Process Safety Incidents - Case Studies

 

Process Safety Incidents - Case Studies

Ventilation Requirements for Confined Space

Process industries are more complex and have more hazards than the normal industries, Most of the process related incidents are catastrophic, many have the possibility of causing significant injury, property and environmental damage, and heavy business impact. The following incidents provide examples for large companies happened around the world.

 Ergonomic Safety – Part 1

• Bayer Crop Science, 2008, United States –

On startup of the methomyl process, which is used to make insecticides, a runaway reaction occurred inside a 4500-gallon pressure vessel that exploded killing two workers and injuring eight. Many roads were closed and 40,000 people in the surrounding areas were asked to shelter-in-place as a precaution. The incident investigation report stating that many safety deviations resulted into this incident. The U.S. Chemical Safety Board (CSB) report concluded that written startup procedures were not followed, safety devices were bypassed, and many other factors contributed to the incident. Fortunately, a nearby tank containing a highly toxic material, methyl isocyanate (MIC), was not damaged by the explosion or the incident may have been worse. This incident resulted into the loss of life and a huge investment. The methomyl process was not operating, and $80 million was invested to improve the safety of MIC storage and handling, although the company decided to shutdown the use of MIC at the facility before startup.

 Confined space standby man responsibilities

• Imperial Sugar, 2008, United States –

Dust explosion in the process industry is highly dangerous with respect to human safety and equipment damage & environmental concerns. This sugar refinery processed raw cane sugar into granulated sugar. Conveyers and elevators were used to transport sugar through the plant and to large storage silos. An initial dust explosion occurred in a conveyer near the storage silos that dispersed additional sugar dust into the air, leading to secondary dust explosions and fires throughout the facility. Fourteen people were killed, 36 were injured, and the facility was severely damaged. U.S. Chemical Safety Board (CSB) concluded that equipment design and housekeeping practices allowed sugar dust to accumulate that led to the explosions.

 FIRE PUMP SYSTEM

• Bhopal, 1984, India –

One of the major incident in India, A pesticide plant was not operating, but a large release of highly toxic methyl isocyanate (MIC) occurred from storage that resulted in many fatalities and injuries in the nearby community in the middle of the night. Water was introduced into a storage tank containing MIC that led to a runaway reaction and subsequent venting of MIC from the tank. Many safeguards at the site, including tank refrigeration, instrumentation, scrubber, and process flare, were shut down or not operating. The lack in safety awareness on the MIC also a leading factor for the more casualties.

 Construction Safety Pictorial Guidelines

• Piper Alpha, 1988, United Kingdom –

This incident is one big in the oil & gas industry, Piper Alpha was a large oil platform in the North Sea. After the accidental release of flammable hydrocarbons, a series of explosions and fires occurred that led to total destruction of the platform, 167 fatalities, and a property loss of $1.5 billion. The investigation of the catastrophe determined that a primary cause of the event was a faulty work permit system that separated the work permits for a condensate pump and its associated relief valve, allowing the pump to be inadvertently started up with the relief valve still out-of-service. The ineffective permit to work / work permit system resulted into the loss of many lives and huge property damage.

Hot Work Safety - A Complete Guide to Safe Practices