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.
Oct 19, 2010
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
Aug 22, 2010
Stress and accidents
Reason for many of the accidents appears very simple and silly at times. Many of the accidents did not occur because of some complex reactions or failure of safety systems. But, why do people get involved in such silly accidents. I think, lack of peace of mind is the reason. When we are not at peace, we cannot concentrate on our activity. Lack of peace can be due to
Accident means an event that unplanned, unexpected, unintentional,...
Though, nobody intends to get in to accident, lack of hazard identification, failure to take preventive measures and not reviewing the safety processes are the reasons for accidents. However simple the hazard appears, we should not be casual. It should be attended immediately. There is no use of repenting after the accident.
Similarly, one should not be relaxed when there are no accidents. May be they are not reported. May be there are many unreported nearmisses. May be the attitude of the manager is not to see minor accidents as accidents.
It is common for top management to boast of good safety record and take credit for it. But, a trulyaccident-free workplace is a reality because of sustained efforts all employees over a period of time. It will not happen overnight or in a week or in a month or in a year.
Some people attach value to human life and workout how much money can be spent on safety programme. My life may be worth $ 1.0 million to you. But, my family does not see like that. For them, it is invaluable. Nobody can remove the tears in the eyes of family members, when somebody dies. Nobody got right to decide the value of human life.
I read in the internet that some organizations care for their employees by attending to their personal problems, employ professionals to teach yoga, meditation and allocate time within working hours so that their employees can have healthy and peaceful life.
What for we earn money, if we do not have stress-free life. Though, some people say, certain stress is required for the growth of the individual, I think this is purely business oriented. The increase in suicide rate everywhere in the world shows that so called acceptable stress is NOT acceptable to the individual. As there is no other means to earn income, persons accept the additional demands and stress themselves. Ultimately, weak hearted will take their lives. Persons responsible for causing stress should think twice by entering into others shoes and then decide about the work.
- arguments with relations / servants / milkman / paper boy/ gas station employ
- children education
- well being of blood relations
- arguments with colleagues
- business loss
- greed
- simple problems like vehicle breakdown, plumbing problem at home, ...
- financial needs
- thinking about meeting, examination, bank loan, ...
- etc
Accident means an event that unplanned, unexpected, unintentional,...
Though, nobody intends to get in to accident, lack of hazard identification, failure to take preventive measures and not reviewing the safety processes are the reasons for accidents. However simple the hazard appears, we should not be casual. It should be attended immediately. There is no use of repenting after the accident.
Similarly, one should not be relaxed when there are no accidents. May be they are not reported. May be there are many unreported nearmisses. May be the attitude of the manager is not to see minor accidents as accidents.
It is common for top management to boast of good safety record and take credit for it. But, a trulyaccident-free workplace is a reality because of sustained efforts all employees over a period of time. It will not happen overnight or in a week or in a month or in a year.
Some people attach value to human life and workout how much money can be spent on safety programme. My life may be worth $ 1.0 million to you. But, my family does not see like that. For them, it is invaluable. Nobody can remove the tears in the eyes of family members, when somebody dies. Nobody got right to decide the value of human life.
I read in the internet that some organizations care for their employees by attending to their personal problems, employ professionals to teach yoga, meditation and allocate time within working hours so that their employees can have healthy and peaceful life.
What for we earn money, if we do not have stress-free life. Though, some people say, certain stress is required for the growth of the individual, I think this is purely business oriented. The increase in suicide rate everywhere in the world shows that so called acceptable stress is NOT acceptable to the individual. As there is no other means to earn income, persons accept the additional demands and stress themselves. Ultimately, weak hearted will take their lives. Persons responsible for causing stress should think twice by entering into others shoes and then decide about the work.
Same rains, but areas are flooded
Of late, there are heavy rains in different parts of our state. Though the rains appear to be same like in earlier years, what is disturbing is the fact that more and more areas in cities are getting flooded. Knee deep water on the roads is seen in TV visuals. Even people are washed off due to flash floods on the roads in the cities. Adding to this misery, open manholes / potholes on the road are endangering the lives of commuters on the road. Few have fallen into open manholes, washed off and died.
This is not seen in earlier years. Only in the last 3-4 years, such incidents are happening. Encroachment of stormwater drains (natural and artificial), laying of roads without leaving open soil for seepage of water, not cleaning the drains before rainy season, etc are some of the reasons for floods on the roads.
Huge apartment complexes are coming in the cities thereby restricting the free flow of rain water. Drainage canals/channels are occupied with hutments leaving little space for the water to flow. When roads are relaid, I read few years ago, that the surface of the existing road should be removed and new road should be laid so that the water on the road can easily seep in to the ground. Though I do not know the principle, may be relaying over and over on the same road may reduce the porosity of the road and thus water will not seep.
Further, of late, instead of bitumen roads, concrete roads are being laid for long life, with good intention. However, concrete roads are not allowing the water to sink into the soil. And concrete roads laid edge to edge in the streets without allowance for rain water to flow in the edges on the soil. Business establishments, residential buildings are also constructed with concrete surface upto the roads. Gardens are not maintained in the housing complexes. Parks are disappearing and thus no open areas are left. Trees are cut and the area is used for constructing some more rooms to get income. All this is leading to total concrete carpeting of cities and towns with narrowed storm water drains.
