Risk factors in the Chemical Industry

An article mentions the risk factors identified by the American Insurance Association after investigating incidents in chemical industries. Some of them are mentioned below:
1. Factory site
(1) vulnerable to earthquakes, floods, storms natural disasters
(2) water is not sufficient
(3) the lack of public Fire Facilities support
(4) high humidity, temperature and other climate change
(5) nearby hazardous impact of large industrial installations
(6) close to highways, railways, airports and other transportation facilities
(7) difficult to safely evacuate
2. Plant layout
(1) process equipment and storage equipment is too intensive
(2) have significant risk and risk-free process safety distance between devices is not enough
(3) expensive equipment too concentrated
(4) the absence of effective protection
(5) boiler, heaters and other sources of ignition too close
(6) with terrain obstacles
3. Structure
(1) supports, doors, walls and other structures are not fire proofed
(2) Electric Equipment without protective measures
(3) inadequate capacity of explosion-proof ventilation
(4) plant is weakened (corrosion)
4. The risk of lack of knowledge of processing material
(1) hazards of mixing raw materials and natural decomposition
(2) potential for gas and dust explosions
(3) not understanding the result of misuse, or poorly controlled process
5. Chemical Technology
(1) inadequate data on the chemical reaction kinetics
(2) lack of knowledgeof the dangerous side effects
(3) does not determine the decomposition energy according to thermodynamics
(4) detection of process abnormalities is not adequate.
6. Material handling
(1) incomplete labeling of products
(2) in adequate Explosion detection/suppression device
7. Maloperation
(1) ignoring maintenance
(2)lack of supervisory role of management
(3) driving and parking plan is inadequate
(4) the lack of emergency shutdown training
(5) not establishing collaboration between operation and security personnel
8. Device Defects
(1) caused by improper selection of equipment corrosion, damage
(2) inadequate equipment, such as the lack of reliable control instrumentation
(3) material fatigue
(4) the metal material is not adequate or no inspection by experts
(5) structural defects
(6) equipment operating above design limits
9. Disaster plan
(1) did not receive strong support from management
(2) the division of responsibilities is not clear
(3) no accident prevention program
Read the article in this link.

Ammonia gas cylinder burst

An incident in an ice factory of an ammonia gas cylinder that burst killing one has occurred in West Bengal. It appears that the factory was located in a residential area and that the Municipality had renewed its licence. The article mentions

"Fire fighters risked their health and entered the factory on Saturday to repair the gas tanker. They lodged an FIR with Titagarh police against the factory owner. Officials of the Disaster Management Group (DGM) and BSF jawans also reached the spot as the tanker repair continued under their supervision. Fire officials complained that the ice factory was being run illegally in a crowded area.
"All the tankers and cylinders containing gas were in use for a long time. They had not been changed despite many tankers and cylinders being outdated. There was also no fire prevention arrangement there," said S Dubey, a senior fire official of North Barrackpore".
I often see gas cylinders being transported in autorickshaws with the cylinder cap protruding out. Authorities must be trained on the dangers of gas cylinders and its handling and transport.
Read more in these links: Link 1, Link 2

Natural gas pipeline leak from cavern storage

A natural gas pipeline that was connected to an underground cavern storage has reportedly leaked in the USA. News reports indicate that the gas from the cavern is now being vented to atmosphere.
The article mentions the following:
The following information is being relayed by Incident Command: As a safety precaution, we are still proceeding with the depressurization of the storage cavern as planned. The depressurization began about 3 p.m. Tuesday. We’re still venting gas to the atmosphere. This is a controlled process. The natural gas vented into the atmosphere will dissipate into the air and does not pose a health hazard to neighbors. Since 3 p.m. yesterday (Tuesday), we’ve vented about 400 million cubic feet. The flow rate is currently around 225 million cubic feet per day. We do not have an estimated timeline of how long the venting will take before the pressure in cavern 3 is zero.
Read my earlier post on gas cavern storage.
Now, I do not have the details of the leak but I was wondering why the whole cavern has to be vented.
Read the articles in these links: Article 1, Article 2

Incident Investigations in India - Aviation and Chemical

A news article mentions that an independent committee will henceforth investigate aviation incidents in India. The article mentions

"Currently, DGCA officials conduct probe into most of the accidents. "The same authority cannot be the prosecutor, investigator and the judge," said Zaidi, referring to the need to keep the DGCA away from probe into accidents.
In the last two months, the DGCA has been trying to make the investigation process transparent. For the first time in India, investigation reports of two serious incidents were made public. The first one was the November 2009 Kingfisher Airlines ATR aircraft runway overrun accident at Mumbai airport.

