June 17, 2014

2 die in steel plant accident

Thanks to Mr Subbu for sending news about Two engineers who were killed at a steel plant when they entered a container laboratory and were apparently asphyxiated by some gas.
Read about the accident in this link

When you enter analyser houses in chemical plants, ensure that the gas alarms are working and that there is no alarm before entering the confined space. As there will be tubing and other places from where gas from cylinders outside can leak, be careful.

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June 16, 2014

Major fire in Russian refinery

Major fire in Russian Refinery courtesy rt.com
See photos and videos in above link.


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The dangers of evaporating liquid nitrogen

A case study where a post graduate student died due to nitrogen inhalation is given in this link . The student was using liquid nitrogen. The accident highlights again the dangers of nitrogen.

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June 13, 2014

Improving road safety in India

Please take some time off to sign this petition. It affects all of us......

Petition to improve road safety in India


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Gas leak in Chhattisgarh’s Bhilai steel plant, 6 killed, 40 injured

A tragic accident where 6 people lost their lives when a water line to scrubber ruptured and gas leaked out: (two DGM's among those killed)

Times of India Gas leak in Chhattisgarh’s Bhilai steel plant, 6 killed, 40 injured


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June 12, 2014

How secure are your redundant systems?

An article in the Guardian highlights the importance of functional testing of your redundant systems. In the incidents mentioned, two helicopters of identical make faced a main lubrication oil system failure while airborne. Though the back up system came on line, an alarm indicated that it was not working properly, so the crew had to make emergency landings in the sea. Later it was found out that the back up system was indeed working fine, but the alarm was wrongly configured.
Read the article in this link. 


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Fire in Refinery

A news article mentions about a fire in a Chinese refinery in the sulphur recovery section. Interestingly, it mentions that the fire reignited a few hours after it was put off due to "chemical reaction of combustible material in an oil tank with fire extinguishing foam".

Read the article in this link. 

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June 9, 2014

Basics of flammability

A good basic primer on flammability, explosion protection and flammable gas detectors can be found in this link. 
PS: I am not endorsing any product - this is for information only.


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June 6, 2014

Ammonia leak hospitalises 54

An ammonia leak due to an apparent pipe burst in a fish processing plant in Tamilnadu has sent 54 of the workers to hospital. The reason is under investigation.
The ammonia leak incidents at the users end as well as incidents related with fireworks are on the increase in India. This is a good case for Large chemical manufacturing companies to take up the education and safety precautions for the small scale industries which handle hazardous chemicals.

Read about the incident in this link.


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June 4, 2014

June 2, 2014

Proposed changes after oil rig accident


The Coast Guard issued a Federal Register Notice of recommended interim voluntary guidelines concerning mobile offshore drilling units, or MODUs, and manned fixed and floating offshore facilities engaged in activities on the U.S. Outer Continental Shelf. This is part of the Coast Guard’s continuing response to the explosion, fire and sinking of the MODU DEEPWATER HORIZON in the Gulf of Mexico on April 20, 2010.

- See more at: http://mariners.coastguard.dodlive.mil/2014/05/02/522014-federal-register-notice-of-outer-continental-shelf-units-fire-and-explosion-analyses/#sthash.zFvYwSqf.dpuf

The Report highlighted the following considerations as areas not specifically addressed by current regulations:
Minimum values are needed for explosion design loads for use in calculating the required blast resistance of structures;
Explosion risk analysis of the design and layout of each facility should be performed to identify high risk situations;
H-60 rated fire boundaries between the drilling area and adjacent accommodation spaces and spaces housing vital safety equipment may be necessary dependent on the arrangement of the facility;
Uniform guidelines for performing engineering evaluations to ensure adequate protection of bulkheads and decks separating hazardous areas from adjacent structures and escape routes for likely drill floor fire scenarios are necessary;
Performance-based fire risk analysis should be used to supplement the prescriptive requirements in the MODU Code; such analysis should use defined heat flux loads to calculate necessary levels of protection for structures, equipment, and vital systems that could be affected by fires on the drill floor;
Maximum allowable radiant heat exposure limits for personnel at the muster stations and lifesaving appliance launching stations in anticipated evacuation scenarios should be implemented.

