Human error likely caused the deadly explosion

http://www.manufacturing.net/news/2016/10/basf-says-deadly-explosion-german-plant-likely-caused-error
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4 killed due to toxic gas leak in Gujarat

http://indianexpress.com/article/india/india-news-india/gnfc-tdi-gas-plant-leak-four-killed-3735121/

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Fire at insecticide factory injures 8

News reports indicate at least eight persons have been injured in a fire at Hndustan Insecticides plant in Kerala. The fire is attributed to carbon disulphide.
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Corrosion Induced Explosion of a High-Pressure Fire-Extinguishing Gas Cylinder

Thanks to Mr Satya Subrahmanyam DGM, EHS, Coromandel International Limited, for sending a link to the article Corrosion Induced Explosion of a High-Pressure Fire-Extinguishing Gas Cylinder in the Journal of Failure Analysis and Prevention -October 2014, Volume 14,Issue 5,pp 564–568 by Yong Jiang,Jian-ming Gong,Peng-jie Tang.
 The abstract of the article mentions "The failure of a high-pressure fire-extinguishing cylinder was investigated. Failure was induced by internal surface corrosion and stress corrosion cracking (SCC) due to condensation of carbonic acid. In internal surface, especially the area near the bottom of the exploded cylinder, severe corrosion was characterized by local pits. SCC initiated from these local corrosion pits was observed by metallurgical analysis. Microstructure of the failure cylinder near the internal surface consisted of multiple-banded structure and the banded structure could accelerate local corrosion initiation and propagation. The corrosion products built up on the fracture surface were primarily ferrous carbonate (FeCO₃). The determination of moisture in fire-extinguishing gas was also examined."
Be careful of your CO2 extinguishers. Traces of moisture which can get in during refilling can cause the formation of carbonic acid and cause corrosion.


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Inadvertent mixing incident causes chlorine cloud

More than 100 people were treated for respiratory problems after an inadvertent mixing of chemicals caused a large gas cloud at a plant in Kansas, USA. The two chemicals involved in the spill were identified as sulfuric acid and sodium hypochlorite, which mixed to create a chlorine cloud.
Are you training personnel on the inadvertent effects of mixing of chemicals?

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Human factors aviation incident

http://www.hindustantimes.com/india-news/ht-exclusive-when-jet-airways-flight-with-150-people-made-a-blind-landing/story-J4G7r26AZbUQC7WzQStbiJ.html

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Walk the Line - Chemical Processing

 http://www.chemicalprocessing.com/articles/2016/process-safety-walk-the-line/?show=all

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Caustic soda handbook

PPG industries, as part of their Responsible Care initiative have published a very good safety handbook on Caustic soda. You can read it in this link.


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Toxic Warehouse Fire In Maywood Out, But Evacuees Still Can't Go Home

Though this incident occurred in June, there are lessons to be learnt in emergency planning and response.

Toxic Warehouse Fire In Maywood Out, But Evacuees Still Can't Go Home: Crews are now making sure there are no lingering health risks before letting the rest of the evacuees return home.


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Ludwigshafen fire: BASF blast hits German HQ - BBC

http://www.bbc.com/news/world-europe-37676974

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Interesting article on incentives and motivation

 http://insight.kellogg.northwestern.edu/article/finding-the-right-performance-incentives-to-motivate-employees

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Hazards of nitrogen asphyxiation in confined spaces

 Hazards of nitrogen asphyxiation in confined spaces

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Van explosion due to epoxy resin

A van explosion and fire in Chelmsford in UK has been attributed to a self-combusting epoxy resin which the van was transporting. Understand the hazards of chemicals by reading the MSDS.
Read more at http://www.essexlive.news/chelmsford-van-explosion-pictures-show-devastation-on-city-centre-road/story-29782245-detail/story.html#lfd47Y66JXsfjDiu.99


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Osha citation

http://www.prnewswire.com/news-releases/calosha-cites-exxonmobil-for-failing-to-repair-equipment-that-exposed-workers-to-dangerous-chemical-leaks-300231305.html

