Worker killed by robot...

As per a report,  worker was killed during installation of a robot in a car manufacturing firm. Though the title leads to wrong conclusion, robots are lifeless and brainless and any action is due to wrong programming/setting by the concerned programmers/assemblers.

The robot must have been in commissioning stage or under trial runs. One has to do thorough event tree and fault tree analyses before putting the logic into field use.

Nobody should be allowed to be within the reach of the machine and suitable physical barriers and sensors/interlocks should be incorporated.

Oil Tank Explosion

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As per the commentary, once the temperature reaches 400 degree Celcius, the tanker blasts. Persons at 200 m distance suffered third degree burns.

BLEVE (Boiling Liquid Expanding Vapor Explosion) Demonstration - How it ...

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Gas Safety Blanket Response to end of Pipe ammonia leak

LINK

https://www.youtube.com/watch?v=03s0bXNUgOU

Something new and easy to use to control anhydrous ammonia leaks. Though the picture of the person is not shown fully in this video, the warning message at the end about not to enter without proper PPE should be followed.

International yoga day: Safety guidelines for yogasanas

Today is international yoga day. A recognition with more publicity for the science taught by our ancestors. 
A link below takes us to safety guidelines to be followed for practicing yoga. No amount of information is a substitute for teacher's advice. Just for information.

http://www.wailana.com/yoga/asanas/guidelines

Yesterday, I heard a lecture from which I learnt that doing yoga helps us to harmonize our thoughts and helps to have more concentration. A practical session for 10 minutes during the lecture also made me to realize the same. All participants were asked to close the eyes gently, to sit relaxingly, to concentrate inhalation and exhalation at the nose entrance. After 10 minutes, after rubbing the palms and touching the eyes, we opened the eyes. The question asked was, how much time we concentrated and observed inhalation/exhalation.
I pondered over this later also and thought that this practice will help us to realize about ourselves and try to get more concentration with practice.

Fire accident at TVS showroom in Anantapur - Tv9

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Short circuit is suspected as the reason. About 200 out of 1000 bikes in the showroom got burnt. Fire Services is facing difficulty in entering the building.

Property of about rupees one crore got damaged.

Ammonia tanker stuck up under flyover, valve damage, 5 deaths, 140 injured near Ludhiana

In an incident of liquefied ammonia tanker driver trying to go through under a flyover, at 11.00 PM, the lid and the valves at the top got damaged, causing release of ammonia affecting several persons nearby.
See the photo here.
5 persons died and 156 got injured in the incident.

It appears that there are no warning signs or no height barriers to prevent overheight vehicles going under the flyover.

The tanker was carrying 22 T of anhydrous ammonia.

Police and fire brigade officials reached the spot to control the situation. 

Some of the affected had breathlessness, eye irritation, choked voice, etc. Few had bleeding from mouth and nose.

A senior police official and others controlling the situation were also affected in the incident as per the reports.

Tanker was moved to a vacant plot.  

Ammonia solubility in water is very high and is instantaneous at temperatures below atmospheric. Water was used to absorb leaking ammonia.

The odour was present for more than eight hours. The affected areas was about four kilometer radius around.

Dead animals/birds and vegetation/plants were seen.

Heavy rain later subsided ammonia in the environment by absorbing and washing.

A case was registered under Sec 304 of IPC (culpable homicide not amounting to murder) on the absconding driver.

http://www.ibtimes.co.in/ludhiana-ammonia-gas-leak-tanker-kills-6-over-100-affected-635709

Toxic gas leak from neighbor factory affects 60 in a garment factory

Some workers of a garment factory sensing strong smell of a gas tried to runaway from workplace but fainted before reaching the gate. A taxi driver outside, seeing them call the help services. Security guards from neighboring factory said that there was a gas leak. About 60 persons were affected in this incident.

From the above, it is important to all persons working in a cluster of factories to know about hazards and emergency actions not only from their work place but from surrounding factories also.

Ammonia leak from food freezing system from the neighboring factory is suspected in this incident.

http://www.thanhniennews.com/society/60-garment-workers-faint-in-southern-vietnam-after-toxic-gas-leak-43833.html

http://www.thanhniennews.com/society/52-garment-workers-hospitalized-again-one-day-after-toxic-gas-leak-in-vietnam-43906.html

For information - safety statistics by ILO from The Nation, Nigeria

The link to the information is here.

http://thenationonlineng.net/new/6000-die-daily-in-work-related-accidents/

As per ILO, following are the work place related injuries, deaths, accidents and loss.

