It suggests that one should engage experience technical persons for shutting down a plant and equipment conditioning, which may not be required to operate in the near future, but may be required at a later date. All process holdups should be drained, cleaned, protective coats applied, instruments/sensors kept in dry condition and kept in good condition so that when plant is to be restarted, it can be done with minimal costs, head aches and damage. One should also record all measures taken during shut down and to be taken while restarting as it is likely that same technical persons may not be available in the future. Cannibalizing also should be avoided so that plant can be restarted at short notice without searching for missing motors, pumps, valves, vessels, etc. One should also ensure periodical maintenance of the equipment and auxiliaries of plant that was shutdown. Else, we have to be satisfied in getting scrap value by sale instead of its full value.
Nov 18, 2012
Measures to be taken before a plant shutdown
The following link provides good information on the above topic.
It suggests that one should engage experience technical persons for shutting down a plant and equipment conditioning, which may not be required to operate in the near future, but may be required at a later date. All process holdups should be drained, cleaned, protective coats applied, instruments/sensors kept in dry condition and kept in good condition so that when plant is to be restarted, it can be done with minimal costs, head aches and damage. One should also record all measures taken during shut down and to be taken while restarting as it is likely that same technical persons may not be available in the future. Cannibalizing also should be avoided so that plant can be restarted at short notice without searching for missing motors, pumps, valves, vessels, etc. One should also ensure periodical maintenance of the equipment and auxiliaries of plant that was shutdown. Else, we have to be satisfied in getting scrap value by sale instead of its full value.
It suggests that one should engage experience technical persons for shutting down a plant and equipment conditioning, which may not be required to operate in the near future, but may be required at a later date. All process holdups should be drained, cleaned, protective coats applied, instruments/sensors kept in dry condition and kept in good condition so that when plant is to be restarted, it can be done with minimal costs, head aches and damage. One should also record all measures taken during shut down and to be taken while restarting as it is likely that same technical persons may not be available in the future. Cannibalizing also should be avoided so that plant can be restarted at short notice without searching for missing motors, pumps, valves, vessels, etc. One should also ensure periodical maintenance of the equipment and auxiliaries of plant that was shutdown. Else, we have to be satisfied in getting scrap value by sale instead of its full value.
Nov 13, 2012
Can we have better surveillance cameras to monitor secured areas?
It is common to see CCTV cameras at important places to monitor the movements of suspicious persons. These are located in super markets, restricted areas, traffic zones, bus stations, railway stations, airports, etc. On many occasions, after the occurrence of an incident, the footage from these helped to nab the culprits. But, the videos that we see in TVs are of poor resolution and less speed. It is beyond my knowledge why it is so and why high resolution cameras can't be installed for surveillance. Normally, the domestic cameras which we use provide good pictures of objects that are at distance, when we zoom. No doubt, the memory occupied by these high resolution pictures will be more and thus require large storage space, but it is affordable and cost should not be an issue when it is with regards to security and safety.
During accidents / incidents, cameras installed at important and critical operation areas also show how they occurred, even if the employees lie about them fearing punishment. This will help in accident investigation and help the organization to take preventive measures.
During accidents / incidents, cameras installed at important and critical operation areas also show how they occurred, even if the employees lie about them fearing punishment. This will help in accident investigation and help the organization to take preventive measures.
Better results for voluntary compliance instead of enforcement
Many times we do things because we were told to do so. Else, there may be repercussions in the form of penalties or punishment. When we work in such an environment, at the slightest opportunity, we try to avoid, which otherwise the enforcing agency (parents/boss/regulator/police/court/etc) wants us to do. This way things will not yield good results in the long term because it is not coming from our heart. This is because either we did not understand why somebody is asking us to do in particular manner or we had wrong perceptions. If somebody asked us to do in a particular fashion, let us try to understand why? It is the experience of somebody, somewhere. We need not learn again by doing things in a wrong manner and get affected whatever the loss others suffered. This is called learning from history. Rules and regulations are nothing but experiences (bad and good) of so many over a long period.
When we make voluntary efforts without others saying so, we can see positive developments in our work atmosphere. Because we fail to do so, rules and regulations have come and this is the first stage in the line of growth. When we comply with all statutory requirements, we can set our own goals much better than statutes and improve further. This is the second stage. When we repeat this towards better workplace, we can become role model in our industry / region. This is the third stage. These three stages are discussed in detail in INSAG-15 document (International Nuclear Safety Advisory Group).
