Fire incident in a chemical factory

In a chemical factory that makes drug intermediates, during chemical reaction, temperature increased uncontrollably leading to release of toxic gases. Two persons who tried to control the temperature and two more got injured in the incident.
It is reported that such incidents are common in small scale chemical factories, where safety standards and procedures are not followed. Contract labour with low wages are recruited who do not know how to operate the plant and even personal protective equipment are not provided. Though, nobody wants to damage their own property, the fact is that incidents do occur regularly and this indicates lack of proper training to the workers engaged on the job.

Factories engaged in any activity should have,

1. approvals from concerned authorities
2. selection of employees with requisite qualification and skills
3. training program
4. hazard identification and rectification procedures
5. safe operating procedures
6. dos and donts
7. testing and calibration of gauges, monitors, equipment
8. fire detection and control measures
9. emergency procedures
10. personal protective equipment for persons engaged on the work, etc

BLEVE Training Video - Safety Engineering Network (SAFTENG)

A video on BLEVE (boiling liquid expanding vapour explosion) is available at the link below.
BLEVE Training Video Part 1 - EXCELLENT Info - Safety Engineering Network (SAFTENG)
BLEVE Training Video Part 2 - EXCELLENT info - Safety Engineering Network (SAFTENG)

http://www.safteng.net/index.php?option=com_content&view=article&id=1038&Itemid=178 (Part 1)
http://www.safteng.net/index.php?option=com_content&view=article&id=1037%3Ableve-tests-results-1-excellent-info-&catid=52%3Aemergency-response&Itemid=178 (Part 2)
LINK

The video explains about the phenomena of BLEVE, the fire ball radii, the safe distance for emergency responders. We will understand that the safe distance for emergency responders is FOUR times the fireball radius with minimum distance at 90 m. For a 400 lit capacity tank, the fireball radius can be 18 m. We also learn that as the capacity of the flammable storage tank increases by a factor of 10, the fire ball radius doubles. The evacuation distances can be taken as 20 times the fireball radius.

However, these distances are not exact as there are instances of explosion fragments travelling more than 20 times fireball radius. During the incident at New Mexico in 1984, a fragment weighing about 20 T travelled 1200 m.

The water required to cool the exposed hot surfaces 10 lpm/sq.m. It may be noted that inspite of all efforts, if there is whistle/jet engine sound from valves, it is indication of over pressurization inside and all emergency responders should stop their activities and move to safe distances.

Some people assume that BLEVE is possible only with flammable substances. But, as the video explains, BLEVE is possible with any substance that leads to vaporization and pressure rise during external heating/impact and the container rupture leads to BLEVE. Fireball is the result if the substance inside is flammable.

Note: Literature gives following equations:

Fireball radius, R (meters) = 29 M^1/3  where M is mass of flammable in the fireball in tonnes
Fireball duration, t (seconds) = 4.5 M^1/3

Most likely distance for 3^rd degree burns = 80 M^0.42 meters

Maximum distance for 3^rd degree burns = 130 M^0.42 meters

Most likely distance for 2^nd degree burns = 150 M^0.42 meters

Maximum distance for 2^nd degree burns = 240 M^0.42 meters

The heat radiation intensity from the fireball can cause damage to human beings and property. From the literature, it can be seen that 12.5 kw/sq.m heat intensity can be fatal, 8.5 kw/sq.m can cause 1^st degree burns whereas solar radiation gives 0.6 kw/sq.m

10 FACTS ABOUT DRINKING & DRIVING

I thought beer is better than wine with respect to safety but as per the article at the following LINK, fatalities are more with beer consumption than liquor/wine.
10 FACTS ABOUT DRINKING & DRIVING

LINK

Use of TCE - increase in risk of developing Parkinson's disease

A study of 99 pairs of twins with and without Parkinson's disease shows that those exposed to trichloroehylene (TCE) are prone to the risk of developing Parkinson's disease six times more than the other. Study shows exposure to perchloroethylene and carbon tetrachloride also increase the risk of developing the Parkinson's disease. No such evidence was found exposure to toluene, xylene and n-hexane. The data taken is less and requires more studies.
TCE is used as a degreasing agent though it is banned in food and pharma industries long time ago. TCE also results in chopped skin and tremors. Where its use is unavoidable, exposure to persons should be minimized by containment, ventilation, use of personal protective equipment (PPE). Excessive exposure may affect central nervous system, numbness, reduced heartbeat, unconsciousness and eventually death.
Heating of TCE can form phosgene that cause pulmonary edema.