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Flare system impaired by cooling water loss through bursting disc failure on an Intercooler Heat Exchanger

 Flare system impaired by cooling water loss through bursting disc failure on an Intercooler Heat Exchanger

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59% of India vulnerable to moderate to severe quakes - Times of India

 http://timesofindia.indiatimes.com/india/59-of-India-vulnerable-to-moderate-to-severe-quakes/articleshow/54436134.cms

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Shell safety chief urges industry not to get bogged down by KPI's

https://www.energyvoice.com/oilandgas/119161/shell-safety-chief-urges-industry-not-get-bogged-kpis/

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China averaged 29 chemical accidents per month so far this year - Greenpeace

China averaged 29 chemical accidents per month so far this year - Greenpeace: Beijing, 21 September, 2016 - 232 chemical-related accidents occurred in China from January to August 2016, an average of 29 per month, according to Greenpeace East Asia’s ‘Chemical Accident Counter’. The accidents caused 199 deaths and 400 injuries. The findings demonstrate the lax management of China’s chemicals industry, the world’s largest. In addition, preliminary findings from Greenpeace East Asia’s chemicals industry distribution mapping shows a worrying correlation of facility location and population density, as well as proximity to ecologically sensitive areas. Greenpeace calls on the Chinese government to radically overhaul the current chemicals management system and introduce greater transparency.


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Bomb Squad: How Cops Safely Move Explosives

Bomb Squad: How Cops Safely Move Explosives

Interesting fact about ""Total containment

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Project Profile: Blast Resistant Central Control Facility | SSOE Group

Project Profile: Blast Resistant Central Control Facility | SSOE Group


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How many people die at US oil refineries each year? - EHS today

An article published in 2015 in EHS today gives the number and reasons for accidents in US refineries till 2015. An interesting statistic from the article is "At least 64 people died at refineries in the 10 years before the BP explosion. At least 58 people have died since March 23, 2005". Read the article in this link.

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Ball valve wrongly fixed causes an incident

A propane gas release took place during the opening of a flange on the downstream side of a ball valve on a propane pipeline.The ball valve was installed in the wrong direction, so that the cavity vent released the flow to the down stream side rather than to upstream side as intended. The incident occurred when vapor was released when the flange bolts on the downstream side of the ball valve were loosened. Personnel arrested and stopped the release of propane vapor after tightening the flange with full bunker gear and self contained breathing apparatus.

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Ammonia tanker accident 1976- lessons to learn

 Ammonia tanker accident 1976- lessons to learn

 http://abc13.com/news/a-look-back-40-years-after-the-worst-accident-in-houston-history/1332062/

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Accident in Sewage Treatment plant

Employee #1, the lead operator of a sewage treatment plant, noticed that the residual levels had dropped in the tanks, and he decided to add more ammonium hydroxide to increase the residual levels. Employee #1 removed the camlock fitting and line from an empty 335 gallon tote and installed it to a full 335 gallon tote containing ammonium hydroxide solution. While installing the camlock fitting and line onto the full tote, he failed to secure the camlock fitting latches into the valve coupling grooves.

As Employee #1 turned the valve to the open position, the camlock fitting and line sprung off the coupling and sprayed ammonium hydroxide onto his upper legs and groin area. Employee #1 immediately turned off the valve and secured the camlock fitting latches into the coupling grooves. He then went to the emergency eyewash/shower, approximately 120 feet away, to rinse off the ammonium hydroxide. Employee #1 rinsed for approximately 15 minutes, but did not take off his clothing.

He then drove a golf cart to the administrative building, to notify management of the accident. Management summoned emergency medical services at approximately 9:45 a.m. and rinsed Employee #1 with an emergency eyewash/shower, located in the administrative building, until the ambulance arrived. Employee #1 was transferred to the hospital via ambulance at approximately 10:00 a.m. He was hospitalized for two days for treatment of chemical burns to his upper legs and groin areas.
The use of ammonium hydroxide to control residual levels in tanks was a new process at the facility. No written procedures or hazard assessments were completed for the assigned task. Employee #1 was wearing safety glasses but no other form of PPE during the accident. Employee #1 said he was in a hurry and normally would have worn rubber gloves and a respirator while transferring the camlock and line from one tote to another.