Many of us are in the first stage for so many decades. Though we obtain certifications for compliance with ISO/OHSAS/IS/BS/FDA, etc, still at heart, we like to bypass procedures and this does not augur well for us as individuals and the organization, as a whole. We think government organizations does not have any dearth of funds and thus they can implement this philosophy. Similarly, we think private organizations are profit oriented and thus do not like to spend. But both are wrong perceptions. There good and bad organizations both in government and private sectors.
It is 'I' who matters in implementation. This I is everybody from top to bottom. The top management should know about rules and regulations and a vision to ensure safety at the work place. And they should convey their intentions to down below and allocate required resources with rewards and punishments to ensure safety.
As long as I am not convinced, I try to do things other way and continue to suffer myself and as a consequence, I put the organization also in a fix not to grow. It is said that safety is not costly, but in fact it is free when implemented in full. It also fetches returns over a long period of time. Just we do not have enough patience to wait for and want to see the results immediately which is not possible. One year when we work with good production, no accidents, better profits, we claim that our work only fetched results and next year when it does not repeat, we blame all sundry instead of taking responsibility for the same. One should realize that our today's results are hard work of somebody in the past.
When we make voluntary efforts without others saying so, we can see positive developments in our work atmosphere. Because we fail to do so, rules and regulations have come and this is the first stage in the line of growth. When we comply with all statutory requirements, we can set our own goals much better than statutes and improve further. This is the second stage. When we repeat this towards better workplace, we can become role model in our industry / region. This is the third stage. These three stages are discussed in detail in INSAG-15 document (International Nuclear Safety Advisory Group).
Many of us are in the first stage for so many decades. Though we obtain certifications for compliance with ISO/OHSAS/IS/BS/FDA, etc, still at heart, we like to bypass procedures and this does not augur well for us as individuals and the organization, as a whole. We think government organizations does not have any dearth of funds and thus they can implement this philosophy. Similarly, we think private organizations are profit oriented and thus do not like to spend. But both are wrong perceptions. There good and bad organizations both in government and private sectors.
It is 'I' who matters in implementation. This I is everybody from top to bottom. The top management should know about rules and regulations and a vision to ensure safety at the work place. And they should convey their intentions to down below and allocate required resources with rewards and punishments to ensure safety.
As long as I am not convinced, I try to do things other way and continue to suffer myself and as a consequence, I put the organization also in a fix not to grow. It is said that safety is not costly, but in fact it is free when implemented in full. It also fetches returns over a long period of time. Just we do not have enough patience to wait for and want to see the results immediately which is not possible. One year when we work with good production, no accidents, better profits, we claim that our work only fetched results and next year when it does not repeat, we blame all sundry instead of taking responsibility for the same. One should realize that our today's results are hard work of somebody in the past.
Nov 10, 2012
Letter about the experiences on lab safety
The link below takes to a letter published in Chemical Engineering News about lab safety, experience about lab safety in the college. Lab safety may be followed to a great extent in developed countries, but my personal experience during my college days is that we were never told about hazards, safety procedures, precautions to be taken in the laboratory. Now, I feel how I went through those days and what could have happened if I did something wrong.
As a safety professional, now I feel that college laboratories should have documented safety programme and should be monitored for implementation. Students should know about properties, hazards, material safety data sheets, procedures for storage-handling-disposal, emergency procedures, proper use of PPE, etc.
When we take chemicals in to a bottle or container, we should ensure that the bottle was used previously for the same chemical or better use only cleaned bottles. Otherwise, it is likely that we will be adding a chemical to the bottle that contains or was used for a chemical that is not compatible and a runaway reaction may take place leading to rupture of bottle, splashing of chemicals, hit with glass splinters, etc.
We should use proper bottle holder to move the bottles instead of holding the bottle at its lid or neck which may lead to fall of the bottles.
When chemical splashes, we should remove the contaminated cloth and wash thoroughly for atleast 15 minutes immediately and consult doctor for further treatment. There were reports in which a student received HF splash on her lab coat. Instead of removing the coat, she washed the splashed portion of the coat with some water and continued her work. She was found dead in her apartment later. The reason listed was that though the contaminated coat was washed, the vapors continued to emanate from her coat which she did not notice but inhaled and this caused edema. Chemicals like HF, phosgene, etc exhibit delayed effects causing respiratory problems and eventually lead to death.
Studies show that even after 15 minutes of thorough wash, only about 95% of the splashed chemical can be washed. Hence, prominent display of 'wash for atleast 15 minutes' should be displayed in the lab and near the emergency shower/eye wash fountain or the rack containing eye wash bottles.
http://cen.acs.org/articles/90/i44/Lab-Safety-UCLA-Accident.html
As a safety professional, now I feel that college laboratories should have documented safety programme and should be monitored for implementation. Students should know about properties, hazards, material safety data sheets, procedures for storage-handling-disposal, emergency procedures, proper use of PPE, etc.
