DO NOT TRY THIS ANY TIME, ANY WHERE.
Superman in India
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Nov 10, 2010
Nov 9, 2010
Responsibilities and limitations of regulators
Recently, I read in local news papers about the fire in a chemical plant. It is stated that during distillation of a chemical to supply to a factory, water entry caused explosion causing serious injuries to four workers. A visiting representative expressed his anger on the concerned Inspector of Factories for allowing the factory to run without permission. The licence for the factory expired a few years ago. Regional Pollution Control Board (PCB) also suspended the operations after a fire incident a year before. The anger of the representative is justified. That the plant was closed by PCB after a fire incident, two years after expiry of licence indicates that the plant was in operation all along.
But, on the other side, what are the resources available to the factory inspectors. What are the powers available to the inspectors. When an inspector identifies a plant with dangerous conditions or without valid licence, he will stop the operations. But, how to ensure physical stopping of operations. The factory inspector can't become watchman for the factory to ensure this. If that is the case, then for every factory or a few factories, one inspector is required. At this rate, the factory department needs hundreds of factory inspectors which is not at all possible because of lack of funds. This is a system failure.
If a factory is run inspite of stopping orders, then the occupier is liable along with the authorities responsible for continuing to supply services likes electricity, water, etc. Similarly, municipality, revenue, police, excise, customs departments which collect taxes and other service charges are also responsible. They can't work independent of other agencies. Once these agencies are intimated about a factory closure, all concerned have to keep check on the said factory. In addition, the customers (factories buying products) of the guilt factory should also be held responsible for making purchases without checking validity of licences. Now a days, with ISO certification, every management needs to ensure proper licences and authorizations before purchasing any items. Of course, if the product is a finished item for purchase by public, then these public can't be held responsible as there is no way of checking the credentials before buying.
There is no information in the news papers about how many times the factory inspector inspected the plant in the last few years. If there were inspections, factory inspector is equally responsible for the incident.
When a proper coordination exists between all concerned agencies as listed above and others, I am sure the hands of factory department will be strengthened to ensure safe work place.
But, on the other side, what are the resources available to the factory inspectors. What are the powers available to the inspectors. When an inspector identifies a plant with dangerous conditions or without valid licence, he will stop the operations. But, how to ensure physical stopping of operations. The factory inspector can't become watchman for the factory to ensure this. If that is the case, then for every factory or a few factories, one inspector is required. At this rate, the factory department needs hundreds of factory inspectors which is not at all possible because of lack of funds. This is a system failure.
If a factory is run inspite of stopping orders, then the occupier is liable along with the authorities responsible for continuing to supply services likes electricity, water, etc. Similarly, municipality, revenue, police, excise, customs departments which collect taxes and other service charges are also responsible. They can't work independent of other agencies. Once these agencies are intimated about a factory closure, all concerned have to keep check on the said factory. In addition, the customers (factories buying products) of the guilt factory should also be held responsible for making purchases without checking validity of licences. Now a days, with ISO certification, every management needs to ensure proper licences and authorizations before purchasing any items. Of course, if the product is a finished item for purchase by public, then these public can't be held responsible as there is no way of checking the credentials before buying.
There is no information in the news papers about how many times the factory inspector inspected the plant in the last few years. If there were inspections, factory inspector is equally responsible for the incident.
When a proper coordination exists between all concerned agencies as listed above and others, I am sure the hands of factory department will be strengthened to ensure safe work place.
Nov 2, 2010
Dangers of confined spaces - Oxygen levels below 19.5%
I read an excellent article on wrong notions of safe oxygen level of 19.5%. One should find why oxygen levels are below 21% and only after getting satisfactory answer, should venture into confined space with proper PPE. I feel that, once oxygen levels are below 21%, one should go inside only with airline respirator / self contained breathing apparatus as suitable it is. We should remember that catridge/canister type respirators are useful only upto 2% of contaminant concentrations and above this, one should use fresh air supply system.
Oct 19, 2010
Process safety and stuxnet worm?
Of late a number of articles are appearing on impact of stuxnet worm on process safety and it is an eye opener for me. Though, I am bothered about safety of my computer at home and office, it never occurred to me that this can lead to accidents in plants which are operated from computers. Possibly, this is due to the fact that only limited sections are operated from computers in the facilities which I saw all along.
Now that I am aware of this stuxnet worm and its cousins that can affect process safety, I though what we can do to prevent such process safety hazards and following are some that came to my mind.
1. As the worm has to enter through internet / removable disks, these computers should not be connected to internet.
2. There should not be any provision to use pen drives, floppy drives, CDs.
3. Realtime protection from viruses, worms, etc should be available. For this realtime protection program loading, the server system should be under lock and key control of a senior officer. If it is affected, then this man only is the channel for viruses/worms to enter the system.
4. A realtime standby system operating on a different mode should be available (diversity in redundancy).
5. Backup should be taken in every shift.
6. The persons manning the control room should change their dress totally in the change room and enter with company provided dress before entering control room / server room.