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May 30, 2014

Tanker explosion

An oil tanker after unloading its cargo of oil has exploded off the coasts of Japan. Apparently, a grinder was being used to clear paint from the walls of the ship when the explosion occurred. Do not underestimate the dangers of hot work even in a so called empty tank. The force of the explosion has ripped open thick metal sheets as you can see in the video in this link. 

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May 27, 2014

Explosion in 3 D printing firm

New technologies but old hazards - A 3-D printing company, was cited by OSHA after an explosion and fire , which inflicted third-degree burns to an employee. The company was using combustible metal powders like titanium and aluminium alloys in the 3D printing process. There were no Class D metal fire extinguishers on-site during the explosion and fire.

"Establishments that use metal powders in this new technology need to scrutinize their processes and take steps to prevent and protect their employees from fire and explosion hazards that arise with these materials," said Robert Hooper, OSHA's acting regional administrator.
Read the details in this link.

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May 26, 2014

Short cuts are wrong cuts - death by H2S

I came across a powerful youtube video about an accident involving hydrogen sulphide in 2008 in the Middle East where 3 people died. The accident occurred in a pit which was open to atmosphere but contained hydrogen sulphide in the bottom.The reason was taking shortcuts and not obtaining a permit. There are lessons to be learnt from this video, my thanks to whoever has shared this on you tube , as it can save many many lives. Ensure all your employees see this video......in this link.

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May 24, 2014

Reactive chemical incident due to human error

In 2012, a tragic accident in a pharma plant in Ireland claimed the lives of two employees. Apparently, the cause was due to human error in a batch reactor, when the reactants were charged without charging solvent first. The rapid reaction took place without the solvent in place to absorb the heat. This caused the reactor to explode. A news article mentions that one of the ambulances that took one victim was later found so contaminated with chemicals that it was decommissioned.
When you know that certain reactions can dangerously overheat if the operator forgets a step, proper engineering controls should be implemented.
Read the details of the accident in this link.

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May 21, 2014

One killed, six injured in NLC steam pipeline burst - The Hindu

One killed, six injured in NLC steam pipeline burst - The Hindu

It appears that the unit in which the accident occurred was over 50 years old and that residual life assessment studies were carried out. Will have to wait for the investigation to understand what happened.



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Williams Cos. reeling from four explosions at facilities in less than year - Tulsa World: Business

Williams Cos. reeling from four explosions at facilities in less than year - Tulsa World: Business

The article explains how a series of accidents have occurred at a company which had a good safety record.



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May 17, 2014

Accident at nuclear power plant - learn lessons

The accident at the newly commissioned Kudankulam power plant highlights the importance of line breaking permits. It appears that while maintenance crew were at work on the shutdown reactor, hot water at about 70 deg C came out of a valve, injuring the workers. While handing over equipment for maintenance, be careful about pockets of trapped hazardous material. Look for any dead legs, which could store them.

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May 15, 2014

Fatal accident during demolition of tank

When you are demolishing a tank or vessel, take adequate care. Conduct a hazard and risk assessment with the demolishing team to make sure the correct method is used. An incident occurred when a  tank being pulled down by an excavator collapsed on the cab of the excavator. Read about it in this link.
 
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May 12, 2014

Fatal accident due to pipe explosion

A good case study on the importance of ensuring proper positive isolation and ensuring the line is gas freed before any hot work is done is given in this link.


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May 9, 2014

Refinery attack In Algeria - Lessons Learnt

On 16 January 2013, terrorists attacked a convoy of gas refinery workers as they departed the housing area of a Refinery in eastern Algeria. The incident led to a four-day siege resulting in the deaths of 38 hostages.
 Read the article of how the emergency was declared by a security guard, (who later died) in this link

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May 5, 2014

Big is beautiful

Shell is building the Worlds first FLNG (Floating LNG production facility) called the Prelude. Watch the youtube video of the launch of the structure from the dry docks in this link. 
Worth watching is the mesmerising work of the tugboats as they steer the Prelude into the sea. The facility is planned to go into operation in 2017.

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May 3, 2014

Micro reactors and process safety

Researchers at Fraunhofer (Europe’s largest application-oriented research organization) have demonstrated how mcro reactors can be used to safely produce even explosives. Read the interesting article in this link.

