Pipeline integrity

Ever since the San Bruno pipeline incident, there has been lot of debate on pileline safety in the USA. A article mentions the following
"Pipelines are by their nature distributed and remote. Having sensors and analytics available to help identify pipes at risk would be a sensible strategy. Oil and gas companies are, in fact, investing in smart technologies for safety monitoring. As part of the 2011 Vertical IT & Communications Survey conducted by IDC in January, 2011, which included 90 North American oil and gas companies, 42% stated that they would be investing in smart technologies for safety monitoring in the next one to two years. This is not surprising given the importance of safety in the upstream side of the business. But in midstream, there are a number of questions still to be answered. The major risks to pipelines are corrosion, digging and failure of materials. Is sensing technology available that can identify these potential risks to pipeline integrity? Sensors in remote locations should not have significant power requirements and should be able to be powered by long-life batteries. Are these sensors now available? Then too, is the telecommunications infrastructure available to support bringing the data back for analysis? We welcome your comments"
Read the complete article in this link..

Process safety - what you don't see will get you!

A news article mentions that an unexploded German mine from World War Two was found near the BP Forties oil pipeline in the North Sea. The article also mentions that there is no immediate threat to the pipeline and the mine will be removed after a shutdown of the pipeline for a few days later in the year. The article reminded me of many chemical manufacturing companies taking over other organizations without doing a proper process safety due diligence. While financial due diligence is no doubt important,it becomes imperative that you also conduct a process safety due diligence to find out if you have any surprises in store!! The due diligence should cover the technical as well as the process safety cultural issues. Look before you leap and you can avoid an incident!

Fukushima and Bhopal

I have been reading with interest the interest in nuclear safety in Indian nuclear reactors after the Fukushima incident. I was wondering that if Bhopal had happened today, would the implementation of laws improve? While the West has learned from Bhopal and implemented stringent laws,we in India are yet to focus clearly on chemical process safety management. With the chemical industry set to boom in the next decade, should we wait for another Bhopal to occur before actions are taken? The current focus on process safety in India is still largely on a reactive basis. While large organisations have proactively and voluntarily taken up PSM, it is the medium and small scale organisations that are not prepared. Many of these units handle highly hazardous chemicals. It is time that the large players in the Chemical Industry start a mentoring program free of cost to enable the small and medium scale players to improve process safety. It is good for the whole industry.

Turbines and fires

According to a 1985 EPRI report, "Turbine Generator Fire Protection by Sprinkler System," by Black and Veatch, a survey of 175 generator related fires and 33 hydrogen explosions from the period 1930 to 1983 indicated that of the 119 fires involving lube oil, 39 fires occurred at the turbine bearings, 16 fires involved lube oil piping, 14 fires occurred below the turbine deck, and seven fires involved the lube oil reservoir. The exciter has also been identified as both a lube oil and an electrical hazard (seven electrical fires and two oil fires).My experience indicates that this statistic is valid even today.
Piping joint leaks, view glass leaks, piping cracks due to vibration etc all cause lube oil to leak, causing fires. These fires can stop production for quite a while as not only equipment but control and electrical cables will also get damaged. A leak of lube oil from a lube oil pump discharge line causes an atomised spray of lube oil and the source of ignition could be an uninsulated steam line. I have witnessed a major fire caused by a lube oil line leak and the damage was enormous. Train your operators to report unusual vibration, minor leaks and ensure your asset integrity program covers the lube oil system.