7. Control room, server room, etc should be under surveillance.
8. As it is seen in the movie Die Hard (2?) of taking over all control systems by connecting from distance, the cables connecting servers with plant data monitoring and control cables should be secured and any attempt to interfere should be sensed and alarmed.
9. Like railway gangmen check the rail tracks regularly, cable system should be checked physically also by authorized staff.
Above are some thoughts which came to me for ensuring process safety from worms like stuxnet. I have to understand about how plants are operated from computers and what are their defence systems.
Now that I am aware of this stuxnet worm and its cousins that can affect process safety, I though what we can do to prevent such process safety hazards and following are some that came to my mind.
1. As the worm has to enter through internet / removable disks, these computers should not be connected to internet.
2. There should not be any provision to use pen drives, floppy drives, CDs.
3. Realtime protection from viruses, worms, etc should be available. For this realtime protection program loading, the server system should be under lock and key control of a senior officer. If it is affected, then this man only is the channel for viruses/worms to enter the system.
4. A realtime standby system operating on a different mode should be available (diversity in redundancy).
5. Backup should be taken in every shift.
6. The persons manning the control room should change their dress totally in the change room and enter with company provided dress before entering control room / server room.
7. Control room, server room, etc should be under surveillance.
8. As it is seen in the movie Die Hard (2?) of taking over all control systems by connecting from distance, the cables connecting servers with plant data monitoring and control cables should be secured and any attempt to interfere should be sensed and alarmed.
9. Like railway gangmen check the rail tracks regularly, cable system should be checked physically also by authorized staff.
Above are some thoughts which came to me for ensuring process safety from worms like stuxnet. I have to understand about how plants are operated from computers and what are their defence systems.
Empowering safety department - How long?
Recently, I read an article that the new boss of BP is reshuffling the safety division and is making it as the most powerful voice and that they can intervene in any of the technical functions of the BP. This is what is required by law also. Only that we do not follow.
I do not doubt about the capabilities of earlier safety staff of BP. I doubt only about the production staff. It is normal to see in any production facility that production staff and their bosses pay little attention to what safety department says. As the safety department is part of the facility, it can only advise. Implementation depends on the whims and fancies of the production department. Safety department becomes powerful only when the top man gives unconditional support to it. In the present case also, though the new boss ALLOWED safety division to be powerful, the time upto which it can be allowed to function this way will be limited, as Mr Trevor Kletz said, "corporate memory is short". As the memory fades gradually, well meant safety advises become additional work and time consuming for the production staff and slowly they start ignoring the safety advises. By that time, the BP boss who is making safety division powerful may also leave the organization and the STORY WILL REPEAT. Again as observed by Mr Kletz in his books.
It is my observation which evolved with my interaction with many of my friends in various industries and also from my knowledge of reading various books, safety blogs and investigation reports of CSB, HSE, etc that it is a worldwide phenomenon of giving importance to safety only after an accident and then slowly forgetting about it.
A KNEE JERK REACTION INDEED.
I do not doubt about the capabilities of earlier safety staff of BP. I doubt only about the production staff. It is normal to see in any production facility that production staff and their bosses pay little attention to what safety department says. As the safety department is part of the facility, it can only advise. Implementation depends on the whims and fancies of the production department. Safety department becomes powerful only when the top man gives unconditional support to it. In the present case also, though the new boss ALLOWED safety division to be powerful, the time upto which it can be allowed to function this way will be limited, as Mr Trevor Kletz said, "corporate memory is short". As the memory fades gradually, well meant safety advises become additional work and time consuming for the production staff and slowly they start ignoring the safety advises. By that time, the BP boss who is making safety division powerful may also leave the organization and the STORY WILL REPEAT. Again as observed by Mr Kletz in his books.
It is my observation which evolved with my interaction with many of my friends in various industries and also from my knowledge of reading various books, safety blogs and investigation reports of CSB, HSE, etc that it is a worldwide phenomenon of giving importance to safety only after an accident and then slowly forgetting about it.
A KNEE JERK REACTION INDEED.
Sep 30, 2010
Process Safety Management - for whom?
Everybody says process safety management (PSM) without knowing or having commitment. Many may be thinking it as day-to-day plant operation. In this regard, to identify, evaluate and control hazards in chemical plants, OSHA has given guidelines and can be read here.
It must be understood that by doing PSM, we are doing favour to ourselves and not to others. Even, production cost can be brought down, if we do PSM sincerely and follow it. If we do not care to spillages/leakages of chemicals, air, steam; do not care to study in detail before going for a new process / chemical / modification; do not make checklists for operations, then it means that enough attention is not paid for plant operations and it adds to cost of production by way of wastage, inefficient operation, accidents, and so on.
We should not feel like Alice in the wonder land when the unidentified hazards manifest into incidents/ accidents. One may feel stressed to follow the safety principles all the while. But, the stress will be more and can also lead to penalties and punishments when there is loss of life/damage to environment/property.
