

• High Temperature

Reactors, heat exchangers, steam lines

Avoid contact, follow SOPs, check insulation

• Mechanical

Pumps, compressors, moving parts

Observe vibration, noise, and leaks

• Electrical

Panels, motors, instrumentation

Follow LOTO, PPE, and interlock safety

Operator Tips:

• Conduct daily hazard awareness rounds.

• Understand which hazards are present in each unit.

• Never ignore alarm indications or unusual observations.

7.3 – Fire Safety

Sources of Fire:

• Flammable gases and liquids (butadiene, hydrocarbons).

• Hot surfaces or sparks.

• Static electricity or friction.

Preventive Measures:

• Grounding & bonding of tanks and vessels.

• Control ignition sources (no smoking, spark control).

• Maintain firewater systems and foam monitors.

Emergency Response:

1. Raise alarm immediately.

2. Follow ESD procedure if necessary.

3. Evacuate non-essential personnel.

4. Use fire suppression (foam, water, dry chemical) if trained.

5. Report incident to control room and safety team.

Analogy:

• Fire prevention = “keeping candles away from curtains”

• Fire suppression = “using fire extinguisher immediately before fire spreads”

7.4 – Gas Leak & Toxic Exposure

Common Gases:

• Butadiene (flammable), VOCs (toxic), hydrogen sulfide (trace).

Operator Response:

1. Detect via gas detectors and alarms.

2. Evacuate personnel from affected area.

3. Initiate ESD if leak is severe.

4. Vent or purge lines according to SOP.

5. Use PPE and SCBA (self-contained breathing apparatus) if entering area.

Preventive Measures:

• Regular inspection of flanges, valves, and compressors.

• Ensure nitrogen blanketing and pressure relief devices are functional.

• Follow confined space entry procedures.

Analogy:

• Gas detection = “smoke detector for invisible hazards”

• Venting/purging = “letting out dangerous fumes safely”

7.5 – Emergency Shutdown (ESD) Procedures

Purpose:

• Safely stop plant or unit operation to prevent escalation of hazard.

Operator Role:

• Recognize alarm triggers or abnormal conditions.

• Activate local or panel ESD if required.

• Follow SOP for stepwise shutdown of units.

• Communicate status to control room.

Key Points:

• Do not attempt manual override unless authorized.

• Always confirm pressure and temperature stabilization after shutdown.

• Assist in safe evacuation if required.

Analogy:

• ESD = “emergency brakes in a train”: stop operations safely to prevent accident.

7.6 – Evacuation & Muster Points

Evacuation Protocol:

1. Recognize alarm and follow site evacuation signal.

2. Exit via designated route; avoid shortcuts through hazardous areas.

3. Assemble at designated muster point.

4. Report attendance to safety officer or supervisor.

5. Await further instructions.

Operator Tips:

• Know all escape routes and muster points.

• Assist new personnel or visitors.

• Never re-enter until declared safe.

Analogy:

• Muster point = “lifeboat on a ship”: safe gathering spot during emergency

7.7 – Personal Protective Equipment (PPE)

Types of PPE:

• Helmets, safety glasses, gloves, chemical suits, hearing protection

• SCBA for toxic gas exposure

• Fire-resistant clothing for flammable areas

Operator Tips:

• Always wear PPE according to unit and task requirements.

• Inspect PPE before use for damage or wear.

• Store PPE in designated clean areas.

Analogy:

• PPE = “armor for the operator” against physical, chemical, and thermal hazards

7.8 – Safety Observation & Reporting

Operator Practices:

1. Conduct daily safety rounds: check fire equipment, gas detectors, alarms.

2. Report near misses or unsafe conditions immediately.

3. Record observations in safety logbook.

4. Participate in emergency drills regularly.

Analogy:

• Safety observation = “checking smoke detectors and fire extinguishers at home”

7.9 – Quiz / Knowledge Check

1. Name three common hazards in a butadiene plant.

2. What is the operator’s first action when a fire alarm activates?

3. Why is nitrogen blanketing used in butadiene storage?

4. What does ESD stand for, and why is it important?

5. List two key points for safe evacuation.

6. Name three types of PPE commonly used in petrochemical plants.

7.10 – Media Sites Integration

• Videos:

  • Fire alarm and response animation

  • Gas leak detection demo (conceptual)

  • Emergency shutdown walkthrough

  • Evacuation drill animation

• Diagrams / Infographics:

  • Hazard matrix

  • ESD flowchart

  • Evacuation routes and muster points

  • PPE selection chart

• PDF Downloads:

  • Fire & gas emergency procedure checklist

  • Daily safety round checklist

  • Operator PPE guide

• Interactive:

  • Embedded quizzes and scenario exercises

7.11 – Summary & Key Takeaways

1. Safety is the top priority for all plant operations.

2. Operators must recognize hazards, respond to alarms, and follow SOPs.

3. Fire, gas, toxic exposure, and mechanical hazards require immediate and correct action.

4. Emergency shutdown (ESD) and evacuation procedures protect people and equipment.

5. Daily safety rounds, PPE compliance, and reporting ensure a safe and prepared workplace.