Thermal imaging to detect gas leaks

A thermal imaging camera manufacturer reports that process operators at a high-pressure, low-density polyethylene (LDPE) plant in Stenungsund, Sweden are using a optical gas imaging camera to detect potentially dangerous gas leaks. The article mentions the following:
"In the LDPE production process - ethylene, a highly flammable hydrocarbon, is converted into polyethylene in a high-pressure polymerisation reaction.
Before the purchase of a FLIR GF306 optical gas imaging camera - Borealis used gas 'sniffers' - devices which measure the concentration of a certain gas in one single location and generate a concentration reading in parts per million (ppm). An operator of the FLIR GF306 stated "The main advantage of the optical gas imaging camera is that it provides you with the possibility to detect gases in real-time visually. Whereas sniffers just give you a number, an optical gas imaging camera allows you to detect gas leakage anywhere within the field of view of the camera."
Now that Borealis have a FLIR GF306 optical gas imaging camera they are able to do a quick scan at every start-up. With a quick scan - process operators are able to scan approximately 80% of the entire plant in about thirty minutes. To do the same task with gas sniffers would need a team of ten people working for two full days".

Read the article in this link
PS: I am not endorsing the product. This is for information only.


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Hot material spill kills two

A newspaper article reports that two people were killed when a hot material at 300 deg C fell on them when they were cleaning a boiler. When issuing confined space entry permits ensure that you conduct all proper checks for any residual energy that may be trapped inside. Read the article in this link.
 
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A day in the life of a Plant manager

I have been harping on the less amount of time plant managers are spending today visiting the plant and talking to the operators. Today Process Safety is being devoured by technology that is being pushed by vendors - including advanced process control, high funda instruments, SIL rated loops, software that promises just about to do anything including HAZOP studies, RCA's etc.., dashboards for monitoring process safety performance etc... While technology can be an enabler, ultimately, we need to realize one thing - there is no substitute for a plant manager to do his daily rounds and talk to operators.Today's plant manager has become a technology slave - be it answering e-mails from his laptop to checking his blackberry for bad news!
I was happy to read that in one major multinational in UK, the plant managers are compulsorily made "free" for the first three hours of their day so that they visit the plant, do a plant round and talk to operators and engineers. If you practice this, most of the process safety issues will be resolved.

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Confined space incident

Thanks to Deivanayagam Sivasankaran for sending a video of a confined space incident. What is striking is the immediate response of the man watch who jumps in to rescue his colleague. An accident in a confined space always has the capability to kill more people as would be rescuers jump in without even realizing that they themselves may be in danger. Train your man watched on proper procedures and what to do in the event of an incident in a confined space. It may save his life!
See the video in this link. 

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Fire risks of IBC's

Intermediate Bulk Containers (IBC's)  are used to store and transport many chemicals. A technical advisory bulletin by Willis North America mentions the significantly greater fire hazard the IBC's pose than the classic 55-gallon drum or smaller containers.
They recommend the following:

1. "Protection alternatives should always be investigated (i.e., possible use of off-site IBC storage facilities, etc.).
   The indoor storage of flammable or combustible liquids in nonmetallic or composite IBCs in plant production or warehouse storage areas should be prohibited. 
2. Attempt to store IBCs at a supplier location and receive the materials on a just-in-time basis. 
3. Consider alternatives such as designing and installing a properly protected bulk storage and piping system.
   Consider the use of steel 55-gallon drums or steel IBCs.
   Determine if nonmetallic or composite IBCs are the only method for receiving and storing flammable and combustible liquids in your plant".

Read the advisory in this link. 

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