An explosion in a reactor in a plant in Vapi has injured at least 6 workers. As per news articles, The blast was powerful and had occurred due to "rupturing of a safety valve". Reading between the lines, it appears it is another case of a reaction gone wrong and inadequate rupture disc sizing.The sizing basis of safety valves and rupture discs need to be documented and understood by plant operators.
The blast wave from the explosion reportedly damaged windows and buildings. Blast waves are extremely dangerous. Read an explanation in this link.
Read the articles in this link: Link 1 and Link 2
Another incident reported is the explosion of an ammonia cylinder or tank in an ice factory in Karnataka. Read about it in this link.
January 15, 2011
January 13, 2011
Bhopal disaster - educating our future leaders
A news article mentions that, as part of standard 8 curriculum,the NCERT has introduced a new realistic account of the Bhopal gas disaster. I am happy that authorities are taking the correct steps and educating our children who will be future leaders of tomorrow. I strongly believe that the Bhopal Gas disaster and its lessons must be made mandatory for all students of MBA, chemical engineering,cost accountancy and chartered accountant aspirants.
The news article mentions the following:
"The Social Science edition, that was released this month, recounts the story of the Bhopal gas tragedy under the chapter Law and Social Justice. It not only has a report on the industrial disaster but also raises serious concerns about the fate of the gas-affected people and the weak environment laws in the country.It dwells on how taking advantage of weak environment laws and availability of cheap labour, environmentally dangerous plants open in developing nations.
Several photographs of the incident, victims, deaths and protests have been published in the book. The background colour of the pages has been kept black while the headlines and photo captions are highlighted in red colour.
A caption of one of the pictures says: "Dow, how many more must die?"
The account begins: "The world's worst industrial tragedy took place in Bhopal 24 years ago. Union Carbide (UC), an American company, had a factory in the city in which it produced pesticides. At midnight of 2 December, methyl-isocyanate (MIC) - a highly poisonous gas - started leaking from the UC plant..."
"Within three days, more than 8,000 people were dead. Hundreds of thousands were maimed."Most of those exposed to the poison gas came from poor, working-class families, of which nearly 50,000 people are today sick to work. Among those who survived, many developed severe respiratory disorders, eye problems and other disorders. Children developed peculiar abnormalities, like the girl in the photo."
"The disaster was not an accident. UC had deliberately ignored the essential safety measures in order to cut costs. Much before the Bhopal disaster, there had been incidents of gas leak killing a worker and injuring several."
"24 years later, people are still fighting for justice: for safe drinking water, for healthcare facilities and jobs for the people poisoned by UC. They also demand that (Warren) Anderson, the UC chairman who faces criminal charges, be prosecuted."
Criticising government apathy in allowing the factory to come up, a paragraph of the chapter reads: "Government officials refused to recognize the plant as hazardous and allowed it to come up in a populated locality. When some municipal officials in Bhopal objected that the installation of an MIC production unit in 1978 was a safety violation, the position of the government was that the state needs the continued investment of the Bhopal plant, which provides jobs."
It also has a comparative account of Union Carbide's safety system in Bhopal and its other plant in the United States."At West Virginia (USA.) computerised warning and monitoring systems were in place, whereas the UC plant in Bhopal relied on manual gauges and the human senses to detect gas leaks. At the West Virginia plant, emergency evacuation plans were in place, but non-existent in Bhopal."
I hope the contents of the book are not revised!
Read the article in this link.
The news article mentions the following:
"The Social Science edition, that was released this month, recounts the story of the Bhopal gas tragedy under the chapter Law and Social Justice. It not only has a report on the industrial disaster but also raises serious concerns about the fate of the gas-affected people and the weak environment laws in the country.It dwells on how taking advantage of weak environment laws and availability of cheap labour, environmentally dangerous plants open in developing nations.
Several photographs of the incident, victims, deaths and protests have been published in the book. The background colour of the pages has been kept black while the headlines and photo captions are highlighted in red colour.
A caption of one of the pictures says: "Dow, how many more must die?"
The account begins: "The world's worst industrial tragedy took place in Bhopal 24 years ago. Union Carbide (UC), an American company, had a factory in the city in which it produced pesticides. At midnight of 2 December, methyl-isocyanate (MIC) - a highly poisonous gas - started leaking from the UC plant..."
"Within three days, more than 8,000 people were dead. Hundreds of thousands were maimed."Most of those exposed to the poison gas came from poor, working-class families, of which nearly 50,000 people are today sick to work. Among those who survived, many developed severe respiratory disorders, eye problems and other disorders. Children developed peculiar abnormalities, like the girl in the photo."
"The disaster was not an accident. UC had deliberately ignored the essential safety measures in order to cut costs. Much before the Bhopal disaster, there had been incidents of gas leak killing a worker and injuring several."
"24 years later, people are still fighting for justice: for safe drinking water, for healthcare facilities and jobs for the people poisoned by UC. They also demand that (Warren) Anderson, the UC chairman who faces criminal charges, be prosecuted."