 Source: Fire Analysis and Research Division,National Fire Protection Association

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Insulation Integrity

Mechanical repair of insulation is important

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Emergency response to a fire in a Motor spirit tank in a refinery

Read about a response to a fire in a Motor spirit tank in a refinery in this link.What lessons can you learn?

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Investigation report on Ammonia gas leak

A few posts back, I had written about the ammonia gas leak in a Bangladesh DAP plant that affected many. The district administration's investigation has determined the following:

• The company constructed the 500-tonnes reserve tank in 2006.The tank was filled with 250 tonnes of ammonia gas when it collapsed on the night of Aug 22.
•  Tank was maintained by unskilled staff. Five essential safety equipment, that were needed to prevent the tank’s collapse, had been out of commission for a long time.“The two pressure gauges of the tank were out of order long before the accident took place. Both the pressure transmitters of the reserve tank were inoperative. The condenser, safety valves and pressure vent were also out of order,” said the investigator. 
•  The factory’s operation department had informed the maintenance department about the faults but they did not pay heed
• The gas spread far and wide so rapidly because the fire hydrant system of the fertliser factory did not work after the accident.”

Read the article on the investigation in this link.

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Molten sulphur tank explosion in refinery in USA

News reports coming in of a molten sulphur tank explosion in a refinery in USA . No one was injured. Read about the incident and see the video in this link


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Confined space incident during rubber lining of a tank

Two workers who were involved in the rubber lining of a metallic tank located in a university campus died as a result of the confined space becoming full of chemical vapours. Basic precautions were not taken. The government appointed a fact finding team whose report you can read in this link.
Read another article on the safety of unorganised labourers in this link.


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Containing the contents - Chernobyl

The massive effort to provide a containment for the damaged Chernobyl nuclear reactors is worth a read. Funded by the G7 countries along with contributions fom many countries, the USD 1.7 billion effort is to construct " A New Safe Confinement that is 110 metres high and 165 metres long, and has a span of 260 metres and a lifetime of a minimum of 100 years. When completed, the New Safe Confinement will prevent the release of contaminated material from the present shelter and at the same time protect the structure from external impacts such as extreme weather.The new structure will be an extraordinary landmark, tall enough to house London’s St Paul’s or Paris’ Notre Dame cathedrals, To minimise the risk of workers’ exposure to radiation, it has been assembled in the vicinity of the site and will be slid into position before the end of 2016.The arch-shaped structure will weigh more than 30,000 tons. Its frame is a huge lattice construction of tubular steel members, supported by two longitudinal concrete beams.It will provide a safe working environment equipped with heavy duty cranes for the future dismantling of the shelter and waste management after the completion of the NSC.It will be strong enough to withstand a tornado and its sophisticated ventilation system will eliminate the risk of corrosion, ensuring that there is no need to replace the coating and expose workers to radiation during the structure’s lifetime."

Read more about it in the EBRD website in this link.

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Training tackles memory distortion to improve process safety

 Training tackles memory distortion to improve process safety


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Ammonia leak from DAP plant affects many in Bangladesh

An ammonia leak from a DAP plant in Bangladesh has reportedly affected many people. Reports indicate that the DAP plant was located near a urea complex and the capacity of the tank that leaked was 500 MT.
Read the article in this link

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Inappropriate maintenance practices and fire protection lead to excavator fire

Inappropriate maintenance  practices and fire protection lead  to excavator fire

For plants which operate payloaders and other heavy equipment, ensure this is not repeated in your facility.

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Interesting human factors incident

Interesting incident about a plane descending 4000 feet as a camera carried by the pilot got wedged between the seat and yoke in this link

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Fatalities during manual tank gauging

An innocuous looking task such as tank gauging has claimed the life of 9 people in the oil and gas sector as per OSHA.  Read the safety alert in this link and share it with your personnel who gauge such tanks.

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