CHEMICAL INDUSTRY IN MALAYSIA-CIMAH.pptx

Penyimpanan dan Pengendalian Bahan
Berbahaya Mengikut Peraturan CIMAH,96
Section CIMAH, Petroleum Safety Division
Department of Occupational Safety and Health Malaysia
Ir Noorazman Bin Soud
SEMINAR PENGENDALIAN BAHAN KIMIA
MERBAHAYA DAN KERJASAMA
INTER AGENSI SEMASA KECEMASAN

Department of Occupational Safety and Health
Content Of Presentation
 Introduction on CIMAH regulation 1996
 Distribution of MHI and NMHI in Malaysia
 Sharing Compilation Data on Major Hazards Accident
 Obligation of Manufacturer, Employee, Local Authority, DOSH
 Safety Report, ERP, ITP & DOSO
 Common Industrial Storage & Operation
 Collaboration With Related Agencies
 Conclusion

Introduction
 Section 15, OSHA 1994 stated duty of the employer and every self-
employed to ensure, so far as practicable, the safety, health and
welfare at work for all his employees.
 In line this section, reg. 5 Control of Industrial Major Accident Hazards
(CIMAH) 1996 – Every manufacturer who undertakes an industrial
activity shall comply with the requirements of these regulation
 Being enforce since February 1996
 Control of risk related to hazardous substances part of new OSH MP
2020

Definition & Terminology
 Hazardous substance- any substance which is within any of the criteria
laid down in schedule 1 or any substance listed in part 1 of schedule 2
 Industrial activity- an operation carried out in an industrial installation
referred to in schedule 4 involving or likely to
involve one or more hazardous substances includes
on site sotrage and on-site transport which are
associated with operation;
 Industrial activity- a storage of hazardous substances or preparations at
any place, installation, premises, building or area land,
whether isolated or within establishment, being a site
used for the purpose of storage

Definition & Terminology(cont.)
 ‘ major accident’- an occurrence including major emission, fire or explosion
resulting from uncontrolled development in the
course of industrial activity which leads to danger to
persons , whether immediate or delayed or inside or
outside an installation, or to the environment involving one or
more hazardous substance.
 ‘MH installation’- an industrial activity which produces, processes, handles
, uses, dispose of or stores, whether permanently or
temporary, one or more hazardous substances or
category or categories in quantities which is or
equal to or exceed the threshold quantity.

Objective of CIMAH
 To prevent major industrial accidents
 To limit the consequence to people and environment
 2 major concern in CIMAH :
Type of hazardous substance Quantity of hazardous substance
Toxic Specify threshold
Flammable Indicative criteria
Explosive
Highly reactive

Classification of Industrial Activities
NON MAJOR
HAZARD
INSTALLATION
MAJOR
HAZARD
INSTALLATION
EXCLUDED
INDUSTRIAL
ACTIVITIES
TQ
10% OF TQ
QUANTITY OF HAZARDOUS SUBSTANCE
[QHS<10% TQ] [10% TQ<QHS <TQ ] [QHS >TQ ]
REFER TO SCHEDULE 1 AND 2 FOR TYPE AND THRESHOLD
QUANTITY OF HAZARDOUS SUBSTANCE
Note: QHS - Quantity of hazardous substance
TQ - Threshold quantity
NMHI MHI

46
31
36
62
49
110
10
32
18
59
72
140
24
122
22
47
55
6
12
22
101
20
60
779
297
Up to 14 Mac 2017
Distribution of MHI and NMHI in Malaysia

Update data until 17 March 2017
Others
Textile Manufacturing
Insecticide mixing
Bulk Storage and Bottling of Ammonia Gas
Glove Manufacturing
Air Separation Plant
Bulk Storage of Hazardous Substance
Bulk Storage of Petroleum Products
LPG Cylinder Storage
Bulk Storage and Bottling of LPG
Petrochemical Plant
Water Treatment Plant
Chemical Processing Plant
47
13
4
2
19
1
30
44
35
9
28
57
30
236
0
5
1
38
12
16
21
324
54
2
166
29
MHI NMHI
Statistics of MHI and NMHI in Malaysia

