Methane is dangerous - regardless of the source!

 A news report mentions of an explosion in a farm shed with cows, injuring one cow. The explosion was attributed to methane gas from 90 flatulent cows.The cause of ignition was reported to be static electricity. The roof of the shed was blown off!



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2 dead, 1 injured in accident at Essar Power plant near Jamnagar | Business Line

2 dead, 1 injured in accident at Essar Power plant near Jamnagar | Business Line



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Toxic gas formation in confined spaces

Confined space accidents due to exposure to toxic gases after entry continues to kill people. Read a warning about how toxic gases can be generated in confined spaces in this link. 


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Phosgene leak in plant at Dahej

A phosgene leak at a new toluene di isocyanate plant at Dahej on January 9th has reportedly affected 21 employees with one in serious condition. Interestingly, the company has filed a FIR against the technology provider.
Read about the incident in these links
Link1

Link2

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The importance of containment

An incident is being reported in the US where a storage tank storing Crude MCHM, consisting mostly of 4-methylcyclohexane methanol developed a hole and started leaking. The secondary containment (dykes) also failed and the chemical entered a river which is the main source of drinking water. 
Maintain your primary and secondary containments.....read about the incident in this link.


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Japan factory blast kills five | euronews, world news

Japan factory blast kills five | euronews, world news

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German oil refinery fire and explosion | euronews, world news

German oil refinery fire and explosion | euronews, world news

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Lessons Learned: When Disaster Strikes A Chemical Plant

Lessons Learned: When Disaster Strikes A Chemical Plant

Thanks to Balu (My classmate who is now in the US) for sending this good case study.

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Incidents in chemical units in Andhra Pradesh

Andhra Pradesh continues to experience incidents in chemical units.
Read about the recent two fire incidents in this link. 
Read about another incident this week in this link. (Thanks to Mr. Subrahmanyam for the info) 

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Workers suffer chemical burns to face

Workers suffer chemical burns to face

The above incident is a classic case of what will happen if you ignore warnings.

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Online leak sealing incident

An incident in a refinery in Belgium in which a bonnet of a steam valve flew open killing two contractors during sealant injection highlights the dangers. Many engineers take on line leak sealing for granted and a quick fix to arrest leaks. Remember on line leak sealing is an inherently unsafe method unless properly engineered. In India a plethora of on line leak sealing agencies have mushroomed offering leak sealing at low cost. Cost should not be the deciding factor while choosing the agency. Check their engineering expertise.
Read about the incident in this link.

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Process safety - where are we heading??

I was reading an article on process safety and a new terminology called "peak risk". In the last decade a number of new terminologies and technologies have mushroomed. But I think we have lost our way somewhere. Ultimately, accidents happen due to decisions taken by Management that have an effect on process safety and causes a catastrophic accident. Over a period of years, chemical manufacturing companies have fewer and fewer technical personnel on the board. As long as we do not address this issue, new terminologies and new technologies will only make someone's purse fatter but will not prevent a catastrophic accident!

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Welding incident

  Welding incident in youtube ... see the response of the fire watch... do you think it was right or wrong?


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Happy New Year 2014!

I WISH YOU AND YOUR FAMILIES A VERY HAPPY, HEALTHY AND PROSPEROUS 2014!

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Confined space engulfment hazards

A fatality in a grain bin in a ethanol manufacturing plant highlights the dangers of entry into bins containing material and its engulfment hazards. The victim apparently enetered the bin to clear a choke when the grain began to flow and he was trapped.
Read about the incident in this link.


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Laws of process safety

 And now for a bit of humour, I have coined some laws of process safety.....

• Process safety performance is inversely proportional to the time a plant / maintenance manager spends in meetings!
• The number of technical persons on the board of a chemical manufacturer is inversely proportional to the chance of a process safety incident occurring
• The more voluminous your PSM program, the more likely a process safety incident would occur.
• Managing process safety is no rocket science - it is look,listen and feel (look at what people are doing, listen to people and feel the pulse of the plant)
• Runaway reactions always happen when the human is around!
• Process safety management does not require six sigma, it requires stick sigma!

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Blast at pharma plant at Tarapur

An explosion and fire has taken place at a pharma plant at Tarapur. Read about the incident in http://www.dnaindia.com/mumbai/report-twin-blasts-rock-tarapur-unit-1937012


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Fire in phenol plant in USA

A fire in a phenol plant in the USA has been captured in this video. Read the article in this link.

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Static charge causes dust explosion

A man was critically injured when a static charge in an improperly grounded vacuum cleaner which was being used to clean machinery, ignited the dust causing an explosion and subsequent small fire,

Read more: Static charge caused explosion in Woburn Tuesday - Woburn, MA - Woburn Advocate http://www.wickedlocal.com/woburn/news/x1892418290/Static-charge-caused-explosion-in-Woburn-Tuesday#ixzz2kIk25U9t

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Salt water tank explosion

In some places, oil and gas reservoirs are found in porous rock formations that also usually contain significant amounts of saltwater. The saltwater produced with oil and gas must be disposed of in a manner that will not cause or allow the potential for pollution of surface or subsurface waters.. In this incident, a salt water tank exploded and 13 other tanks caught fire. The explosion, which occurred after a truck driver had unloaded the salt water into the tank and was leaving the site. The only victim was the truck driver who offered to help firefighters by getting more water to extinguish the fire. While the truck driver was heading back, he suffered a suspected heart attack.The cause of the explosion is under investigation. But this incident highlights the need to treat all tanks with respect.

Read about the incident in this link.

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