May 4, 2015

LOPA and its usefulness

 I posted this question in a PSM group in LinkedIn:

"I am interested to know whether a comprehensive study has been done anywhere, after the introduction of LOPA in the late 90's, with the study objective - "Has LOPA actually led to a reduction in incidents?"
Thanks, in advance.."

William Bridges, one of the co inventors of the LOPA technique posted his comments as follows:

"I doubt seriously if such a study is possible as you have to hold ALL OTHER influences constant and then start doing LOPA after that. I think this would be useless graduate project as well (for the same reason).

As one of the co-inventors of LOPA, the greatest improvements I have seen from the introduction of a LOPA, are from using the definition of an IPL within PHA/HAZOPs and from maintaining all IPLs per their respective industry best practices.

At a macro scale, it does not appear that introduction of LOPA or even introduction of process safety best practices have reduced the number of catastrophic accidents. This is no fault of the methods or disciplines; this is because Most companies still choose to do the bare minimum. Some companies have made great strides due to implementing best practices in risk assessment and process safety management; the majority have NOT improved because (1) their PHAs/HAZOPs still fail to find scenarios during all modes of operation so they are missing IPLs they need for those modes of operation, or (2) they fail to maintain IPLs appropriately, or (3) they fail to implement effective steps against the effectives of corrosion, erosion, or external impacts (for which there are no IPLs)."


 
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May 1, 2015

Process safety and jugaad!

During my trips to Uttar Pradesh, I often see a "Jugaad" modification that highlights the innovativeness of India.  A people transporter, fitted with a agriculture pump set engine powers the vehicle. I was commenting about the vehicle to my driver, when he asked me a question "Do you know what is the brake fluid they use in that vehicle?". Then he told me that it was sachets of one rupee shampoo!!
I marvelled at the inventors ingenuity. Which brings me back to PSM and management of change. India should not loose its sense of innovation, while at the same time, it should manage the changes in a technically right way.....




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April 27, 2015

Hydrochloric acid handbook

Occidental Chemical Corporation (Oxychem), as part of their Responsible Care initiative have brought out a good handbook on hydrochloric acid including design and safety aspects. You can read it in this link. 

Link has been updated now.

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April 24, 2015

Chlorine gas leak incident in 1991

 A FEMA report about a chlorine gas release in 1991 (70 Mt of chlorine escaped) mentions the following:
"Chlorine release caused by leak of brine from heat exchanger mixing with liquefied gas. Mixture created corrosive acid which ate through pipes when product was transferred from storage tank.Leak increased as acid ate larger hole in pipe.
Plant employees believed they could contain the leak. Fire department notified by passer-by who was unsure of source. Response delayed until second call provided additional information. Further delay caused by long response distance and several possible sources to check for hazardous materials (Hazmat) release.
Firefighters and plant personnel overcome when chlorine cloud moved in unexpected direction.Command post had to be relocated three times to avoid moving cloud. Some residents exposed during evacuation; over 200 examined at hospitals; 30 admitted."


 Read about the incident in this link.

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April 18, 2015

April 16, 2015

New eyewash shower and stations standard

 The International Safety equipment association has published a standard for eyewash showers and stations. It is a useful document. Read it by logging in this link

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April 10, 2015

Safety features at Kudankulam nuclear power plant by NPCIL

A good presentataion of the safety features at Kudankulam nuclear power plant by NPCIL  is available in this link 

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April 7, 2015

Blast in China Chemical Factory

Blast in China Chemical Factory -RT.com

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Another pump accident

'On Monday, January 28, 2002, a clean coal filter drain pump exploded due to steam build up within the pump, inflicting fatal injuries to the fine coal operator at a preparation plant of an underground mine. The victim was standing approximately 8 feet away at the on/off switch when the pump cover struck him. The pump overheated after almost all liquids had been pumped from the filter drain tank causing the remaining fines to solidify, thus preventing flow. The inlet and discharge lines then became clogged with coal fines causing the pump to become a closed pressure vessel".Read about the accident in this link.



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