Thermal expansion accident

Thermal expansion inside a valve caused the bonnet of the valve to fail. The safety alert mentions the following:

Pressure build-up occurs in the gate valve cavity from thermal expansion of fluids. Extreme pressure build-up from fluid expansion can occur if the valve body is completely full of fluids (e.g., a grease/oil/water mixture) and heated to elevated temperatures. Such pressure can exceed the rated working pressure of the valve.

A valve with the ability to isolate the body cavity from the flow line may be at risk.
Presence of grease or compounds designed to enhance sealing ability may exacerbate the condition.
Grease or a grease/oil/water mixture when heated in a sealed enclosure can exceed 7000 psi (48.5 MPa) at 250 °F (121 °C).
Gate valve body cavities that are not 100% full of fluids do not experience excessive pressure as the vessel was heated. Trapped air or gas allows room for thermal expansion.

Read the safety alert in this link. 

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Managing chemical reactivity hazards -EPA Alert

Managing chemical reactivity hazards -EPA Alert

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Depending on ROV's for isolation is bad design

An accident in a refinery in 2007 that killed 4 contract workers highlights the dangers of depending only on ROV's (remotely operated valves) for isolation. A maintenance job was being carried out on a hot oil line. Operators closed a ROV in the line and issued the permit to remove a blind on the downstream flange of the ROV. Instrument air to the ROV was left open. (ROV is a fail to close valve) When the maintenance workers were fixing the chain block to remove the blind, it inadvertently hit the switch on the ROV control field panel and opened the valve, causing hot pressurised oil to spray, ignite and kill the 4 workers.  

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Blast in Hyderabad-two-die-13-hurt- Times of India

Blast in Hyderabad, two die, 13 hurt - Times of India

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Lessons from Fukushima

Read the lessosn learnt from Fukushima in this link  http://nas-sites.org/fukushima/files/2012/10/Kitazawa.pdf

It applies to us in the CPI, too!


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Management decision during crisis

Continuing with Fukushima, a very interesting read on Fukushima and management decisions!
http://www.nikkeibp.co.jp/rebuild/en/article_09/index_03.shtml

 
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Explosion at Exxon Mobil refinery in Torrance, California, injures four - Reuters

Explosion at Exxon Mobil refinery in Torrance, California, injures four - Reuters

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Inherently safer design

Inherently safer design - Safety+Health magazine

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Don't Normalise deviations!

 In 1994, a fatality caused by exposure to hydrogen sulfide occurred at a refinery. The accident  occurred while draining of a fuel gas knockout drum in a hydro treating unit. Normal work procedures included periodically opening a valve that carried a water-gas mixture to a separator which removed and vented hydrocarbon gases to a flare. During the preceding winter, the piping to the separator froze, and the drum was temporarily drained to the sewer. This deviation went unnoticed and the temporary practice of draining to the sewer continued. On the day of the incident, the operator opened the valve to the sewer believing it to be part of the draining procedure, resulting in the release of toxic amounts of hydrogen sulfide that killed the operator.

Source: osha.gov

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Vizag steel plant official dies in accident | Business Line

Vizag steel plant official dies in accident | Business Line


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chemical plant explosion creates toxic cloud over barcelona - euroweeklynews

Chemical plant explosion creates toxic cloud over Barcelona
 
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Oil rig blast causes casualties

Petrobras oil rig blast causes casualties

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