June 4, 2015

Hydrogen safety

Good practical article on hydrogen safety. Worth reading in this link

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May 28, 2015

NTSB Safety Alert Urges Pilots to ‘See and Be Seen’ in the Air

NTSB Safety Alert Urges Pilots to ‘See and Be Seen’ in the Air

The safety alert has parallels in Process Safety. I feel that with overdependence on automation and technology, plant operators also are slowly forgetting how to run a plant!


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May 24, 2015

Piping failure incident

 Read about a case study of a piping failure incident due to external corrosion in this link


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May 18, 2015

Phosphoric acid tank explosion

The late Dr Trevor Kletz had written about this incident in a safety bulletin:

'Small quantities of hydrogen are usually produced when corrosion occurs. If the hydrogen cannot escape and accumulates in the plant, an explosive mixture may be formed. This has caused some fires or explosions in surprising places. Some years ago an explosion occurred in a storage tank of phosphoric acid due to hydrogen produced by corrosion. The tank vent discharged downwards near a walkway. A welding spark ignited the escaping hydrogen and blew the roof off the tank.

The tank was modified so that the vent was in the centre of the roof and the hydrogen could escape easily".

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May 12, 2015

Process Safety Challenge

PROCESS SAFETY CHALLENGE

A fertiliser plant burns natural gas in a hot air generator and uses the hot air to dry the product. The natural gas line inside the enclosed fertiliser plant building is getting corroded due to the corrosive atmosphere inside. Recently, a leak occured in the natural gas line due to corrosion. The NG line pressure is 2.5 barg. A suggestion to enclose the NG line inside the building with an enclosure and providing gas detectors within that enclosure has been raised. You are the MOC (management of change)  approving authority. Will you agree for this change? If not, please list down your comments.

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May 10, 2015

Firefighters, DuPont employees evaluated after leak at plant

Firefighters, DuPont employees evaluated after leak at plant


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Be careful while cleaning "empty" drums

During drum washing operations, a 45 gallon drum exploded due to a buildup of pressure inside the drum.The force of the explosion resulted in the drum flying out of the site onto the roof of a neighbouring building.The drum was one of a batch 70  "empty" drums delivered to the site to be cleaned.The drums all contained residues of acetyl-chloride (a water reactive substance).
Treat "empty" drums with great care! It may look innocent but can kill.


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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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April 1, 2015

Incomaptibile chemicals cost you!

A radiation leak from a drum containing radioactive waste at an underground nuclear waste dump in New Mexico was caused by “chemically incompatible” contents, including cat litter, that reacted inside a barrel of waste and caused it to rupture. It is reported that cat litter containing silicates is purposely used as a stabilizing agent in nuclear storage for stabilizing radioactive nitrate salts. A scientist inadvertently used an organic brand of cat litter which does not contain silicates. After some days, the nitrate salts in the barrel heated up, releasing hot gases, pressurised the drum and ruptured it.
 The damage caused a  radiation leak that will cost approx. USD 240 million to clean up!
Read the report in the Telegraph in this link


This is not an April Fools day joke!!!!!

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March 28, 2015

Access and Accidents

The German wings plane that crashed in the Alps on Tuesday killing all onboard is being attributed to the co pilot intentionally crashing the plane, when the pilot went out of the cockpit. The pilot was not able to regain access to the cockpit as the copilot is alleged to have locked the door from inside. There is an interesting video from popular science about how the cockpit door locking arrangement works.

Coming back to our industry, more and more electronic access systems are being installed in chemical plant control rooms and hazardous chemical storages to prevent unauthorized access. But have you thought about everything including emergency response or evacuation requirements in case of malfunction of these access control systems?

See the video about how the cockpit door locking arrangement works in this link.

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March 27, 2015

March 22, 2015

Could a Texas City blast happen again? Read the investigation at HoustonChronicle.com

Ten years after a Texas City refinery blast killed 15 and rattled a community, workers keep dying. The Houston Chronicle and The Texas Tribune investigate.
 http://www.houstonchronicle.com/texascity



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March 21, 2015

March 13, 2015

Golden Rules of Total

 Total, the oil and gas multinational has Golden rules for safety in its website which can be accessed in this link

 
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March 10, 2015

Confined space fatality in chemical tanker - lessons to learn

A confined space fatality incident in a chemical tanker highlights the dangers when we take safety precautions and permits lightly. This can happen to even the most experienced persons. Discuss this incident with your personnel and the lessons learnt. The incident case study is in this link.

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March 4, 2015

Chemical Safety Board Under Fire

Chemical Safety Board Under Fire



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Thermal expansion accident

Thermal expansion inside a valve caused the bonnet of the valve to fail. The safety alert mentions the following:

Pressure build-up occurs in the gate valve cavity from thermal expansion of fluids. Extreme pressure build-up from fluid expansion can occur if the valve body is completely full of fluids (e.g., a grease/oil/water mixture) and heated to elevated temperatures. Such pressure can exceed the rated working pressure of the valve.

A valve with the ability to isolate the body cavity from the flow line may be at risk.
Presence of grease or compounds designed to enhance sealing ability may exacerbate the condition.
Grease or a grease/oil/water mixture when heated in a sealed enclosure can exceed 7000 psi (48.5 MPa) at 250 °F (121 °C).
Gate valve body cavities that are not 100% full of fluids do not experience excessive pressure as the vessel was heated. Trapped air or gas allows room for thermal expansion.

Read the safety alert in this link. 

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February 27, 2015

Depending on ROV's for isolation is bad design

An accident in a refinery in 2007 that killed 4 contract workers highlights the dangers of depending only on ROV's (remotely operated valves) for isolation. A maintenance job was being carried out on a hot oil line. Operators closed a ROV in the line and issued the permit to remove a blind on the downstream flange of the ROV. Instrument air to the ROV was left open. (ROV is a fail to close valve) When the maintenance workers were fixing the chain block to remove the blind, it inadvertently hit the switch on the ROV control field panel and opened the valve, causing hot pressurised oil to spray, ignite and kill the 4 workers.  

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February 24, 2015

Blast in Hyderabad-two-die-13-hurt- Times of India

Blast in Hyderabad, two die, 13 hurt - Times of India

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Lessons from Fukushima

Read the lessosn learnt from Fukushima in this link  http://nas-sites.org/fukushima/files/2012/10/Kitazawa.pdf

It applies to us in the CPI, too!


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February 22, 2015

Management decision during crisis

Continuing with Fukushima, a very interesting read on Fukushima and management decisions!
http://www.nikkeibp.co.jp/rebuild/en/article_09/index_03.shtml

 
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February 16, 2015

Don't Normalise deviations!

 In 1994, a fatality caused by exposure to hydrogen sulfide occurred at a refinery. The accident  occurred while draining of a fuel gas knockout drum in a hydro treating unit. Normal work procedures included periodically opening a valve that carried a water-gas mixture to a separator which removed and vented hydrocarbon gases to a flare. During the preceding winter, the piping to the separator froze, and the drum was temporarily drained to the sewer. This deviation went unnoticed and the temporary practice of draining to the sewer continued. On the day of the incident, the operator opened the valve to the sewer believing it to be part of the draining procedure, resulting in the release of toxic amounts of hydrogen sulfide that killed the operator.

Source: osha.gov

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February 12, 2015

February 11, 2015

Explosion in pyrolysis plant

 Read case study of explosion in pyrolysis plant


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