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May 1, 2014

Hydrogen from CO2 and sunlight

An interesting article in the Times of India mentions the experiment of producing hydrogen using carbon dioxide and sunlight. Worth a read in this link.


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April 27, 2014

Two lab analysts die

Further to my earlier post of an accident due to a naphtha fire in an ammonia plant , it is sad to note that two lab analysts who suffered 80% burns have died in a hospital in Chennai. This incident highlights the dangers which personnel face when dealing with hazardous chemicals. They do not give you a chance. The reason for the incident is being investigated. I had worked as a shift in charge at this plant 30 years back. The place where we used to collect naphtha samples regularly was at the hydrodesulfurisation sections ( primary and secondary) outlet.
Look at all you sample collection procedures and whether all hazards have been identified. Train lab personnel to recognize these hazards and report them to plant personnel.


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April 25, 2014

Simultaneous jobs and their dangers

Many times, during an annual shutdown of a chemical plant, many jobs will be taking place and there is pressure to complete the  jobs on time. Be careful during this period as there may be a tendency to overlook some of the hazards due to simultaneous jobs. Your regular HIRA (hazard identification and risk assessment) may not be adequate and some risks due to nearby jobs may be skipped. Before every turnaround ensure that a special training is given to the people who conduct HIRA on how to identify hazards from simultaneous jobs.


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April 22, 2014

Are you travelling in a confined space?

In a lighter vein........
I am sure many of you will be flying frequently on official visits. Though planes are designed to be evacuated very quickly during an emergency, I often compare them to flying in a confined space! I have tried to correlate the system in chemical industries used for confined space entry to that of flying in a plane:

Confined space entry permit = boarding pass
Man watch = flight stewards
24 V lighting = emergency escape path lighting
Air blower system for ventilation = cabin air pressurisation system
Oxygen monitoring = oxygen masks drop down when oxygen is less
Rescue plan = emergency exits and chutes
Chief emergency and rescue controller= pilot!


I am sure you will be more comfortable when u fly next!! All the best!


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April 14, 2014

Accident at chemical facility at Tarapur MIDC

Close on the heels of the accident at a chemical facility in Andhra Pradesh, news about a series of explosions in a chemical facility in MIDC, Tarapur has been reported. No causalities have been reported. Read about the incident in this link.
 
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April 12, 2014

Chemical factory blast kills two in Andhra Pradesh - The Hindu

Chemical factory blast kills two in Andhra Pradesh - The Hindu



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Fire in ammonia plant injures 7

I felt sad to read the news about a naphtha fire in the ammonia plant of Madras Fertilizers which injured two people seriously. A total of 7 people were reported injured. Read the news article in this link.

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April 11, 2014

Mists of flammable material can be dangerous

In my career as a process safety consultant, I have investigated some fires caused by fine spray of a flammable  liquid. The most common include pressurised lube oil leaking from a defective hose or hose joint and the fine mist catching fire.
Read a good reference of various fire incidents caused by mist fires in this link.


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April 7, 2014

Sulphuric acid spill/leak incidents

Sulphuric acid leak/spill incidents continue to occur. Read about two incidents in these links
Accident 1
Accident 2

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April 5, 2014

PSM internal audit survey results

My thanks to the 22 persons who participated in the survey. The survey results are as follows:

  1.  Over 65% of repsondents say that their PSM internal audit is carried out once in 6 months
  2. All respondents say that they audit all their elements at a time
  3. 30% of respondents replied saying that they audit process safety culture also
  4. 50% of respondents use a rating system for the PSM internal audits
  5. 85% of respondents replied saying that they feel the PSM issues are coming out during the audits
  6. 60% felt that management was not viewing the PSM internal audits seriously
  7. 85% felt that technical competency for conducting PSM internal audits needs improvement
  8. 50% of the respondents say they classify audit findings as per risk.
 
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LNG tank leak incident

An incident at a a large LNG storage facility in Washington state in USA when an explosion in a "processing vessel" sent sharpnels into an LNG storage tank, puncturing it,has lessons in Quantitative RIsk Assessment and assumptions made.
The graphic leak of LNG from the tank ( which is similar to liquified ammonia tanks) but stores LNG at a temperature of -160 Deg C is shown in the video in a news report. The tank also appears leaking at two different places on the outer shell. The wind direction has helped in not igniting the vapour leak.