Many times when we land into simple accidents outside factory, we vow not to repeat such mistakes. But, when we commit such mistakes in a factory, the consequences will be very high and at that time we can move the time back to correct our mistakes. There is no time machine yet available to correct ourselves otherthan following safety principles in toto.
It must be understood that by doing PSM, we are doing favour to ourselves and not to others. Even, production cost can be brought down, if we do PSM sincerely and follow it. If we do not care to spillages/leakages of chemicals, air, steam; do not care to study in detail before going for a new process / chemical / modification; do not make checklists for operations, then it means that enough attention is not paid for plant operations and it adds to cost of production by way of wastage, inefficient operation, accidents, and so on.
We should not feel like Alice in the wonder land when the unidentified hazards manifest into incidents/ accidents. One may feel stressed to follow the safety principles all the while. But, the stress will be more and can also lead to penalties and punishments when there is loss of life/damage to environment/property.
Many times when we land into simple accidents outside factory, we vow not to repeat such mistakes. But, when we commit such mistakes in a factory, the consequences will be very high and at that time we can move the time back to correct our mistakes. There is no time machine yet available to correct ourselves otherthan following safety principles in toto.
Leniency to violators by authorities
Every day, we see reports of many accidents, incidents, violations by factories. There will be hue and cry for lenient attitude / laxity on the part of the regulating authorities. There will be injuries/fatalities/release of fumes, gases from plant to public domain/dumping of chemicals in the night in public areas/failure of containment from tankers, etc. Immediately, regulators are found fault for not keeping eye on violators. Regulators also visit the affected areas, factories and say that there is no licence for operation or matter is under investigation or notices are slapped, etc. The issue will be left. Media also will leave it as the importance is lost after the item is aired in all channels.
This is not happening in our country alone. When we see reports appearing in several websites of different countries, we come to know that this is worldwide phenomenon. Even, in countries where regulators are tough nuts, stiff penalties are imposed, still accidents/incidents/violations continue to occur and reasons seem to be silly. Though, many do not agree now-a-days that 'safety is nothing but common sense', still that common sense alone can prevent many accidents.
We are all greed and want to save few bucks by following short cuts. Finally, after sometime, everybody would have experienced a huge loss because of one accident and the loss far exceeds all savings accrued so far from short cut methods. Still, the lessons are confined to the affected individual alone and again the same individual will bypass safety after sometime, because our memory is short.
In such a situation, what a regulator can do is the big question, when we do not have self discipline. Then, we have to face the consequences and suffer.
This is not happening in our country alone. When we see reports appearing in several websites of different countries, we come to know that this is worldwide phenomenon. Even, in countries where regulators are tough nuts, stiff penalties are imposed, still accidents/incidents/violations continue to occur and reasons seem to be silly. Though, many do not agree now-a-days that 'safety is nothing but common sense', still that common sense alone can prevent many accidents.
We are all greed and want to save few bucks by following short cuts. Finally, after sometime, everybody would have experienced a huge loss because of one accident and the loss far exceeds all savings accrued so far from short cut methods. Still, the lessons are confined to the affected individual alone and again the same individual will bypass safety after sometime, because our memory is short.
In such a situation, what a regulator can do is the big question, when we do not have self discipline. Then, we have to face the consequences and suffer.
Safety of cockroach killing sprays
Last week, my wife was in the kitchen and suddenly she shouted for help. I ran to her only to see that she is in a state of shock. Later, I was told that the gas burner was lit for cooking. After seeing few cockroaches nearby, she sprayed the killing chemical from the container around the cockroaches. Immediately, the spray caught fire from the gas burner and the flame came towards her. She turned off the burner knob and went into shock. I never thought that spray will be within flammable limits and this taught me a lesson.
Earlier, few years ago, when I sprayed the same chemical for killing cockroaches, over the electrical switch board and also inside the electrical winding section of kitchen mixie and then switched ON the electrical point, the MCB tripped in the house. Without understanding the reason, I set it ON and again switched ON in the kitchen. This time MCBs tripped at home as well as at the LDB in the ground floor of our apartment complex, from where power cables are drawn to my residence. Then, I set it ON. Next, when I switched ON the mixie, there was burning smell from it. Then only it occurred to me that the spray caushed short circuit and lead to tripping of MCBs and coil burning.
Earlier, few years ago, when I sprayed the same chemical for killing cockroaches, over the electrical switch board and also inside the electrical winding section of kitchen mixie and then switched ON the electrical point, the MCB tripped in the house. Without understanding the reason, I set it ON and again switched ON in the kitchen. This time MCBs tripped at home as well as at the LDB in the ground floor of our apartment complex, from where power cables are drawn to my residence. Then, I set it ON. Next, when I switched ON the mixie, there was burning smell from it. Then only it occurred to me that the spray caushed short circuit and lead to tripping of MCBs and coil burning.
Sep 15, 2010
Wrist band tool to identify persons in danger and help in Safe Evacuation
A demo found in youtube on above subject is available here.
http://www.youtube.com/watch?v=UdTIYvKhhoc
http://www.youtube.com/watch?v=UdTIYvKhhoc
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