1. Every second 15 persons die, 6000 a day and 2 million a year due to accidents/diseases. This data is from reported data. There can be many more.
2. In addition, 268 million non-fatal accidents and 160 million new cases of work related illness also occur.
3. The direct and indirect loss due to accidents and diseases is 4% of global gross domestic product or USD 2.8 trillion.

Bus accident

During bus driving, a driver wants to spit by bending outside his side window. With his unsafe behavior, he loses control over the bus and rammed a lorry coming opposite. In this accident, 4 persons died and few passengers received injuries. Generally, vehicle drivers keep chewing betal leaf or pan masala, particularly during night driving.

Driver should have observed before spitting outside. Some drivers keep a bottle/tin with them to spit instead of doing the same outside.

Professional hazards - thief trapped in chimney

In a local newspaper, it is reported that a thief tried to enter a locked house through the chimney and got trapped. 

The residents came next day morning and found the person trapped inside.

The chimney was broken to rescue and handed over to police.

Liquor bottle in trouser pocket breaks - person dies

A person kept liquor bottle in his trouser pocket. He ran when it rained and fell. Liquor bottle broke and its pieces injured private parts. Person died while undergoing treatment.

Source: Times of India, 18.05.2015

Sometimes, it may not be possible to assess the hazards. Atleast one can learn from others experience.

Gas leak

Dupont is cited by US for gas leak that killed four persons, with fines totalling USD 99,000.

http://abcnews.go.com/US/wireStory/us-cites-dupont-gas-leak-killed-workers-31056772

Short circuit initiated fire in Haryana transport office

A fire incident reported due to short circuit from old electrical wire cause damage of records, files, computers, etc. It is reported that recommendations of investigation committee on a fire incident in some other building last were not implemented.

Some of the recommendations are as follows:

1. ensuring obstruction free passage of 6 m width for fire tender movement
2. ensuring no parking zones around buildings for fire fighting
3. clearing / pruning trees/lobbies/extensions, etc for fire ladder movement
4. removing wooden partitions thus reducing fire load
5. regular checking 
6. keeping balconies/staircases/emergency escape routes free from obstructions (it is common to see many office building corridors filled with broken chairs, cupboards, coffee/tea vending machines, old record bundles, etc)

Apart from the above, we have to ensure availability and functioning of fire detectors and fire fighting system (hydrants, hoses, fire water storage, pumps, emergency power supply to these pumps, fire hoses, training). Regular drills should be conducted to know drawbacks in the system and make improvements.

Lessons learnt from process safety accidents - an article from insurancenewsnet.com

A good article is found on the above title, narrating lessons from five less known accidents. The lessons are,

1. containment of water from fire fighting operations to avoid contamination of water sources in the rundown 
2. to consider all auxiliary equipment also as important as main plant equipment for understanding hazards
3. not to ignore hazards and need for monitoring even during shutdown 
4. positive isolation, purging and checking for hazardous atmospheres (using flame is not a correct check for presence of flammable atmosphere)
5. follow written approval system to override interlocks
6. follow safety permit procedures
7. identify the correct equipment before taking up work
8. communicate with clear identification while handing over the equipment for maintenance
9. ensure physical check by another agency before permitting equipment operation/maintenance
10. hazards from dust, propagation of dust explosions
11. preparation of emergency response management, with detailed instructions for every type of emergency
12. good house keeping
13. establish process safety management procedures
14. inculcate good safety culture, starting from the top management

Fire & Explosion Prevention Strategy in Refineries

Please see the LINK on the above article with download link. The download PDF document lists hazards in LPG bullet area, fireball radius, thermal radiation, probability lethalities, etc

Two persons killed, three injured during LPG line cleaning

Two persons standing in front of gas piping during cleaning were hit by cleaning device at high pressure, hit the compound wall and died. There was no fire or explosion. Only mechanical impact caused the incident.
http://indianexpress.com/article/india/india-others/two-killed-in-accident-at-gails-lpg-pipeline-in-telangana/

The reason reported was nonisolation of pressurized gas supply to the pipeline, though it was assured (?). On any energized system, before working, one should do positive isolation and vent and flush the system, which seems to be not done in this case. Assurances alone will not help.

http://www.thehansindia.com/posts/index/2015-04-05/Negligence-behind-the-mishap-in-GAIL-gas-leak--142181

Red oil explosion (?) in a different form?? - cat litter causes radiation leak in nuclear waste dump

In an incident on 14.02.2014 in nuclear waste isolation pilot plant, cat litter containing organic matter used for stabilization of nuclear waste with nitrates, before storage, caused a chemical reaction generating heat and gases, bursting of lid off the drum and radiation leak.  The temperature was at 1600 degrees (Celsius or Fahrenheit?) causing melting of plastic and rubber (from drums or nearby?). 22 workers were exposed to the incident but without any harmful effects. The cost of cleanup is estimated at USD 240 million.