Example of Major Hazards Accident
Substance Involve
Death Injury
Location Year
Phosgene 10 0 Mexico 1950
Cyclohexane 28 89 Flixborough, UK 1974
Dioxin/TCDD 30 320,000 Seveso Italy 1976
Hydrogen sulphide 8 29 Chicago 1978
Methyl isocyanate 2,000 200,000 Bhopal, India 1984
LPG (Explosion) 650 2,500 Mexico City 1985
Fireworks 11 8 Philippines 1986
Chlorine 0 76 USA 1986
Ammonium nitrate 6,000 evacuated France 1987
Methane (fire) 4 1 Italy 1987
Ammonium Nitrate 173 797 Tianjin, China 2015
Consequences

Example of Major Hazards Accident in Malaysia
Location
Death Injury
Event Year
Bright Sparklers,
Sungai Buloh
22 103 Fire works factory
explosion
1991
Matan Maju,
Beranang
2 3 Fire works factory
explosion
1992
Shell Tiram Kimia,
Port Klang
13 solvent depot fire
and explosion
1992
Shell MDS,
Bintulu
12 Air separation unit
explosion
1997
Consequences

 Flixborough 1 June 1974
Release of cyclohexane
plant destroyed
28 people killed

 Flixborough
Interconnection pipe
of Reactor No.5
replaced by a dog-leg
shaped pipe – failure
in management of
change
4
6
5

 Bhopal: 3 December 1984
Over 3500 people were killed
immediately and
170 000 sought medical
treatment

 BP Texas City Refinery : 23 March 2005
15 DEAD
100 INJURED
30 PUBLIC INJURED
8 IN CRITICAL CONDITION
USCSB :organizational and safety
deficiencies at all levels

 Hertfordshire Oil Terminal Fire, UK : 11 December 2005
15 DEAD
100 INJURED
30 PUBLIC INJURED
8 IN CRITICAL CONDITION

 Shell Middle Distillate Synthesis (Shell MDS) : 25 December 1997
• Air separation unit
exploded
• 12 people injured

Container Storage Station, Port of Tianjin , China
 Series of Explosion, 12 August 2015
Some Facts:
Cause : Ammonium Nitrate
Total No’s of Death: 173
Injuries: 797
Economy Impact: Multi Million USD

ARE WE DOING ENOUGH TO KEEP MAJOR HAZARD SAFE FROM
ACCIDENT OR DISASTER IN FUTURE?
Enforcement
Role & Responsibility Duty

Obligation of DOSH
 Enforced regulation on CIMAH 1996
 Receive notification of industrial activity from manufacturer and develop
an installation inventory in the nation
 Assess safety report and emergency plan
 Conduct Compliance Audit
 Conduct Accident Investigation
 Interview and gazette the CIMAH Competent Person

0
8
14
9
22
2
10
9
25
11
10
0
7
10
4
0
1
3
4
14
0
7
3
7
3 3
0
3
0 0
0
5
10
15
20
25
30
Perlis
Kedah
Pulau
Pinang
Perak
Selangor
WPKL
&
Putrajaya
Negeri
Sembilan
Melaka
Johor
Pahang
Terengganu
Kelantan
Sabah
Sarawak
WP
Labuan
Pencapaian Tahap Pematuhan Pepasangan MHI Mengikut Negeri (2012-2016)
Memuaskan (A,B,C) Tidak Memuaskan (D,E)

45
39
18
24
15
10
15
6
13
4
0
5
10
15
20
25
30
35
40
45
50
2012
2013
2014
2015
2016
Pencapaian Audit Pematuhan MHI mengikut Tahun (2012 - 2016)
Memuaskan (A,B,C)
Tidak Memuaskan (D,E)

