Initial findings seem familiar!
U.S. Chemical Safety Board Finds Multiple Safety Deficiencies Led to February 2015 Explosion and Serious Near Miss at the Exxon Mobil Refinery in Torrance, California - General News - News | the U.S. Chemical Safety Board
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January 14, 2016
January 13, 2016
Maintaining old assets
An interesting article has been published in Offshore Engineer, titled "Tackling the backlog".
It talks about how many assets in the UK oil exploration industry is more than 25 years old and that critical maintenance backlogs have been going up since 2010. It mentions "Safety critical maintenance backlog has increased from just above 700 man hours per installation to more than 4000, as at Q3-4 2014, with the increase having started from 2010, and the greatest rises in 2013 and 2014. Meanwhile, unplanned losses account for the greatest increase in the lost production efficiency, with planned shutdown time also increasing” . The article is worth a read. Please google "Offshore Engineer Tackling the backlog"
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It talks about how many assets in the UK oil exploration industry is more than 25 years old and that critical maintenance backlogs have been going up since 2010. It mentions "Safety critical maintenance backlog has increased from just above 700 man hours per installation to more than 4000, as at Q3-4 2014, with the increase having started from 2010, and the greatest rises in 2013 and 2014. Meanwhile, unplanned losses account for the greatest increase in the lost production efficiency, with planned shutdown time also increasing” . The article is worth a read. Please google "Offshore Engineer Tackling the backlog"
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January 10, 2016
Skyscraper blaze in Persian Gulf raises questions about safety | The Japan Times
Skyscraper blaze in Persian Gulf raises questions about safety | The Japan Times
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
January 8, 2016
Explosion in plant injures 4
http://www.breakingnews.com/t/IKq
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
January 7, 2016
Human error by a Pilot
On 08.08.2014, an Indian commercial passenger jet was involved in loss of altitude incident during cruise over Turkish Airspace. The incident occurred after the aircraft had flown for 04 hours 43 minutes from Mumbai. The aircraft was flying on westerly track which was between 230 and 300 degrees and was flying on auto pilot at a height of 32000 feet. The Pilot in command was undergoing controlled rest as per statutory requirements and the controls were with the First Officer.
The First Officer, while updating the direction heading 292 degree, instead turned the altitude knob to 292 FL (29000 feet) and pressed thereby causing the aircraft to descend as the auto pilot obeyed the order to descend to 29000 feet. The Turkish Air Traffic Controller noticed the aircraft descent and called through radio about the unauthorized descent. Subsequently, the First Officer pressed ALT HOLD and climbed back to FL320 (32000 feet). The First Officer then woke up the Captain who was undergoing controlled rest and informed him of the incident. (Source: DGCA incident report).
In our industry, there have been numerous incidents where wrong setpoints or outputs have been entered by the DCS operator, leading to plant upsets. Do you consider this in HAZOP's?
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The First Officer, while updating the direction heading 292 degree, instead turned the altitude knob to 292 FL (29000 feet) and pressed thereby causing the aircraft to descend as the auto pilot obeyed the order to descend to 29000 feet. The Turkish Air Traffic Controller noticed the aircraft descent and called through radio about the unauthorized descent. Subsequently, the First Officer pressed ALT HOLD and climbed back to FL320 (32000 feet). The First Officer then woke up the Captain who was undergoing controlled rest and informed him of the incident. (Source: DGCA incident report).
In our industry, there have been numerous incidents where wrong setpoints or outputs have been entered by the DCS operator, leading to plant upsets. Do you consider this in HAZOP's?
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
January 5, 2016
One man dies in water-treatment plant explosion - MRT.com: Top Stories
One man dies in water-treatment plant explosion - MRT.com: Top Stories
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
January 4, 2016
OSHA Announces Top 10 Safety Violations for 2015
OSHA Announces Top 10 Safety Violations for 2015
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
January 1, 2016
December 31, 2015
Weak Sulphuric acid FRP tank collapse
In a factory, where 10 MT weak sulphuric acid was stored, suddenly the suction line valve tank nozzle assembly got broken and through this opening sulphuric acid drained out from the tank. This resulted in vacuum formation in the tank. This FRP tank hit against the supporting channel legs due to the formation of vacuum.