The second involved the Air India Express Dubai-Pune flight, which plunged several feet after the commander left the cockpit and the first officer could not handle the flight controls.
However within days of making the reports public, the DGCA had to pull them off its website after several technical questions about the quality of the probe were raised by air safety experts. For instance, the DGCA investigation report called the Kingfisher Airlines case a "serious incident". Going by International Civil Aviation Organisation's definition though it was clearly an "accident
Currently, DGCA officials conduct probe into most of the accidents. "The same authority cannot be the prosecutor, investigator and the judge," said Zaidi, referring to the need to keep the DGCA away from probe into accidents".
It is high time that accidents in the chemical industry in India are also investigated by an independent agency.

Read the article in this link.

HAPPY NEW YEAR!

WISHING ALL MY READERS A VERY HAPPY NEW YEAR 2011!

Defense Less? The story of Deepwater Horizons last moments

An investigation by the New York Times graphically depicts the last moments of the Deepwater Horizon oil rig.The article mentions the following:

"What emerges is a stark and singular fact: crew members died and suffered terrible injuries because every one of the Horizon’s defenses failed on April 20. Some were deployed but did not work. Some were activated too late, after they had almost certainly been damaged by fire or explosions. Some were never deployed at all.At critical moments that night, members of the crew hesitated and did not take the decisive steps needed. Communications fell apart, warning signs were missed and crew members in critical areas failed to coordinate a response.The result, the interviews and records show, was paralysis. For nine long minutes, as the drilling crew battled the blowout and gas alarms eventually sounded on the bridge, no warning was given to the rest of the crew. For many, the first hint of crisis came in the form of a blast wave.

The paralysis had two main sources, the examination by The Times shows. The first was a failure to train for the worst. The Horizon was like a Gulf Coast town that regularly rehearsed for Category 1 hurricanes but never contemplated the hundred-year storm. The crew members, though expert in responding to the usual range of well problems, were unprepared for a major blowout followed by explosions, fires and a total loss of power.They were also frozen by the sheer complexity of the Horizon’s defenses, and by the policies that explained when they were to be deployed. One emergency system alone was controlled by 30 buttons".

"The industry has long depicted blowout preventers as “the ultimate fail-safe.” But Transocean says the Horizon’s blowout preventer was simply incapable of preventing this blowout. Evidence is mounting, however, that the blowout preventer may have been crippled by poor maintenance. Investigators have found a host of problems — dead batteries, bad solenoid valves, leaking hydraulic lines — that were overlooked or ignored. Transocean had also never performed an expensive 90-day maintenance inspection that the manufacturer said should be done every three to five years. Industry standards and federal regulations said the same thing. BP and a Transocean safety consultant had pointed out that the Horizon’s blowout preventer, a decade old, was past due for the inspection.

Transocean decided that its regular maintenance program was adequate for the time being."

Read the full article in this link.

Static charge + Flammable dust = EXPLOSION

A news article mentions that OSHA is investigating an explosion that occurred on Thursday morning,caused by static charge and flammable dust at a facility in the US.

"Six employees were working, but none were near the eruption, said Trumbauersville Fire Chief Josh Mallery.“They were very lucky,” said Mallery, whose company led the blaze battling effort. The explosion blew an interior wall eight inches back off the foundation and sparked spot fires in the walls, said Rafferty. A corrugated roll up door was blown out, its bottom half ripped off and flung about 30 feet. A portion of the plant’s exterior wall bellied out, and a heap of cinderblocks from the structure tumbled on the ground outside the plant.“It was amazing. I’ve been a firefighter for 15 years and I’ve never seen anything like it,” said Mallery.

Fearing more explosions, firefighters first directed their hoses at about 1,200 pounds of Polyclar10, the powdered substance that was at the root of the explosion. In a wetted, condensed form, the powder does not pose the explosive threat it does when airborne as fine, particulate dust, said Mallery.

Firefighters then concentrated on extinguishing the flames. “It was about 2 ½ hours before we had the situation stabilized,” said Mallery.The explosion happened while the Polycar10 was being packaged. The packaging equipment was grounded to prevent static charges that could combust the compound, but a bag the powder was being deposited into was not grounded, said Rafferty. As the powder moved across the plastic interior of the bag, a static charge was generated, providing the heat source that ignited the powder, which is used to clarify beer before bottling, the fire marshal said".

