LPG GAS leak, explosion and burns

Many times it is reported in news papers that there was LPG stove explosion leading to burns / deaths. Not many people are clear whether it is the explosion of stove or cylinder or gas. Normally, the leaking gas creates flammable atmospheres and when someone tries to switch on the light in the morning or uses lighter, the leaking gas in flammable range ignites and explodes. Bursting of cylinder is a rare case which can happen only when the cylinder is exposed to external fire and contents inside are pressurised and then the cylinder explodes with fragments flying all around.

Few years back, it is reported that a fragment from such explosion killed a person on the road. Otherwise, the gas explosion causes burn injuries and deaths to occupants of the building, causes collapse of the roof, shatters window panes, doors, etc.

Simple precautions like closing the regulator after use every time, keeping constant vigil / observation when milk or other items are kept on the stove, changing the hose once in two years or as recommended by the hose manufacturer will keep safe our homes and save us from consequences.

Similar to the above, auto rikshaw drivers check the level of petrol / diesel in the tank in the darkness with the help of a lighted match stick and the vapour in the tank catches fire leading severe burns. Such news reports also appear now and then in the news papers.

Such incidents as above show that people lack even common sense and it is a big question mark about how governments, regulators, society can protect them. Because such acts not only injure these silly people but also affect nearby persons and may cause destruction to persons / property located even 50-100 m away.

Injury to a worker while cleaning concrete mixer - on a HOLIDAY

A new item came today in a Telugu daily that one worker died while cleaning a concrete mixer. As per the news item, Wednesday is a weekend holiday for the company. Therefore, the worker went to the machine to clean the mixer. Not knowing this, another worker switched ON the mixer leading to injuries.
Though the intentions can't be questioned about cleaning on a holiday, it is not clear why different jobs are taken up on the same machine on the same day, by different teams. If such jobs are to be done, then LOTO systems has to be followed. Atleast, one supervisor should stand near the machine so that activities can be coordianted.
Similar incidents happened a few months ago as reported in a news paper that lead to death.
Normally, when someone opens the mixer chamber, a power trip mechanism gets actuated to trip the power supply to the machine, even if he does not switch OFF initially. Just to save few minutes, safety systems are bypassed leading to loss of many days of work. The persons responsible for bypassing the systems should be held guilty and punished severely. The punishment should not be worker level people but to supervisors or higherups who fail to see functionality of safety systems.
Such safety systems should not be located outside where they are easily accessible and can be bypassed. They should be located deep inside the machine so that one has to open entire machine to bypass. May be such designs can prevent persons from bypassing the safety systems.
Again, permit system should be enforced for works on all days irrespective of whether it is holiday or not. Persons should not be allowed to work on machines even if he is over enthusiastic to do the work. They should get permission from Manager of the plant to work on holidays or at period other than normal working hours and it should be logged and intimated to concerned supervisors and safety people. The equipment should have a sort of locking system with keys deposited in Security so that when some one draws the key of the equipment for some work, it will be recorded and the next person who wants to work will be aware of existence of persons.

Such injuries and deaths are total loss and painful to the families, organization and to the society and should be dealt with all seriousness.

Safety for whom - safety officer or plant

Some plant people think that safety officer gives advise / points out unsafe conditions only to show his existence or to protect his job. Protecting job may be correct but it applies to all. We are not here to do some social service. Obliging safety officer is again not to satisfy him or his ego but to protect the people, property and environment in the plant and surroundings and creat a safe work place. This also protects themselves from hassles of occupier and/or regulator from possible penal actions. Because of such thinking by plant people, appointment of safety officer was made mandatory and those organizations which listened to safety officer have shown improvement in working conditions and seen visible and invisible returns in financial terms. Even in these organizations, when there are no accidents for some reasonable period, the memory fades and finance people think that investment on safety is waste till some accident occurs.

It must be remembered that when accident occurs, it occurs after giving sufficient warnings in the form of nearmisses. Thus accidents, though do not assume any human form are like persons with good heart that they warn us sufficiently. And, we the real human beings do not want to see and take corrective actions leave alone preventive actions.

Finally, when accident occurs, it happens with a BANG and everbody questions everybody. Some drama also can be seen. We pretend to have woken up from slumber and soon slip into sleep again.

Though, it has become common to question regulators for their failure to inspect, it impossible task for any regulator to inspect a factory, understand the systems and find hazards or violations. If the sufferer in case of an accident do not want to learn, then nobody can can correct the system. These organizations are destined to suffer and regulators only have to listen some unpleasant things for sometime in the media, because the samething repeats.
Only self control will save the organizations and all other controls are helpful to improve the system, not to correct the system.

If strict regulation is to be done, then governments have to appoint one inspector for every industrial zone containing say 10-15 factories and any violations are to be dealt with strictly by penalties and other forms. When such appointment of regulators is done, financial outgo will be very high and therefore, government has to collect monthly fees from these factories to pay for the regulators and running the regulator's office. Then, may be, safe conditions can be created in the work place.

Safety - headache now or later?

I heard someone saying that following safety principles is a headache but had to be lived with. If such a statement comes from a factory manager, it got more serious repurcussions i.e there will not be any wholehearted commitment and involvement by plant persons. Only lip service will be paid by the shopfloor supervisors and workers. Those who do not understand the evils of not following safety and only live under threat of being questioned by regulators can have such opinions and nobody can help organizations with such people. Not even GOD.

Learning from others-blogs or accidents whatever it is!

I used to write a lot in my earlier posts. However, it's my feeling that these are lengthy. I also saw posts of some bloggers which are brief. So I decided to write only to the point. If I want to explain, I can do it in different posts. This is what I learned from others. Similar thing we can do in learning mistakes done by others when they had accidents or near misses and avoid the same.