Criticising government apathy in allowing the factory to come up, a paragraph of the chapter reads: "Government officials refused to recognize the plant as hazardous and allowed it to come up in a populated locality. When some municipal officials in Bhopal objected that the installation of an MIC production unit in 1978 was a safety violation, the position of the government was that the state needs the continued investment of the Bhopal plant, which provides jobs."
It also has a comparative account of Union Carbide's safety system in Bhopal and its other plant in the United States."At West Virginia (USA.) computerised warning and monitoring systems were in place, whereas the UC plant in Bhopal relied on manual gauges and the human senses to detect gas leaks. At the West Virginia plant, emergency evacuation plans were in place, but non-existent in Bhopal."
I hope the contents of the book are not revised!
Read the article in this link.
January 12, 2011
Iphone app manages fatigue
An Iphone app has been developed that manages fatigue of flight crew. "The predictions are based on the Boeing Alertness Model developed jointly by Boeing and Jeppesen, which is based on a modified version of the long-validated Three Process Model of Alertness. This contains circadian and homeostatic components to yield predicted alertness.
The modular design of the fatigue risk management solution, however, allows operators to make use of alternative alertness models if desired.An iPhone application based on the Boeing Alertness Model called CrewAlert has also been released by Jeppesen. Available in the Apple App Store for $19.99, CrewAlert is billed as "the first app designed specifically to help airlines and their crews manage alertness and fatigue".This is an interesting development and maybe we in the chemical industry can use a similar type of app for managing worker fatigue!
Read the article in this link.
The modular design of the fatigue risk management solution, however, allows operators to make use of alternative alertness models if desired.An iPhone application based on the Boeing Alertness Model called CrewAlert has also been released by Jeppesen. Available in the Apple App Store for $19.99, CrewAlert is billed as "the first app designed specifically to help airlines and their crews manage alertness and fatigue".This is an interesting development and maybe we in the chemical industry can use a similar type of app for managing worker fatigue!
Read the article in this link.
Ammonia leak incidents
An ammonia leak in a poultry company in US has forced the evacuation of 800 people. The leak occurred from a refrigeration system. The leak inside the plant was so thick the emergency workers "could'nt even see".
It appears that the plant was an "aging" plant. This again raises the question of how residual life assessment of equipment is tracked by companies.Read the article in this link.
Another ammonia leak from a gas cylinder in India which later caused a fire has also been reported. Time and again I see gas cylinders treated with scant respect in many companies. Read the articles about the ammonia incident in these links
Link 1
Link 2
It appears that the plant was an "aging" plant. This again raises the question of how residual life assessment of equipment is tracked by companies.Read the article in this link.
Another ammonia leak from a gas cylinder in India which later caused a fire has also been reported. Time and again I see gas cylinders treated with scant respect in many companies. Read the articles about the ammonia incident in these links
Link 1
Link 2
January 9, 2011
H2S leak at manganese plant in China kills 3
The dangers of toxic gases like H2S are often underestimated. Plant personnel must be always aware of the various ways in which H2S can be generated and its dangers. In a manganese plant in China, three people were killed due to a H2S leak. The manufacture of manganese involves reducing the milled ore, which is then dissolved in acid solution, followed by purification.The solution is then fed into the electrolytic cells, where manganese is deposited on the cathodes. Sulphuric acid, formed at the anodes, is re-cycled back to the dissolution process.
Read the full article about the accident in this link.
Read the full article about the accident in this link.
Bhopal - Pictures speak a thousand words
A fellow blogger had compiled various images of the Bhopal Gas Disaster and its continuing aftermath. See it in this link.
Purse String Management Vs PSM
Purse Strings Management (PSM!) has a direct effect on the management of process safety. Controlling costs is important for a company to achieve profitability. But the question that arises is - at what point does it stop? For example - maintenance budgets - how should they be allocated? Money required to keep equipment in running condition is one thing but how about money to assess residual life and scheduling replacements? A distinct trend in chemical process industries is the high turnover of personnel, even at the top management level. This has a direct effect on the amount of effort that a manufacturing head will take to ensure that money required for process safety issues is budgeted and spent. I am observing a dangerous trend of maintenance budgets not paying heed to process safety issues in many companies. Wake up before it is too late!
Many articles blame it on "poor culture". I would say it in one sentence "short term gains overriding process safety". No amount of behavioural change programs will help unless some one at the top is in a position to understand and recognise the risks that a chemical industry faces. The truth is bitter!
Many articles blame it on "poor culture". I would say it in one sentence "short term gains overriding process safety". No amount of behavioural change programs will help unless some one at the top is in a position to understand and recognise the risks that a chemical industry faces. The truth is bitter!
January 7, 2011
BP oil spill- Process safety and its Management
A news article mentions the following from the report of the presidential commission set up to investigate the BP oil sill disaster:
"A "complacent" attitude to safety and a cost-cutting culture by BP's management and that of its partners contributed to the oil spill that ravaged the Gulf of Mexico last year, the official US inquiry has ruled.