Read the full article in this link

Mumbai Port Chlorine gas leak - recommendations

The PIB has published the recommendations of the expert committee set up to probe the chlorine gas leak from old cylinders I had mentioned in my earlier post. One of the recommendations states "The Head of Civil and Mechanical Engineering Department of MbPT should take immediate action to repair the fire hydrant system and ensure that the fire hydrant system is in working condition. This activity shall be completed by 31^st, December, 2010".
Maintain your fire water systems. You never know when they will be needed.
Read the PIB press release in this link.

US Unions view of oil industry safety

An union in the US has told the CSB which is currently investigating the BP oil rig disaster about the following issues regarding safety:

"After the 2005 Texas City blast" which killed at least 15 people at BP's USW-represented Texas City, Texas refinery, "We got a federal grant to develop a process safety curriculum," he explained. "It was approved by OSHA and we offered it, for free, to the companies," where USW would train workers in safety, "if they would just pay the salaries of workers to come to it" for 3-day sessions, he added. They turned it down.

The industry's attitude extends down to the local level, the two Alaskans said. At Prudhoe Bay, until local management changed last year, bonuses depended on how few accidents managers reported. Health and safety data was "manipulated" and workers did not report accidents "for fear of being disciplined," Trimmer, Local 4959's secretary-treasurer, said. BP has "a safety matrix" for each pipeline work area, with standards set for how few accidents are allowed. Report more, the 30-year veteran said, and supervisors lose bonuses.

"One guy had a bad vehicle accident. He had a broken leg and didn't report if for three hours. When he finally had to and we asked him why he delayed, he responded that he feared being fired," Trimmer said. Overtime and fatigue are also problems: 18-hour days for 2-week stretches are technically banned, so workers toil 16 hours. Guenther, a 25-year chief steward at Prudhoe, said that from 1979 to 1994, management emphasized preventive maintenance on the pipeline, but things have gone downhill since. Workers left and were not replaced, while the oil field he worked at doubled in size. Only recently has new hiring exceeded retirements, Guenther added.

"We went from preventive maintenance to running around fixing problems at all hours of the day and night," even in Alaska's sub-zero cold, Guenther said. Problems pile up and are shoved into "a backlog." Structures at the pipeline are reaching the end of their useful working lives, 15-25 years old, developing cracks that are patched. And BP rejected the local's contract proposal for a full-time health and safety specialist.

"We have to fundamentally change how we regulate this industry - and there's an even wider gap between regulation and the industry" than elsewhere, Wright told the CSB. "What we need are effective management programs, with strong regulation, backed by strong unionization and strong worker involvement" in safety"

Read the article in this link

Two killed after inhaling nitrogen gas

Thanks to Mr Shritharan for sending news about a nitrogen gas leak that has killed two people in a pharma plant in Hyderabad. Reason is under investigation. The incident happened in the night shift.You should always be careful when dealing with hazardous gases. My condolences to the family of the bereaved.
Read more about the incident in this link.
Read an updated news article in this link

Pipeline explosion -"Rivers of Fire"

A pipeline in Mexico has failed due to thieves reportedly trying to steal oil from it. 28 people have been reported to be killed. The video in the news article shows a "river of fire". Could this tragic incident have been prevented? In India we do have a large number of cross country pipelines. The reliability of safety shutdown systems and compartmentalization of pipelines to isolate leaky sections immediately is very important. More important are the actions of the operators and staff manning the control stations. Ensure that clear unambiguous instructions are communicated to them detailing the steps to be taken in the event of a leak. An operator sitting in a control room manning a cross country grid is going to be very hesitant to stop flow as the ramifications are huge. This is where automatic shutdown systems and their maintenance becomes very important.
Read the news article about the incident with video in this link.
For an article about India's petroleum and gas pipeline network, read it in this link.

Safety valves and their importance

A news article (a little old) mentions about an accident in an alumina digestor plant where 2 persons were killed apparently when a safety valve "exploded" and spread chemical around . Safety valves will do their job of relieving pressure if they are properly maintained and erected. Many times, plant and mechanical personnel do not bother to observe whether the safety valve downtake pipe (if open to atmosphere) is located away from personnel. The testing of safety valves is very important. All data regarding safety valves must be preserved carefully as part of your asset integrity program.
Read about the incident in this link.