Obligation of Manufacturer
Major Hazard Installation (MHI) Non Major Hazard (NMHI)
Notify to DOSH of an industrial activity Notify to DOSH of an industrial activity
Prepare and submit Safety Report and
On-Site Emergency Response Plan to
DOSH
Prepare and submit Demonstration
Operation Document and Emergency
Response Plan to DOSH if DG request
Keep up to date report and plan Keep up to date report and plan
Inform to the local authority -
Help local authority to prepare off-site
ERP
-
Inform to the public -
Inform DOSH of any major accident Inform DOSH of any major accident

Obligation of Employee (MHI & NMHI)
 Co-operate with the manufacturer in complying the CIMAH
 Act in such a manner as not to endanger or injury to himself or
other persons or damage to life and property
 Notify the manufacturer as soon as he becomes aware of any
potential hazards

Obligation of Local Authority
 Received notification from MHI manufacturer of the following –
 Category of the plant (MHI)
 Need for preparation of off-site ERP for that particular area
 Prepare, keep up to date and implement an off-site emergency
response plan

Importance of Safety Reports
 The core of the information for determining:
 The suitability of the prevention and control measures;
 The events which the manufacturer’s on-site emergency plan should be
designed to handle;
 The events which off-site emergency plans should be capable of dealing with;
and
 The identification of the key areas for dosh’s inspection effort.

Importance of Safety Reports
 Objective of the document are being to:
 Identify the nature and scale of use of the dangerous substances
 Describes the type, relative likelihood and consequences of major accidents
 Describe the arrangements for safe operation and control and mitigation of
major accidents.
 The document is of practical use:
 As a management tool for use by the company; and
 As a tool for inspection for use by inspector.

Contents of Safety Reports
 Information to be included in a report:
 Information relating to every hazardous substance
 Information relating to the installation
 Information relating to the management system for controlling the
industrial activity
 Information relating to the potential major accidents in the form of
risk assessment.

ERP
o Distribution list
o Equipment/maintenance Requirement
o Training requirement schedule
o Procedure update
o Equipment/alarm testing frequency
o Evaluation/Audit Reports
o Debriefing
o Requirements of incident reports
o Organizational Chart & Roles and Responsibility
o Notification List and Call Out List
o Plant Site Map and Security
o Emergency Equipment List
o Evacuation, Rescue and First Aid Operation Procedure
o Emergency Shutdown Procedure
o List & Location of Hazardous Materials including MSDS
o Relatives/Media Response Guide
o Audit Checklist
o Breakdown of First Line Response Centers, etc & function
o Specific Response to Fire, Explosion, Toxic, etc.
o Specific Response to On-Site Emergencies.
o Alarm Sequences
o Termination of Emergency
01
02
03
Plan, Administration
and Maintenance
Information
Emergency Action
Procedure and Format

Emergency Response Plan (ERP)
On-site ERP Off-site ERP
Prepared and keep up to date by
manufacturer MHI and NMHI
Prepared and keep up to date by
local authority under CIMAH
Plan to deal with emergency that can
cause damage
inside plant
and required minimum
response from outside emergency
services
Plan to deal with emergency that can
cause damage
inside and outside plant
and required extensively
response from outside emergency
services

Information to Public (ITP)
 Information to be communicated:
 Name of manufacturer and address of site of industrial activity
 Identification by position held of person giving the information
 Confirmation the major hazards site and safety report submitted
 Brief explanation on site activity
 Names of hazardous substances
 Information relating to the nature of a major accident hazard
and potential effects
 Information on how the population concerned will be warned
and kept informed of accident

Information to Public
 Information to be communicated (continued):
 Information on the action the population concerned should take
in the event of accident
 Arrangement on site and liaison with off-site emergency
services to deal with emergency
 A reference to the off-site emergency plan drawn up to cope
with any off-site effects
 Further relevant information can be obtained.

