Accident prevention - sharing of information between the Japan factories

A news item on the above subject is interesting to read.

A good effort by Japanese factories to share information to prevent accidents. It is worth emulating by others also. Only that, the participants should not criticize the speakers for sharing the information about the accidents in their facilities. The speakers and their factory management should be appreciated that they came out boldly to tell about accidents  and the lessons learnt to others with a godly view of preventing such accidents in other facilities.

Fire during welding

A fire incident took place while welding work was in progress. The sparks caused fire involving combustibles nearby. The incident was brought under control within 10 minutes and no casualty is reported.

As a general principle, it is suggested to keep 15 m from any hot work area to keep free from combustibles to avoid sparks that can fly off that much distance. Though, this may look silly to many working agencies, but occasional fire incidents like these prove the point.

See the video , video here.

http://www.hindustantimes.com/india-news/fire-breaks-out-in-parliament-complex-10-fire-tenders-sent-to-control-blaze/article1-1329269.aspx

Safety Rules and Regulations - there will be blood stains behind

It is quite common for safety professionals to be at receiving end, bombarded with questions, when suggestion / advice is given based on rules and regulations. Leave apart general advice when given, safety professionals are questioned for the basis. 

But, everybody should remember that nobody is interested in slowing down the work pace. Nobody is interested in doing additional work. Nobody wants to take blame, knowing fully well that any safety advice communicated will have questions directed back to them. Still, it is rendered for the reasons of doing their mandated job. A safety professional is not a namesake fellow  to be shown to factory inspectors during their visits. There are some good organizations, national and multinational, who follow safety in toto. And, they proved that in the end, safety aids in increased production. 

But, to realize this, we have to sweat initially, should have thinking and application in the conceptual and design stage itself. Okay, it is not there initially. Then, let us struggle for some extra time, to implement during operational stage. 

But, during this stage, if incharge sees this work of implementing safety retards production during his period and he will not be recognized, then it should be made known to this incharge by top management that goals will be set considering all factors. Give, sometime for seeing the results of implementation of safety procedures (if implemented late, not required if implemented during design stage itself). Do not encourage the ideas of shopfloor employees to bypass safety systems for achieving higher production in a short time. This will be shortsightedness. One will get higher production initially for some time, as there may not be deterioration of culture quickly. However, with time, with changing mindset and taking roots, joining of new recruits who learn such bad practices from first day, one can see the signs of near misses and later accidents resulting in injuries and property damage.

Study of such accidents leads to internal regulations which when published and / or goes to the notice of regulators, will turn into legislations. Slowly, one forgets the reasons for a rule or regulation and then questioning of basis for such rule begins (wheel needs to reinvented).

This becomes like one chanting mantras and then getting involved in all acts against the meaning of these great mantras (pseudoism).

Engineering education - Thinking beyond jobs

There is a thought provoking article in New Indian Express on the title. As pointed out, the education system needs a paradigm shift from classroom teaching to hands-on practical approach. With mushrooming of schools and colleges without sufficient infrastructure, many of the present day engineering students are unable to learn the subjects clearly and this can be a reason for so many engineering graduates remaining unemployed and trying to seek for even small jobs, irrelevant to their education.

Many of the engineering colleges are also not getting enough students due their poor infrastructure and there are reports of colleges reducing the number of courses, number of students or even going for closure.

Assessment of facilities and renewal of college licence based on the assessment is required. 

Also, the syllabus for engineering students should include that of ITI and Diploma courses with more stress on practicals/workshops. Like MBBS, the duration of engineering course should be extended to 5-6 years taking into account of practical teaching instead of just going for four year classroom teaching with limited practicals.

 

Crashing of false ceiling in the airport

During early hours, false ceiling of a portion of the airport near arrival area fell down and no injuries were reported. And, such incidents happened about eight times in the last two years. Recurrence of such incidents in such areas where large crowds gather during busy hours requires immediate action for integrity assessment and repair/replacement.

Explosion in detonator factory during disposing of rejected detonators from explosives

In an explosion in one of the largest explosives exporting factory, during separation of rejected detonators from explosives by cutting wires, a mechanical cutter fell down on the explosives below causing the blast leading loss of two lives and injuring 13 others with some of them receiving severe burns.

One of the injured suffered hearing loss during the incident.

The site was visited by State Home Minister, Police and other officials.

