Boiler burst kills 4

A boiler of a dyeing unit  burst on Tuesday, killing four persons and injuring 20 others on Tuesday. Inquiries are on to find out the reason for the blast. An official said that the safety valve failed release in time, leading to pressure building up inside the boiler.Read about it in this link.

A change in piping material may overlook something else!

A plant decided to change its sulphuric acid piping from Cast Iron to SS. However, they decided to conduct piping design analysis as per code requirement.The analysis found out that design did not adequately consider the difference in cross-sectional thickness between Cast Iron and SS (Cast iron is very thick compared to stainless steel). Also, the heat transfer rates of CI and SS differ. The piping expert redesigned the piping system to account for the thinner cross-section and thermal expansion properties of stainless steel and thus avoided premature failure. 
Read the article in this link.

Explosion in sulphuric acid tank

An explosion in a sulphuric acid tank has injured four personnel in Japan. There is the danger of presence of hydrogen in sulphuric acid tanks and when you do hot work be aware of the simple precautions like gas testing etc.
Read about the accident in this link. The Chemical Safety Board had earlier brought out a safety bulletin on the Dangers of Hot work, which is worth reading for every plant operation, maintenance and safety personnel. Read it in this link.

Fire in Pharma Plant

A fire in the vacuum dryer area of a pharma plant has reportedly seriously injured three people. As per Company press release, it states "There was a fire incident in a powder processing area at early hours on Nov 28,2011, at unit 11 which is located at Pydibhimavaram, Srikakulam near Vizag, A.P. Three persons were injured and they were taken to the hospital. The powder processing area is isolated from the intermediate block. There was no impact to the operations as well as to the assets".
Another news report indicates that the fire was caused by an explosion due to high pressure in the vacuum dryer.
Read the news reports in these links
Link 1
Link 2
Link 3

Remembering Bhopal............

Please spend December 2nd/3rd as “Process Safety Day” in your organisation. Educate your personnel on the Bhopal Gas tragedy and its lessons. 27 years ago, on the night on December 2nd/3rd, 1984, on a wintry night in Bhopal, thousands of men, women and children died an excruciating death when MIC leaked from the Union Carbide factory. The survivors and the next generation children born to those exposed to the gas still are suffering from the effects of the gas. Bhopal is an ongoing tragedy and should never be forgotten. The Bhopal gas disaster comprises actually of three disasters - the first was the actual incident, the second was the inadequate compensation received and the third is the ongoing legacy of genetic defects and effects of the hazardous waste that has seeped into the ground water. Every plant operating, maintenance and safety personnel must never forget the lessons of Bhopal. They are still relevant today:
1. Do not cut costs without looking at the effects on process safety
2. Maintain all your layers of defense including asset integrity
3. Continually ensure that competency of personnel operating and maintaining plants are updated and current
4. Be prepared for the worst case scenario.
5. Understand the risks and measures to eliminate / reduce or control them
6. Learn from your past incidents. Those who do not learn are condemned to repeat the incidents.
7. Pay heed to your process safety management system audit reports

As you are aware, this blog is also dedicated to the surviving victims of Bhopal and for my regular subscribers, I appeal to you to buy my book "Practical Process Safety Management", the proceeds from which are donated to the surviving victims of Bhopal.Contact me at bkprism@gmail.com for buying the book.

See a presentation on the Bhopal Gas Tragedy by Vijita S Aggarwal, Associate Professor, University School of Management Studies,GGS Indraprastha University,Delhi, India in this link.
Read my older post comparing the Bhopal and the BP incident of 2005 in this link
Read the then Police Chief’s account of the tragedy in this link.