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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