DSEAR for manufacturing
Manufacturing can bring several DSEAR-relevant hazards together: solvent use, coating, fuel systems, gases, powders, dust extraction and ignition-capable equipment.
Check my situationFollow the material through the process
A store that looks well controlled does not answer what happens during transfer, mixing, heating, spraying, machining, extraction, cleaning or waste handling. Map where the material can be released and where an ignition source could be effective.
- Where does the substance enter, change state, become airborne or leave as waste?
- What happens during start-up, shutdown, maintenance, blockage or ventilation failure?
- Are new equipment, layout or throughput changes already covered by the current assessment?
What to do next: If the process has multiple hazards or is being designed or changed, involve competent DSEAR input before equipment and layout decisions become expensive to alter.
Map the process, not just the stores
Assessment should follow substances through receipt, storage, transfer, use, by-products, waste and maintenance. Normal operation and foreseeable abnormal events both matter.
Talk to operators and maintenance staff as well as reading the written procedure. The real release point may be a sampling step, filter change, cleaning method or temporary container that is not obvious on a high-level process diagram.
Separate control questions
The assessment should distinguish preventing or containing a release, avoiding an explosive atmosphere, controlling ignition, and mitigating the consequences if prevention fails.
Ventilation, equipment selection, bonding and earthing, segregation, housekeeping and emergency arrangements solve different parts of the problem. A list of controls is useful only when it is connected to the assessed scenario.
Information to prepare
A specialist will work faster with current layouts, safety data sheets, inventories, extraction information, equipment records and a clear description of process changes.
- Process flow and layout drawings
- Substance quantities and current safety data sheets
- Extraction, ventilation and maintenance information
- Existing zoning, equipment and inspection records
- Incidents, near misses and planned changes