July 4, 2014

Article on flange leaks

Even though this article is 9 years old, the causes of flange leaks remain the same. Worth reading in this link.
PS: This is for information only.

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July 2, 2014

Responsible Care - reinforcing public opinion

The Indian Chemical Council is promoting Responsible Care and trying to motivate organisations into obtaining the RC logo it awards. This is a good initiative but the public needs to have faith in the process. The public are always sceptical of any self regulation by an industry body as they feel that it will be compromised. I have a few suggestions to the ICC to help to make RC more acceptable by the public:

1. The logo should be awarded with the condition that it will be withdrawn if a fatal or reportable accident occurs after awarding the logo. The company then has to go through the whole process for obtaining the logo. ICC must not only publicise the list of companies that have been awarded the logo, but also publicise the names of companies for which the logo has been withdrawn.
2. The best practices of every company that has been awarded the logo should be publicly displayed in ICC website for anyone to emulate.
3. One of the conditions of awarding the logo should be contribution to a fund to improve safety in the SME sector of chemical industries, including fireworks industries. The contribution could be fixed as a percentage of turnover.The improvement of safety in the SME sector of chemical industries should be taken up by ICC themselves and this must be publicised.


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June 30, 2014

A simple slogan

 Yesterday, while driving behind a car, I saw a sticker on  its rear window which said
" WEAR YOUR SEAT BELT - YOU PAID FOR IT"
 A simple yet effective slogan!

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Technology is not a complete substitute

The saga of the missing Malaysian airlines MH370 flight highlights the fact that technology is an enabler but it cannot override the human. The way in which vendors are hard selling process safety technology these days worries me. A typical case is SIL rated instrumented systems. While the statistics and numbers sound very good, no vendor is gong to tell you about the life cycle needs and cost of maintaining these systems.

Nowadays, I also see many cases of the operation staff  left out of the design loop. The net result is that the operator gets a system which leads to work overload during emergencies. Then the vendor hard sells "alarm management software"!!
Somewhere in our journey of process safety management we have forgotten Dr Trevor Kletz's inherent safety philosophy of "keeping it simple".
I often see complicated PSM systems in many "World Class" companies. These systems are "managed" by separate PSM cells.....have we forgotten that the owner of PSM is operations? I often see the systems getting more complicated because the PSM cell needs to justify their existence! (My due apologies if I have hurt anyone).

Having had the fortune to learn about process safety when the word was not in "fashion" , I pray the post bhopal generation of chemical engineers realise that managing process safety is not only about technology........design it for humans who make mistakes.....keep it simple and easy to understand.


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June 28, 2014

Visakhapatnam pharma unit blast: Condition of three critical - The Hindu

Visakhapatnam pharma unit blast: Condition of three critical - The Hindu

Thanks to Mr Subbu for sending news about the blast.
Ammonia and high temperature are dangerous due to the thermal expansion coefficient of liquid ammonia.

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June 27, 2014

Update on GAIL pipeline blast


The Hindu: GAIL pipeline blast in AP


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Pipeline fire kills 14 in AP

News filtering in of a GAIL pipeline blast in Andhra Pradesh which has reportedly killed 14 people. Read the story in this link


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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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