Safety legislations - management support

Sometimes, it becomes very difficult when production people question the safety officer about the basis for particular requirement mentioned in legislations or good practices. For example, 15 meter distance between hot work area and combustibles, or 1.05 m extension of ladder above landing, or 4:1 for vertical to horizontal of a ladder, etc. Though one can explain about flying of sparks / proper support for the person to walk on to the landing / prevent fall of persons as reason for these requirements, still one questions in meeting the requirements exactly. Similarly, testing of equipment in the specified period, say once in four years for pressure vessels. Questions will be like, whether pressure vessel will fail, if not tested after 4 years. Such questions look silly and safety professional will loose control of his patience. Further with his role as advisor, he can't reply authoritatively unless top management supports safety officer. If such support is extended, then whatever safety officer says will be obliged, though production people will be unhappy internally. So, legislations alone will not help in improving safety culture in an organization. Legislations or not,what is required is top management support expressed in public and supported to the core.

Don't Relax after peak production in March - examine all your systems for safety

Normally, the month of March is peak production period for meeting the targets of production for manufacturers, financial expenditure for those who ordered various machinery, etc so that they will not receive any flak from Board Directors or Finance Department.

The month of April will be somewhat a lean period, having met the targets and waiting for good news of bonus / pay increase, etc. However, it is good if all establishments plan their annual shutdowns for maintenance in April, test their equipment / vessels / material handling equipment / earthpits, etc as per statutory requirements in this month so that there will not be any question of non-availability of particular system for testing. Production department will be reluctant to release the system for examination in the second half of the year. Thus, April-May is the best period for statutory examinations and annual mainatenance.

Spark arrestors for vehicles entering flammable areas

Last week, when I was driving my motor cycle, I heard bursting soundings most possibly from my bike. Initially, I looked around other vehicles but as I did not see anything unusual, I thought that the sound is from my bike exhaust. Earlier also I saw similar bursting sounds from other vehicles exhaust pipe along with short duration flame.

Imagine if vehicles like fire tender or ambulance with such exhaust enter flammable areas. Instead of saving the property or rescuing the persons, the sparks from these vehicles can initiate fire and explosion.

Safety culture

Recently, I heard a person questioning about preaching of safety culture. He questioned about the credentials of the culture of the preacher saying that the person does not wear helmet while driving from home to office and he preaches about safety culture to others.

Yes, the person is wrong that he is not using helmet. But, by his act, he will be at risk of getting injured. But, in a plant, if the Manager can't inculcate safety culture, then entire staff of the concerned plant as well as those in the vicinity will be affected. By saying you are wrong will not make my wrong act a RIGHT. A wrong act is always a wrong act only. By telling the safety man that your acts outside are wrong and you can't tell me how I should do is not a correct statement at all. These types of arguments are like shadow boxing and will not help in improving safety at the plant.

Another example is a theft has occurred in the house when the occupant is not in the house. Suppose the neighbour informs about the same to the occupant. If occupant replies not bother about what is happening in his house and advises to look into his own house affairs, who will be the loser. Obviously, the occupant. Similarly, in a factory the plant manager will be loser and will be responsible for acts and deeds and may be charged by the regulator depending upon the seriousness of the violations. At that time, plant manager can't tell the regulator that regulator is not wearing shoe or not using the helmet. Before such a thing occurs, the internal safety officer monitors and advises the plant manager for suitable action so that plant manager can avoid embarrasing and difficult situations from his employees as well as the regulator.

Static Electricity - my experiences

I am into the field of industrial safety for the last 10 1/2 years. Before that, I was involved in process equipment design. When, I joined safety department, I started reading about various topics in safety and one such topic is static electricity. For first few years, I had only book knowledge and no experience of what it is.

What already read in books is that static charge will be generated, when we

- comb our hair
- wear synthetic dress
- walk on wool carpets, etc

Following are my practical experiences

- when I approached TV, the hair on the forearm attracted to the picture tube
- After travelling, to get down, I tried to open the vehicle door by lifting the knob on door outside and I received shock
- my friend took out pen drive from his shirt pocket and when he inserted in the USB port, cracking sound came
- when I touched the monitor of desktop computer, I heard noise


- one night, I got up and went to bathroom for pressure relief. I saw some flash from my dhoti ( a cloth worn around instead of knickers / shorts ). I thought it is light reflection because of someone outside my apartment switched ON the light in his house or some vehicle light from ground floor. I had some fear also thinking it as some ghost, as a person died in the house above my house in the apartment block (though I don't believe, but a serious discussion on the issue before sleep with my family members and my denial of existence of ghosts made me to think that something of such sort is there). Then, next day while thinking about the flash in my dhothi, suddenly it occurred to me that my dhothi is synthetic and as it is in two layers, friction between layers might have caused charge accumulation and discharge in the form of flash. After reaching home from office, I waited for night and then closed window and door of my room, covered the window with thick curtain and blanket. Then, I took the same dhothi and rubbed fast and saw flashes generated. Then, I repeated the same and showed to my wife and children. The flashes were light green in colour. I don't know the reason for the colour of the flash, which I has to explore or search.

The last one narrated above is the one which I want to share with all and the lesson is that we should not wear synthetic dress when we work on or near flammable solvents / pyrophoric materials. The practical application of this information is that we should not wear synthetic dress when we go for petrol / gas filling. As we travel for sometime before we reach the pump, charge would have accumulated on the synthetic dress and it is likely that the discharge in the form of spark can initiate fire in the petrol pump station.