Demonstration of Safe Operation for NMHI
 NMHI manufacturers must :
 Identify the possible major accident hazards
 Take adequate steps to prevent any major accidents
 Take adequate steps to minimize their consequences to
persons and the environment
 Prepare and keep up to date an adequate on-site emergency
plan detailing how major accidents will be dealt with
 Provide, at anytime, evidence including documents to show that
he has carried out the above items whenever requested by the
DG

Notification of Major Accidents
 Notify by the quickest means available the nearest DOSH Office of
major accident
 provide the following information relating to the accident as soon
as it becomes available
 the circumstances of the accident;
 the hazardous substances involved
 the data available for assessing the effects of the accident
 the emergency measures taken

TOXIC
Potential Failure
• Connecting pipe
damage
• Pipe erosion
• Malfunction of safety
valve
• Storage tank
physical defect
• Chlorine alarm
system failure
Chlorine
Consequence
• Toxic gas
dispersion

HIGHLY FLAMMABLE LIQUID
Potential Failure
• Pipe rupture
• Malfunction of safety
valve
• Floating roof failure
• Malfunction of level
alarm indicator
ULG RON
95
Consequence
• Pool fire
• Flash fire
• Explosion

FLAMMABLE GAS
Potential Failure
• Damage of valve stem
seals and flange gaskets
• Damage of transfer piping /
storage vessel due to
corrosion
• Failure of transfer pipe
flexible joint or cargo hose
• Tank overfilling, which
forces liquid out the
pressure relief safety
valves
LPG
Consequence
• Flash fire due to
delayed ignition of
a vapour cloud
• Fireball/BLEVE
(Boiling Liquid
Expanding Vapor
Explosion)
• UVCE (Unconfined
Vapor Cloud
Explosion)

HIGHLY REACTIVE SUBSTANCE
Potential Failure
• Damaged or poorly
maintained hoses, pipes
and valves
• Poor connections
• opening valves deliberately
or accidentally / not closing
valves properly after use
• Poor ventilation / confined
space
Oxygen
Consequence
• Fire
• Explosion

Potential Factors Lead Major Accident
 Poor plant design, fabrication and installation, including the use of low-
standard components
 regular plant maintenance
 Management of change is not manageable
 Changes of technology
 Human and organizational errors
 Natural occurrences and catastrophes
 Component failure
 Deviations from normal operation
 Lack of regular inspection of the installation, with repair and replacement of
components where necessary
 Aging Plant- majority of installation above 15 years

Important Information During Emergency
 List of hazardous substance
 Location of Hazardous Substances being kept inside premise- refer the
latest update plan lay –out
 Latest Chemical Safety Data Sheet (CSDS)
 Name of Person In-Charge (PIC) and contact number (Phone)
 Contact no : Nearest agency(Bomba/ DOSH/Police/Hospital/local
Authority)

Off-Site Drill Tier III-Level 1 (Special Project-2017)
 Reg. 22 - to conduct off-site emergency drill
 Main objective : i- Comply Regulation, CIMAH 1996
ii- Readiness of the industry in managing emergency
iii- Readiness of related agencies in control of
emergency
 Target Area: Kerteh Area
 Name of MHI : TBA
 Target Event : Q3 2017
 Target Agencies : TBA
 Selection of Scenario : TBA

Collaboration Inter Agencies
 DOSH
 BOMBA
 LOCAL AUTHORITY
 PORT AUTHORITY
 Local Mutual Aid
 Police
 Others
REDUCE
IMPACT TO:
PEOPLE
PROPERTY
ENVIROMENT

Caution Statement
 Regulation is not totally avoid major accident but provide a
minimum guidance for prevention and mitigation of major accident
 Penalty - RM50,000 OR < 2 years imprisonment or both
 Punitive Action- Charge to Court and Notices,

CONCLUSION
 Information related to storage and handling of hazardous substance
being share to audience
 Involvement and cooperation inter agencies can be establish for
prevention and mitigation of major accident hazard
 Determine of prevention method in early stage
 Right method and procedure are in place related industrial activity.
 Good collaboration , support and cooperation with other agencies.

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