Police registered case under various sections of IPC (Indian Penal Code) for negligent act and others leading to personal harm and initiated the probe.

As per reports, the persons doing the job were retired employees as contract workers having experience.

There were also reports of demanding for shifting of the factory from residential premises.

There were some fatal incidents earlier also in the last 10-15 years.

To avoid such incidents, possibility of  automation of removal of rejected detonators needs to be explored.

As the cutter fell down below on explosives during the job, and it is likely that such slippages can happen, suitable path for shifting of material below as soon detonator is separated from the explosive material for every explosive or collecting the explosive material under water or any other medium has to be seen.

Governments have to ensure that industrial areas are well separated from residential areas. There should a sort of no habitat zone between industries and residential areas. It is natural that wherever development is there, the surroundings will see growth of residential areas with a view to gain from real estate price increase. 

Definitely, large industrial complexes would have been set up far away from residential areas at that time. Earlier remote places would have become part of the present cities due to growth. Shifting of industries also will be costly and who will foot this cost. 

Hence, a policy as suggested above is required with marked zones and no-man zones.

Orange colour toxic cloud formation in a chemical explosion

Due to mixing of chemicals (possibly nitric acid, ferric chloride and some other chemical) during handling, there was a chemical reaction leading to an incident of release of orange coloured gas cloud. Three persons were injured due to the incident.
Short video can be seen here.

Times of India - Goa ranks 6th in Top 10 Nightlife Cities list (in the world)

As per the article appeared in Times of India website today, National Geographic ranked Goa as sixth top city in the world for nightlife. Goa tourism minister claimed that this demonstrates Goa as a safe place for tourism 24 x 7. This is truly heartening. If someone feels that he/she is safe to move on the roads even in the midnight, what else is required. Kudos to rulers and law enforcing agencies. This should be sustained. Tourism will increase by taking care of safety of tourists, keeping the city clean, having good facilities for stay, food, transport and charging reasonably and avoiding fleecing.

Fires involving oil soaked cotton waste

Winter season is moving out and slowly, temperatures are rising. Reports of fire incidents are appearing in various media. Reasons are generally not available and mostly attributed to short circuit at the first instance. Grass fires also will appear in news.

My attention went to such grass fires and cotton waste fires. Earlier, in this forum, when I wrote on the same topic, I found not much information. However, a search in books like Kirk's fire investigation (John D.DeHaan) and  a hand book of fire technology (R.S.Gupta) and in internet revealed lot of information. It is observed that self ignition of cotton waste that got some moisture and drying oil is possible within few hours (5-24), at temperatures above 15 deg C and optimum ventilation and oil load (0.1-0.3 lit/square meter surface of cotton). 

The drying of oils produce heat. May be bacterial action inside also produce heat. This heat, if not dissipated i.e more than enough to heat other oil / cotton or not vented out and there is sufficient porosity to permit entry of oxygen (in air) but not enough for generated heat to dissipate, there will be heat accumulation and can lead to so called spontaneous combustion. 

This is possible with slightly wet grass also, or if laundered and pressed clothes are kept in piles before allowing to cool. 

What to do to avoid such conditions? The solutions suggested are, to dry such cotton waste / grass by spreading sufficiently so that the moisture in it can be dried. Cotton waste can be disposed to authorized dealers or can be burnt regularly (preferably on daily basis), or land burial. It it is to be stored, then after drying, such cotton waste can be kept in air tight metallic drums and sealed. The oxygen initially present in the drums after sealing will be used for oxidation but as there are no fresh supplies, further oxidation process will stop. Or, keep such cotton waste in drums with sufficient water above so that insufficient moisture conditions do not arise.

Few years ago, I saw fire involving electrical cable reel, covered under tarpaulin in front of a telephone office, that also on a summer day. May be the heat accumulated inside might have caused this fire.

Many such summer fires involving material under tarpaulin were reported.

A spontaneous heating parameter Z is given in an article (SINTEF Report NBL A05145), to know  about the topic. More can be read from the link given above.

Few years ago, I had read about bursting of drums filled with used oil. The reasons mentioned were bacterial action causing generation of gases like methane, hydrogen sulfide, carbon dioxide, etc leading to pressurization and bursting ultimately. It is suggested that as soon as somebody observed any bulging of the top cover of such drums, one should release the pressure from the drum by slowly opening the lid with gaps between uncorking. I feel this pressurization in such drums may increase in summer.