As per practice, the cat litter with silicates is used for stabilization of the volatiles in the nuclear waste to prevent reaction with others. However changing the cat litter from clay based to organic based (corn/wheat) is suspected to have caused the exothermic reaction, failure of containment of the drum and radiation exposure.

We learnt about red oil explosion which can result from reaction of nitrates and organic and temperatures of above 135 deg C (generally) though it is possible at temperatures as low as 45-50 deg C.

We have to know many things before we do something. Definitely, this incident in New Mexico nuclear waste isolation plant is a clear case study for all of us to learn.

Please see the following links on the above incident.

http://www.theverge.com/2015/3/27/8299325/kitty-litter-nuclear-waste-accident-wipp

http://www.npr.org/blogs/thetwo-way/2014/05/23/315279895/organic-kitty-litter-chief-suspect-in-nuclear-waste-accident

http://www.telegraph.co.uk/news/worldnews/northamerica/usa/10842691/Cat-litter-may-have-caused-nuclear-leak-in-New-Mexico.html

http://motherboard.vice.com/en_au/read/a-scientist-bought-the-wrong-brand-of-kitty-litter-caused-a-nuclear-accident?trk_source=recommended

http://www.telegraph.co.uk/news/worldnews/northamerica/usa/11499595/Wrong-kitty-litter-led-to-radiation-leak-at-New-Mexico-nuclear-waste-dump.html

http://www.santafenewmexican.com/special_reports/from_lanl_to_leak/lanl-officials-downplayed-waste-s-dangers-even-after-leak/article_54d7f3d2-8c99-5793-8c17-c4bdb0b72ef1.html?mode=jqm

http://www.currentargus.com/carlsbad-news/ci_25750452/doe-examining-possibility-kitty-litter-contributed-radiation-leak

http://www.livescience.com/50286-kitty-litter-to-blame-for-nuclear-waste-leak.html

2 page report:
http://energy.gov/sites/prod/files/2015/03/f20/TAT_Fact_sheet%2032615%20FINAL.pdf

277 page report on the incident:
http://energy.gov/sites/prod/files/2015/03/f20/MARCH%202015%20-%20FINAL%20TECHNICAL%20ASSESSMENT%20TEAM%20REPORT.pdf

At least four killed in PEMEX explosion in Gulf of Mexico - World Socialist Web Site

At least four killed in PEMEX explosion in Gulf of Mexico - World Socialist Web Site

http://www.reuters.com/article/2015/04/02/us-pemex-fire-idUSKBN0MS4MU20150402

http://www.greenpeace.org/international/en/news/Blogs/makingwaves/save-the-arctic/blog/52512/

Few incidents occurred earlier also in PEMEX operations. The famous and widely referred in text/reference books and websites including Loss Prevention by Frank P Lees is the one that happened in 1984 where about 500 persons died. This 1984 accident happened just before another accident in Bhopal.

Teacher gets burns during demo in the chemistry class

In a fire incident, a teacher got first and second degree burns while conducting an experiment in front of the students in a chemistry class. The school science classrooms had emergency showers and the teacher doused flames by using it.
It is highly appreciable that the school management has kept emergency showers in the classroom which is rare.
However, one could have checked the material safety data sheet (MSDS) for the chemicals handled before the experiment. Or, was there any slip during the experiment, though the hazards are known?

An article in Yahoo - Forbes on assessment of continuing our present job

In an article that I saw in Yahoo, six points are listed as checkpoints to see whether our present job is suitable or not to continue.

Some of the points are like, no more impact, people are not liking the ideas, don't like going to the work, etc which are mostly faced by safety professionals. Unless safety culture is introduced from day one of the factory started, people don't like to follow safety principles, as they feel that they are imposed. With people around not liking/listening means no impact in safety culture in the factory inspite of best efforts by the safety professional making him feel irrelevant, no job satisfaction, and don't feel like going.

But, this will be the situation generally everywhere as there will be hard nuts everywhere and if one keeps changing the job, finally the person will be branded as rolling stone and will not be considered for jobs at all. Possibly, one should do more research on the company he intends to join before and try to settle.

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.