Health effects of TCE: http://www.ccohs.ca/oshanswers/chemicals/chem_profiles/trichloroethylene/effects_trichloro.html

Video link: Chemical Accident Response

Please see the following video link on chemical accident response.

http://www.youtube.com/watch?v=4AfGEtVzRz8

Deaths of job aspirants during run test

http://timesofindia.indiatimes.com/city/hyderabad/Youth-dies-during-police-recruitment/articleshow/10835495.cms
http://articles.timesofindia.indiatimes.com/2010-01-01/allahabad/28148565_1_police-recruitment-drive-youth-awadesh-kumar-vijeta
http://www.moneycontrol.com/news/wire-news/youth-dies-during-police-constable-recruitment-test_603133.html
http://ibnlive.in.com/generalnewsfeed/news/youth-dies-during-police-recruitment/748524.html
http://www.moneycontrol.com/news/wire-news/youth-dies-during-police-recruitmenthingoli_620934.html
http://www.indianexpress.com/news/youth-dies-during-police-recruitment-test-in/562428/

The above are some of the several news reports about the death of job aspirants while taking part in the physical endurance test (marathon/running). Though many of these unfortunate are weak and not maintaining good health, out of personal compulsions to get job to feed their families, they took part in the test and died due to heart attack, physical exertion, strain, etc. It is reported that in one state, the authorities changed the test timings from day time to morning 0500 hr so as to complete the test by 0830 hr.
The team of doctors available at the test centre can do little in case of persons already having medical problems suffer from exertion, chest pain, etc during the run test.
The purpose of the test can't be questioned as it is expected that only physically fit persons can withstand the tough requirements of police job. To avoid such deaths, all job aspirants should undergo true medical examination and are certified for the run. It requires both self assessment and medical examination as if we do not tell the doctor about our health problems, a realistic assessment can't be done unless a thorough medical checkup is done which costs a lot.
Apart from the above, today there is a news report (see the link below), wherein a person died after workout in the gym. It is reported that the person might have died because of chemical reaction of the tablet he took as pain killer for backache after the gym workout.
http://expressbuzz.com/cities/hyderabad/techie-dies-after-workout/336064.html

All above incidents point to straining oneself for different reasons and one should participate in test runs or have workout in gym or in such similar activities only after getting medical fitness examination and based on the advise of the physician.

BLEVE

In a report (http://www.homernews.com/stories/111611/news_fdef.shtml#.TsiKjT38Kxw), it is mentioned that a fire started in a residential garage eventually led to BLEVE (boiling liquid expanding vapor explosion) and fireball involving a fuel oil tank kept inside the garage. The fireball sucked the oxygen and led to containment of fire. The fire was noticed by a neighbor who cautioned the resident of the house to escape.

Due to this, the tank failed with main tank shooting of 150 feet through a wall into the field, while the tank bottom blew through a steel door. The blown tank flew between fire fighters and nobody suffered even any minor injury.

The wind pushed the flames towards the house from garage and some front portion got burnt.

It is reported that the fire fighters heard venting sound like a jet engine and shortly afterwards, the blast took place.

The panicked owner could not tell the fire fighters about the fuel tank inside, though she told about other flammables inside. Fire fighters were unable to see the tank because of flames and heat.

There are no state fire codes to prohibit storage of fuel tanks in residential properties, though such codes exist for commercial and multi-dwelling units.

The Chief of Fire Service is not sure of proper working of vent. It is said that the fuel oil tanks are not designed to hold pressure. It appears that the fuel oil tank is having oil only to some level as per the visible line showing where it was empty.

The Chief advised to keep the oil to the full so that the heat can be absorbed and that vapor build up will be less inside the tank thus preventing pressure rise and explosion. He also feels that the tanks should be kept in open area with ventilation instead of keeping them inside.

From this incident, we can draw following lessons:

1. Flammable storage tanks should be kept outside with proper ventilation and fencing.
2. It should have proper vent relief.
3. It should have properly designed water sprinkler system.
4. It should be fenced to prevent others coming closer to it.
5. The whistle/jet engine sound from a tank exposed to fire is an indication of blast / explosion / BLEVE in a short time and all people including emergency responders should vacate the area to a safe distance.
6. No other flammable/combustible materials should be stored in the area.
7. The safe distance depends upon the maximum capacity of the storage tanks exposed to fire, the distance up to which blast fragments can travel, the distance up to which thermal radiation from a resulting fire ball can cause first degree burns, the distance up to which the over pressure can cause damage to the glass panes.
8. The name plate containing the details of the contents, capacity, design pressure, safe distance in case of fire along with emergency contact numbers should be displayed at a place easily visible and accessible, away from the storage area.
9. Periodical mock drills should be conducted to take prompt action in a real emergency.