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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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