Bhopal disaster - Police Chief's account

I met Mr Swaraj Puri, the then Chief of Bhopal Police when the Bhopal gas disaster occured, at an international conference on Bhopal gas disaster at IIT Kanpur in 2004. He recounted the horrors of that night and the difficulty he and his men faced in the aftermath of the tragedy. I chanced upon his website where he mentions all the details of that fateful night in December 1984.He mentions the following:

"The Shortcoming and the Lessons for the future
One of the first thing that struck us when the gas leak took place was our total lack of preparedness and ignorance about how to deal with such a situation.
The medical fraternity and the chemists were unaware about the effects of Methyl Isocynate on humans and also the medical treatment to deal with cases of exposure. The Chief Medical Officer of the Union Carbide Factory initially deemed MIC as only an irritant! Since the gas was of the cyanide family, Sodium Thiosulphite was administered as a probable antidote. Specifically the factory was to blame because:

• The plant did not give vital information about the storage and handling of hazardous and dangerous materials.
• Effect of MIC on humans and the antidotal treatment was not known to the medical fraternity and such knowledge if available was not disseminated to the emergency services.
• There was a lack of appreciation of disaster management within the Government and also inadequate co-ordination between the factory and the emergency services.
• There was an absence of proper warning system in the plant. No practice drills were ever held.
• Union Carbide itself had limited data on MIC and probably had never anticipated the 'worst case scenario
• Poor plant maintenance practices. Inventory of vital spares had been depleted.
• Exodus of some of the experienced engineers and operating personnel from the plant.
• Economy measures, overriding safety concerns.

Apart from these, we noticed some other difficulties all inextricably linked up with the developmental process in the country.

• Densely populated areas around the plant. Often shanties / slums come up on vacant areas surrounding the factories greatly increasing the danger of loss to human life. Urban planning authorities are powerless, there is an absence of political will since much of the problem is caused by the poor flocking to the cities in search of employment.
• Absence of a proper road network, rescue workers had to move on foot through densely populated areas
• Poor communications, though things have improved now.
• Lack of effective emergency medical facilities.
• Inadequate transport for emergency evacuation, even today the infrastructure is woefully in adequate.
• Cattle living in residential areas, a peculiar Indian problem, not there in the metros, but very much in existence in other urban centers.
• People sleeping on pavements/ railway platforms.
• Unidentified dead bodies. Creating difficulties in identification of religion and also medico- legal problems. Many could not be identified. They were photographed, given numbers and cremated/buried
• Along with humans a large number of animals, mostly cattle perished in the disaster. Their disposal became a serious health problem. There was a threat of an epidemic. Cranes and bulldozers had to be put in operation to remove the dead animals and then bury them in a mass grave disinfected with tonnes of bleaching powder.
• Administration collapsed with key functionaries running for their lives instead of manning key positions
• Relief operations became difficult as the disaster caused total enervation in those entrusted with emergency relief.

SUCCESSES
Not every thing was a failure, the Police and the Medical Department with whatever meager resources at their disposal put up a tremendous immediate response. NGOs and social service organizations moved in immediately to help in the relief efforts. Local media was extremely helpful in scotching rumors and in disseminating essential information. Even the international media cooperated. The most affected area included the Bhopal Railway Station, the station master perished from the effects of the gas but the railway personnel immediately alerted the concerned, regulating the movement of trains and thus saving many lives.
FOR THE FUTURE 
The Administration, the Police and other essential services must know the location and exact nature of any hazardous chemical that is stored by any industrial establishment. The procedure to be followed in case of exposure and the antidotal treatment should be known to the aforesaid. Adequate quantity of antidote should be available with the industry which stores such hazardous chemical.

1. The people living in the vicinity should be made aware of

• the chemicals being stored
• The likely symptoms and antidote
• Emergency procedures which should be also rehearsed
• Nearest medical facilities
• System of contacting the Factory management
• Sources of transportation for emergency evacuation and the availability of ambulances.
• Rumors and unfounded fears should countered by local Radio and TV
• NGOs and other Voluntary Organizations capable of providing help should be involved in the disaster management process and be listed and known to the administration as well as the residents of the vicinity
• Residents living in the vicinity should train with the emergency services"

I still do not believe that we are ready for handling another similar disaster. Read Mr Swaraj Puri's account of Bhopal disaster in this link.