A pre-released chapter from the final report of the White House oil spill commission set up by President Barack Obama is scathing in its attack on management failure, warning that the cause of the crisis was "systemic" and that without reform of the industry a similar disaster "might well recur".
"Most of the mistakes and oversights at Macondo can be traced back to a single overarching failure – a failure of management. Better management by BP, Halliburton, and Transocean would almost certainly have prevented the blow-out," the report said.
It added: "Whether purposeful or not, many of the decisions that BP, Halliburton, and Transocean made that increased the risk of the Macondo blowout clearly saved those companies significant time (and money)."
BP staff are accused of making several critical mistakes, including the misinterpretation of a vital "negative pressure test" to check that the well had been properly sealed before removing the rig. The report said BP's "fundamental mistake" was its failure to exercise caution before relying on the cement as a barrier to the flow of oil and gas up the well.
BP's US partners, Halliburton and Transocean, do not escape censure either. Halliburton is criticised for failing to ensure the cement used to seal the well had been tested properly. Transocean, which owned and ran the rig, is attacked for not learning the lessons of a similar incident that almost led to an accident in the North Sea four months prior to the Macondo disaster".
Read the full article in this link.
"A "complacent" attitude to safety and a cost-cutting culture by BP's management and that of its partners contributed to the oil spill that ravaged the Gulf of Mexico last year, the official US inquiry has ruled.
A pre-released chapter from the final report of the White House oil spill commission set up by President Barack Obama is scathing in its attack on management failure, warning that the cause of the crisis was "systemic" and that without reform of the industry a similar disaster "might well recur".
"Most of the mistakes and oversights at Macondo can be traced back to a single overarching failure – a failure of management. Better management by BP, Halliburton, and Transocean would almost certainly have prevented the blow-out," the report said.
It added: "Whether purposeful or not, many of the decisions that BP, Halliburton, and Transocean made that increased the risk of the Macondo blowout clearly saved those companies significant time (and money)."
BP staff are accused of making several critical mistakes, including the misinterpretation of a vital "negative pressure test" to check that the well had been properly sealed before removing the rig. The report said BP's "fundamental mistake" was its failure to exercise caution before relying on the cement as a barrier to the flow of oil and gas up the well.
BP's US partners, Halliburton and Transocean, do not escape censure either. Halliburton is criticised for failing to ensure the cement used to seal the well had been tested properly. Transocean, which owned and ran the rig, is attacked for not learning the lessons of a similar incident that almost led to an accident in the North Sea four months prior to the Macondo disaster".
Read the full article in this link.
One killed in explosion in chlorine plant
An explosion in a chlorine plant has killed one person and released chlorine gas in a plant in France. It is reported that "leak of water containing sodium caused this explosion". It is not clear what is meant by this. Read the full article in this link
January 6, 2011
Major fire in depot near Rotterdam
Refinery cited for multiple safety hazards
OSHA has cited Pasadena Refining Services Inc. with 21 serious violations for exposing workers to multiple safety and health hazards at the company's facility in Pasadena. Proposed penalties total $115,650.
"The serious violations include failing to provide properly constructed scaffolds, provide supports to hold piping, provide controls to prevent valves from closing, conduct annual confined space audits, ensure guard rails are adequate, and ensure that operating procedures are up-to-date and accurate. A serious violation is one in which there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known".
It is interesting to note that these violations have occurred even though PSM is mandatory.
Read the article in this link
"The serious violations include failing to provide properly constructed scaffolds, provide supports to hold piping, provide controls to prevent valves from closing, conduct annual confined space audits, ensure guard rails are adequate, and ensure that operating procedures are up-to-date and accurate. A serious violation is one in which there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known".
It is interesting to note that these violations have occurred even though PSM is mandatory.
Read the article in this link
January 4, 2011
Fire in oil storage depots in India
Thanks to Abhay Gujar for this info:
In the current year (2010-11) 4 instances of fires have been reported at oil depots in India:
A fire occurred at a railway siding due to spark from the overhead power line. Reason: Poor maintenance.
A fire incident took place at a Terminal's engineering store due to electrical short circuit.Reason: Poor maintenance.
Another incident took place in the cabin of TT at a Depot.Reason: Poor maintenance of TT and unsafe operating practices.
A fire broke out at a railway siding while loading.Reason: Unsafe practice and non-adherence to safety standards.The company has been advised by OISD to close the railway siding for all operations since it endangers the public life as it is close to the main Delhi-Kolkata railway track.
In the current year (2010-11) 4 instances of fires have been reported at oil depots in India:
A fire occurred at a railway siding due to spark from the overhead power line. Reason: Poor maintenance.
A fire incident took place at a Terminal's engineering store due to electrical short circuit.Reason: Poor maintenance.
Another incident took place in the cabin of TT at a Depot.Reason: Poor maintenance of TT and unsafe operating practices.
A fire broke out at a railway siding while loading.Reason: Unsafe practice and non-adherence to safety standards.The company has been advised by OISD to close the railway siding for all operations since it endangers the public life as it is close to the main Delhi-Kolkata railway track.
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