Causes :
1. The FRP tank was not maintained with a adequate strength and stability
2. The FRP tank was not tested and certified by the Competent person every year
Source: DGFASLI
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Causes :
1. The FRP tank was not maintained with a adequate strength and stability
2. The FRP tank was not tested and certified by the Competent person every year
Source: DGFASLI
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Urea prill tower incident
In a Fertilizer manufacturing factory urea manufactured in prill tower passes through a grizzly (a stainless steel sieve) and falls on a conveyor. To facilitate repair works to be carried out to a grizzly bar, two metal rods were placed above the grizzly bar and this was covered by a tarpaulin sheet.Right below this arrangement welding of grizzly bar was carried out. When the welding process was being carried out heavy lumps of urea started falling down from the prill tower and fell on the iron plates placed over the grizzly bar. The iron plates along with heavy lumps of urea fell on the workers working right below the covered tarpaulin sheet and they sustained head Injuries and died.
Causes :
The temporary arrangements made above the grizzly bar to facilitate welding work was not of a strong and rigid construction to withstand falling of heavy lumps of urea from prill tower.
Ref:DGFASLI
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Causes :
The temporary arrangements made above the grizzly bar to facilitate welding work was not of a strong and rigid construction to withstand falling of heavy lumps of urea from prill tower.
Ref:DGFASLI
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December 26, 2015
How the Apollo 1 Fire Changed Spaceship Design Forever
Interesting article on how designers learn from their mistakes.....after all they are also human.
How the Apollo 1 Fire Changed Spaceship Design Forever
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How the Apollo 1 Fire Changed Spaceship Design Forever
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 23, 2015
Accident and emergency | Chemistry World
Accident and emergency | Chemistry World
‘2015 should be remembered as a year when the chemical industry was sharply reminded of its social responsibility’
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
‘2015 should be remembered as a year when the chemical industry was sharply reminded of its social responsibility’
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 22, 2015
Empty drums are deadly drums
Often empty drums are treated with much less safety precautions than filled drums. An empty drum that has not been purged free of residues chemicals is a potential bomb. Read about an incident from HSE UK, with a small film about the incident in this link.
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 18, 2015
Management of Change or Change of Management?
In 1999, when I was carrying out a PSM audit, we were auditing a maintenance mechanic. I was asking whether he can explain what is the meaning of management of change. He replied that when his company was recently taken over by another company, that is management of change!
Are you carrying out MOC for change in Management?
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Are you carrying out MOC for change in Management?
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 15, 2015
Whitepaper on dust explosions
Read a good white paper by Fike about Dust explosions in this link.
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 11, 2015
Ammonia leak kills one
News reports coming in of an accident in an ammonia plant in Canada when a contractor employee who was doing weather proofing job on an ammonia storage tank was killed due to an ammonia release. Apparently, a piece of equipment struck a valve on the tank and caused the leak. This accident highlights the dangers of working with highly hazardous chemicals and the need for proper JSA's to be carried out.
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 9, 2015
4 die in boiler explosion - TAMIL NADU - The Hindu
4 die in boiler explosion - TAMIL NADU - The Hindu
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 8, 2015
OSHA Investigating Explosion at Orla Gas Plant Previously Fined - KWES NewsWest 9 / Midland, Odessa, Big Spring, TX: newswest9.com |
OSHA Investigating Explosion at Orla Gas Plant Previously Fined - KWES NewsWest 9 / Midland, Odessa, Big Spring, TX: newswest9.com |
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Caspian sea oil rig fire
Thanks to S.Sanjeevi for sending news about the Caspian sea oil rig fire. Read about the incident in this link.
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
December 6, 2015
Lessons relearned - TCE - inadequate isolations
Read a TCE article on Lessons relearned - inadequate isolations in this link.
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
Contribute to the surviving victims of Bhopal by buying my book "Practical Process Safety Management"
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