I feel the above are reasons for flooding of roads even with normal rains. The capacity of the underground stormwater drains got reduced because of choking / use of stormwater drain for normal sewage drain. With ever increasing population, these drains are becoming insufficient. When it rains, persons staying near the roads are removing manhole covers thinking that flood water will go into the drains through open manholes. But due to insufficient capacity, drains are full and water stays on the road. Commuters on the road, not knowing about open drains, are falling into these drains and precious lives are lost.
What can be done?
This is not seen in earlier years. Only in the last 3-4 years, such incidents are happening. Encroachment of stormwater drains (natural and artificial), laying of roads without leaving open soil for seepage of water, not cleaning the drains before rainy season, etc are some of the reasons for floods on the roads.
Huge apartment complexes are coming in the cities thereby restricting the free flow of rain water. Drainage canals/channels are occupied with hutments leaving little space for the water to flow. When roads are relaid, I read few years ago, that the surface of the existing road should be removed and new road should be laid so that the water on the road can easily seep in to the ground. Though I do not know the principle, may be relaying over and over on the same road may reduce the porosity of the road and thus water will not seep.
Further, of late, instead of bitumen roads, concrete roads are being laid for long life, with good intention. However, concrete roads are not allowing the water to sink into the soil. And concrete roads laid edge to edge in the streets without allowance for rain water to flow in the edges on the soil. Business establishments, residential buildings are also constructed with concrete surface upto the roads. Gardens are not maintained in the housing complexes. Parks are disappearing and thus no open areas are left. Trees are cut and the area is used for constructing some more rooms to get income. All this is leading to total concrete carpeting of cities and towns with narrowed storm water drains.
I feel the above are reasons for flooding of roads even with normal rains. The capacity of the underground stormwater drains got reduced because of choking / use of stormwater drain for normal sewage drain. With ever increasing population, these drains are becoming insufficient. When it rains, persons staying near the roads are removing manhole covers thinking that flood water will go into the drains through open manholes. But due to insufficient capacity, drains are full and water stays on the road. Commuters on the road, not knowing about open drains, are falling into these drains and precious lives are lost.
What can be done?
- Floor space index (FSI) should be brought down
- The capacity of drainage system should be in line with the population and industries
- A parameter like open garden area with open (earth) area should be made conditional for all buildings while giving permission
- Either side of the roads should be left open without laying bitumen/concrete
- Summer months should be declared as months of dechoking of drains
- All establishments which do not have parking space and making their customers to park in the roads should be asked to create parking space or to shift to some other location where they can have their own parking so that roads are not encroached
- It is common to see at the entrance of many apartment complexes mentioning that VISITORS VEHICLES ARE NOT ALLOWED INSIDE. Such practice should not be allowed. All residential buildings also should have sufficient parking space within their complex for visitors. Otherwise, they can have multilevel parking instead of grumbling that they do not have sufficient space.
- Though it is not possible in already developed areas, sufficient water catchment areas / lakes should be part of city plan where expansion is taking place so that water can be held instead of allowing to flow like flood and this will also help to meet water needs of the city. Every city should be a LAKE CITY so that floods can be restricted and water need are met.
Aug 18, 2010
Safety Poem - I Could Have Saved A Life That Day
There are very few poems / songs available with safety theme. Here you can find one. An emotional one that reminds safety professionals not to be scared / afraid / hesitant to caution and advise when we see some unsafe act or unsafe condition.
Aug 17, 2010
Noise - Hearing protection programme
There is an article on ill effects of noise and about hearing protection measures. But, today I learnt that though all of us know to reduce the noise levels to below 85 dBA, it is also not advisable to reduce it below to 70 dBA as it can cause hearing problems to operators regarding instructions, warning alarms, etc.
There is also a calculator in the above link to calculate the effectiveness of hearing protection based on the results of noise survey in your shopfloor.
Though Factories Act says 90 dBA is the noise limit for 8 hour exposure, it is a good practice to subject all employees to audiometry test, if they are exposed to 85 dBA even once in a year. Though supervisors will be reluctant to send the employees to audiometry tests to avoid production loss, considering the ill effects of noise induced hearing loss (NIHL) and in extreme case may lead to loss of life if the employee is unable to hear warning alarms.
There is also a calculator in the above link to calculate the effectiveness of hearing protection based on the results of noise survey in your shopfloor.
Though Factories Act says 90 dBA is the noise limit for 8 hour exposure, it is a good practice to subject all employees to audiometry test, if they are exposed to 85 dBA even once in a year. Though supervisors will be reluctant to send the employees to audiometry tests to avoid production loss, considering the ill effects of noise induced hearing loss (NIHL) and in extreme case may lead to loss of life if the employee is unable to hear warning alarms.
Subscribe to:
Posts (Atom)
Featured Post
Reduced my weight from 96 to 76 kg and tummy from 38-40 to 34-35 inches in about 9 months
I am working in the safety department of a government organization. As a part of the job, I used to go around and interact with person...