When we take chemicals in to a bottle or container, we should ensure that the bottle was used previously for the same chemical or better use only cleaned bottles. Otherwise, it is likely that we will be adding a chemical to the bottle that contains or was used for a chemical that is not compatible and a runaway reaction may take place leading to rupture of bottle, splashing of chemicals, hit with glass splinters, etc.
We should use proper bottle holder to move the bottles instead of holding the bottle at its lid or neck which may lead to fall of the bottles.
When chemical splashes, we should remove the contaminated cloth and wash thoroughly for atleast 15 minutes immediately and consult doctor for further treatment. There were reports in which a student received HF splash on her lab coat. Instead of removing the coat, she washed the splashed portion of the coat with some water and continued her work. She was found dead in her apartment later. The reason listed was that though the contaminated coat was washed, the vapors continued to emanate from her coat which she did not notice but inhaled and this caused edema. Chemicals like HF, phosgene, etc exhibit delayed effects causing respiratory problems and eventually lead to death.
Studies show that even after 15 minutes of thorough wash, only about 95% of the splashed chemical can be washed. Hence, prominent display of 'wash for atleast 15 minutes' should be displayed in the lab and near the emergency shower/eye wash fountain or the rack containing eye wash bottles.
http://cen.acs.org/articles/90/i44/Lab-Safety-UCLA-Accident.html
Nov 9, 2012
About HF spill in Gumi City - updates in Chemical World
The report in the following link gives some important information about leakage of eight tonnes of HF. The police stated that workers did not follow safety procedures for unloading to save some time. The company or local government does not have slaked lime for neutralization of HF and they could get the same only after one day of the incident. The fire fighters are not aware of the chemical spilled or the hazards of HF as they came with normal fire fighting and personal protective equipment.
It is stated that as per CCTV footage seen, workers tried to transfer the HF from tanker by connecting an air hose to a valve in the tank and the white vapors at high pressure from the tank engulfed the workers. And, when firefighters sprayed the water, the spilled acid spread further.
Pressure transfer system is fraught with dangers and many incidents were reported in such transfers across the world.
The above incident is a lesson for us that
http://www.cdc.gov/niosh/pdfs/76-143f.pdf
It is stated that as per CCTV footage seen, workers tried to transfer the HF from tanker by connecting an air hose to a valve in the tank and the white vapors at high pressure from the tank engulfed the workers. And, when firefighters sprayed the water, the spilled acid spread further.
Pressure transfer system is fraught with dangers and many incidents were reported in such transfers across the world.
The above incident is a lesson for us that
- we should review chemical transfer methods
- carry HAZOP study to know the hazards, consequences and measures to be taken
- train the workers and supervisors about the hazards and procedures to be followed
- ensure display of procedure, material safety data sheets for the chemicals used
- provide sufficient capacity of secured collection pit for collecting neutralized acid or for collecting acid and they to do neutralization
- ensure availability of scrubbing/neutralization system for maximum credible scenario
- ensure supervision during the work, etc
http://www.cdc.gov/niosh/pdfs/76-143f.pdf
Nov 6, 2012
Picture This! Three Little Words Versus One Big Risk-Taker » SafetySmart
Picture This! Three Little Words Versus One Big Risk-Taker » SafetySmart
What we say is not always followed.
What we say is not always followed.
Nov 5, 2012
Two employees receive chemical burns - firm is fined
It is reported that a cleaning firm was fined after two of its employees received chemical burns in two separate incidents. The firm was fined for lack of enforcing supervision. Though there are no details about the extent of injuries or procedure followed, it appears that the accidents could have been due to (i) lack of procedure or violation of procedure, or (ii) hiring of persons without knowledge about the work, or (iii) lack of training, apart from the lack of supervision.
Training and supervision are generally the two most commonly found recommendations made by the Chemical Safety Board (CSB) of US in their investigation of several accidents. And, these are also statutory requirements.
We have to ensure proper selection of persons, training, job hazard analysis, safe operating procedure, do's and dont's material safety data sheets and supervision to carryout given task safely.
http://www.nzherald.co.nz/nz/news/article.cfm?c_id=1&objectid=10845300
Training and supervision are generally the two most commonly found recommendations made by the Chemical Safety Board (CSB) of US in their investigation of several accidents. And, these are also statutory requirements.
We have to ensure proper selection of persons, training, job hazard analysis, safe operating procedure, do's and dont's material safety data sheets and supervision to carryout given task safely.
http://www.nzherald.co.nz/nz/news/article.cfm?c_id=1&objectid=10845300
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