Link 1 - video
Link 2- news report


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April 3, 2014

The GM recall - what are the lessons in process safety culture?

You must be reading the news about the recall of 2.6 million cars GM made due to a problem in the ignition switch which could shut off the car while driving, disable the airbag, power steering and anti lock brakes. However it is reported that GM took 10 years from the time the problem was discovered and recalling the cars to fix the problem. Meanwhile 13 deaths have been attributed to this.
 In the ongoing Senate hearing, the recently appointed CEO of GM Ms Barra told the subcommittee, "that the new GM is more "focused on the customer" compared to a "cost culture" years ago at the automaker."

What is the commonality between a giant automotive maker and PSM? The answer is "cost culture". Beware of the cost virus in your organisation's PSM system.It can cause deadly accidents.
  
Read about the problem and recall in this link
Read about the testimony of GM Chief in this link

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April 1, 2014

Uzbek fertiliser plant acid spill investigation

In late February 2014, a sulphuric acid spill from a storage facility in a fertiliser plant in Uzbek was reported. Now the investigation reveals that it was a seam failure of the tank. Read the article in this link


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March 29, 2014

Role of HR in Safety

Mr M.K.Rao, Executive Director of India Glycols Limited has written a good article on "Role of HR in Safety". You can read the article in this link.  My thanks to him.

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March 22, 2014

Process safety management internal audit survey

I would appreciate if, for those who are running PSM systems, you answer this survey (8 questions). Results will be published in the blog later.
Take the survey in this link.


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March 19, 2014

Fire in chemical unit

A fire in a  chemical unit in Udaipur has gutted the unit. In the pictures in the news report in this link, you can see remnants of barrels that have caught fire. Often, plants store chemicals in barrels on roads due to lack of space. This practice is a waiting time bomb. Barrels exposed to heat from a fire can explode violently and  spread the fire rapidly. 

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Confined space accident kills 7

 The Hindu Business Line has reported a confined space accident in a textile mill in Erode where 7 workers lost their lives. Apparently, the accident took place when maintenance work was taking place in a sunken pit in a ETP, when a valve broke and released poisonous fumes. The would be rescuers ( 6 of them) entered the  pit one by one to rescue the others and died. Please emphasize in your training the importance of rescuers NOT to enter any space for rescue unless they are adequately protected. This incident  is a tragic loss of life
Read about the incident in this link.


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March 18, 2014

When the back up fails........

 When I was working in Saudi Arabia, the 3000MTD gas based methanol plant was operated with state of the art DCS systems. Just before a planned turnaround, instrument personnel were working with some control room underfloor cables when, by mistake, all power to the DCS displays were lost. It was restored after 30 minutes. The plant parameters were maintained throughout the upset without any safety issue as the controllers in auto were doing their job. However a case study presented in 2012 by Shri KC Tripathy and others of NTPC shows how safety hazards cropped up during "complete and simultaneous DCS failure in two 500MW units"
The case study mentions among other useful learnings, the following:
"All processors (active and redundant) abruptly rebooted at once. Thereby both redundant network & redundant processor concepts of DCS design were defeated".

 Read the case study in this link.



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March 15, 2014

Common causes of flange leaks

Often flanges are a source of leaks, causing release of hazardous chemicals that may result in a fire or toxic chemical exposure. Read a good article on the basic causes of such leaks in this link.
 

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March 11, 2014

Process safety - voluntary or regulatory?

I read an interesting editorial in the "Record" about the above subject. Worth reading in this link.


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March 7, 2014

Lessons from NASA astronaut "water in helmet" incident

In July 2013, during a spacewalk outside the International space station, an astronaut reported water entry into his helmet. He was asked to get back only after he made three calls saying the water didn’t appear to be from a drinking bag. Later it was found out that the drinking bag was not the problem and a choked filter was the cause of the leak. The NASA investigation report mentions some of the reasons for the incident as inadequate training, the crew members and ground misunderstanding the severity of the situation, and a (false) perception that any water leak is likely due to a problem with the drinking bag. Do not normalize deviations!
Read more: http://www.universetoday.com/109814/as-astronauts-helmet-filled-with-water-he-told-nasa-three-times-it-wasnt-from-the-drinking-bag/#ixzz2uuMFin1Z

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