Assessment of fire and explosion risk that may occur in reactors in industrial chemical plant manufactured with flammable liquids

Preparation of Explosion Protection Document was carried out in the facility where flammable and combustible chemicals are found in the reactor at the industrial facility. Flammable and flammable chemicals are used in the process in the facility. As a result of the work done, the areas where possible explosive atmosphere in the facility can be formed were determined. Danger zone classes have been identified in potentially explosive atmospheres. ATEX certified exproof equipment or equipment should be used in appropriate areas and categories in these areas. When evaluating the potentially explosive environments that may occur in the facility and the magnitude of a possible explosion effect, other than major industrial accidents and catastrophic errors or normal working conditions in accordance with the Regulation on Prevention and Mitigation of Major Industrial Accidents and Article 1c of TS EN 60079-10-1: 2015; and rare abnormal malfunctions are excluded. As a result, hazardous areas are classified by evaluating possible explosive environments in the facility, and the explosion risk assessment is made by determining the types of equipment to be used in these areas and the measures to be taken. A risk assessment study has been conducted on the fire and explosion risks that may occur in reactors in an industrial chemical plant where production is carried out using flammable liquids. Various hazards and risks that can result in explosions and fires are encountered in the facility where chemical raw materials are converted into usable substances. The definitions of chemical substances, the production and historical use of chemical substances, and the increasing number and variety of chemicals used in the chemical industry with advancing technology are also increasing. The chemical industry is one of the most important sectors in the manufacturing industry. The chemical sector is largely dependent on imports both in terms of raw materials and technology. The petrochemical market in Turkey is one of the fastest-growing markets globally, following China and India. Definitions of hazardous substances and preparations provide information about the dangers to the health, safety, and environment of employees. Classification, packaging, and labeling of hazardous substances and preparations are carried out in compliance with the regulations, and these classifications are taken into account in all industrial activities (production, transportation, storage, handling, etc.). Chemical-containing facilities can pose many risks to both human health and the environment. General risks associated with these facilities include: -Fire and explosion hazards -Health hazards -Environmental hazards Specific chemical risks depend on the type of chemicals stored, processed, or handled in the facility, such as: -Chemical spills or leaks -Chemical reactions -Chemical exposure -Chemical waste disposal It is important for facilities containing chemicals to implement appropriate safety measures for the proper storage, transportation, labeling, and disposal of chemicals, as well as to train employees in safe practices and emergency procedures. Chemical facilities have many potential causes of accidents, which can vary depending on the specific structure of the facility and the chemicals involved. Some common causes of accidents in chemical facilities include: -Human error -Equipment failure -Electrical problems -Chemical reactions -Natural disasters -Sabotage or terrorism To prevent accidents in chemical facilities, it is important to apply strict security protocols such as regular equipment maintenance, employee training, and safety inspections. Conducting risk assessments is also important to identify potential hazards and take steps to mitigate them. There are four main causes of accidents in chemical facilities: human error, lack of training, manufacturing defects, and failure to perform maintenance and controls. When we examine accidents in the chemical industry, we can say that they occur mainly due to fire and explosion incidents at both national and international levels. For an explosion event to occur, the following factors must be present simultaneously: -Explosive mixture -Oxygen -"Ignition Sources" such as sparks, heat-temperature, open flame, or static electricity. Fires and explosions are not unavoidable events. Measures to protect all employees from flammable and explosive environments and risks are specified in regulations and directives. After identifying hazardous areas and determining the hazardous zone classification, equipment suitable for the identified hazard zones should be used based on risk assessment studies. To prevent explosions and ensure protection from them in the workplace, measures should be taken that are suitable for the nature of the operations performed. These measures should adhere to the basic principles and priority order mentioned below. To ensure safe working conditions in areas where there is a possibility of an explosive atmosphere in the workplace, the following measures are taken: -Evaluation of the ignition and explosion risks -Implementation of risk assessment -Design, operation, control, and maintenance of work equipment within the work areas should be done in accordance with safety regulations. -Evaluation of the possibilities of the presence of ignition sources and the occurrence of static electricity in the workplace. -Measures appropriate to the nature of the operations performed should be taken for the prevention of explosions and protection from them. -The Occupational Health and Safety department in the facility has created safe working instructions, and it is necessary to comply with these instructions. -Areas where explosive atmospheres may occur in the facility have been classified according to the following criteria: 1.Flammable and explosive chemicals are used in the process in the facility. As a result of the work conducted, potential areas where explosive atmospheres may occur in the facility have been identified. Risk assessment studies have been conducted for these areas. 2.Hazardous zone classifications have been determined for potential explosive atmospheres. In these areas, appropriate group and category ATEX certified explosion-proof equipment should be used. 3.When assessing potential explosive atmospheres and the magnitude of a possible explosion effect in the facility, the Regulation on the Prevention of Major Industrial Accidents and the Reduction of their Consequences and TS EN 60079-10-1:2015 standard, section 1c, exclude assessment of major industrial accidents, catastrophic errors, or rare abnormal failures outside normal operating conditions. Specific measures should be taken to prevent the formation of explosive atmospheres throughout the workplace. ATEX equipment should be used in processes. Ventilation systems should be available in relevant sections for occupational health and safety (OHS) practices. The entire facility should be protected against lightning risks with lightning rods. Safety data sheets for chemicals should be available. In conclusion, potential explosive atmospheres in the facility have been evaluated, hazardous zones have been classified, and explosion risk assessments have been conducted by determining the types of equipment required and the precautions to be taken in these areas. As a result, the danger zones were classified by evaluating the possible explosive environments in the sample facility, and the types of equipment to be used in these zones and the precautions to be taken were determined and an explosion risk assessment was made. The risk assessment method was carried out according to the fine kinney risk assessment method. During the facility design process, fire and explosion risks in production facilities with flammable and combustible chemicals should be evaluated and the facility should be designed according to the evaluation results. When we consider the risks of flammable and combustible chemicals; It creates fire, explosion, volatile harmful gases. In order for these not to pose a risk in terms of employee health and safety, effective ventilation systems should be established in danger zones, vocational training should be given to ensure that employees are aware of the risk, exproof equipment should be selected and used in accordance with the danger zones. Grounding systems against static electricity should be ensured to be in working condition. Constant control and surveillance should be provided.