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Parithi
Nov 02, 2023
In Lessons Learnt (OHS)
The incident took place inside a refinery while handling a sample bomb in which sample had been taken from a liquid nitrogen tanker. Prior to unloading the liquid nitrogen tanker, purity of nitrogen was to be checked. Accordingly, a sample had been collected. Subsequently, the sample bomb exploded during leak checking of the bomb valve and split into 02 pieces. One of the pieces (dome along with valve) penetrated in the upper part of left thigh of the truck cleaner/ helper. Truck helper succumbed to the injury a day later. Recommendation - 1. Usage of non-standard sample collection devices: Nitrogen Gas sample shall be taken instead of nitrogen liquid sample in line with the operating manual and standard practice. If liquid nitrogen sample is required, then appropriate collection device, suited for cryogenic services, is to be used. 2. Training: Induction & refresher safety training shall be strengthened for all employees and contract workmen handling cryogenic product to improve awareness level. Toolbox talk, adequate training with coverage to all possible hazards should be ensured to all concerned personnel. 3. Sample Collection Responsibility: a) Responsibility of sample collection should be fixed and shall be done by the company designated persons who are trained and have the necessary skills to perform the task. b) Purview of the contract labours/ drivers should be restricted to the job they are meant and skilled for. 4. Documentation: a) Use of the sample bombs whose OEM documentations/ engineering design details are not available, shall be suspended. b) OEM documentations/ engineering design details of equipment should be available as and when required. c) Hydrotest records shall be maintained in standard format. 5. PPE: Use of specialised cryogenic gloves while handling liquid nitrogen shall be ensured as per clause 8.1.8 of OISD-STD-155. 6. Other Recommendations: a) Non-standard practices, like of testing of leakage of valve by dipping in flowerpot filled with garden water hose shall be brought to notice of concerned through reporting of unsafe act/condition and shall be discontinued. b) In the event that laboratory reports that a sample bomb, used for the purpose for which it is meant, was received empty, the subject bomb usage should be discontinued immediately and the same should be sent for testing. c) Tracking mechanism, like numbering of the sample bombs, should be followed religiously so that it can be known at any time that how many times the bomb has been used. d) Company should take non-conformity to procedures mentioned in operating manual, improper usage of equipment for which the same is not meant/ designed, & inadequate supervision, seriously and take necessary corrective actions for improvement. Source : https://www.oisd.gov.in/(https://www.oisd.gov.in/)
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Parithi
Nov 01, 2023
In Lessons Learnt (OHS)
A fixed roof acrylic acid tank exploded in which there was one fatality and 36 people were injured. The tank acted as an intermediate storage between two distillation columns for purifying acrylic acid. Originally the tank had been used at full capacity. The contents were cooled and mixed by pumping from the bottom of the tank to the top. Later, the normal operating level was reduced to a level below the cooling coil. After routine shutdown maintenance, the recirculation circuit was not commissioned. Thus there was no recirculation of the liquid to the top of the tank. At the time of explosion, the plant was conducting a test of the downstream distillation column, which required stopping feed from this tank. The level of the tank gradually increased to its original operating level. Without recycling of the liquid to the top of the tank, the acrylic acid above the cooling coils was not mixed and cooled. The temperature of the incoming acrylic acid was believed to be below the onset temperature for polymerization, and the acrylic acid contained a polymerization inhibitor. However, the temperature in the tank built up causing the tank to get over-pressurized, leading to the explosion and consecutive fire. Findings 1. Originally the pipe feeding the tank was hot water jacketed to provide freeze protection, but this was changed to steam. 2. Removal of a steam trap made temperature control unreliable. 3. The top layer was no longer mixed with cooler acrylic acid , and stayed warm from incoming acrylic acid . 4. There are two exothermic acrylic acid self-reactions: dimerization and polymerization. Polymerization inhibitors do not stop the dimerization reaction. Experiments showed that heat from dimerization raised the temperature sufficiently to start a runaway polymerization reaction. 5. The hazard of heat from dimerization was not recognized, so recirculation to the top of the tank was not resumed. 6. The tank had no temperature indicator. The first indication of a problem was observation of acrylic acid vapors escaping from the top vent on the tank. Direct Cause Insufficient Cooling and onset of Exothermic Reaction. Root Cause 1. Recirculation system was not commissioned after maintenance, which suggests that the criticality of the recirculation system was not established in the system. 2. There were no temperature sensors in the system to warn the operator of a potential runaway reaction. 3. MSDS of the material was not frequently reviewed  Corrective Actions 1. List of safety critical equipment which are required for the smooth functioning of the plant shall be identified and communicated. 2. There shall be suitable interlocks in place which shall prevent system operation with the safety critical equipment under bypass condition. 3. Any and all changes shall be routed through Management of Change Process. 4. MSDS of the materials shall be reviewed at set frequency or a similar system shall be in place to track and update the changes in the MSDS. 5. Evacuation zone for the worst case scenarios to be established with explosion proof shelter. 6. Process critical parameters such as flow, temperature, pressure and flow shall be properly identified with effective ways to monitor them. Ref: Nippon Shokubai Co., Ltd. Himeji Plant Explosion and Fire at Acrylic Acid Production Facility Investigation Report March 2013.
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Parithi
Oct 25, 2023
In Lessons Learnt (OHS)
A blast occurred in the factory during the manufacturing of plastic granules from cigarette lighter scrap, resulting in injury to six people. Two of them died at spot. An explosion occurred within the confines of a factory situated in Bawana, Delhi on September 20th, 2023, at approximately 4:30 p.m. The incident transpired during the grinding process of plastic waste which contained a plastic cigarette lighter.Grinding of plastic waste in a grinding machine caused fire and explosion leading to the unfortunate loss of one life and injuries sustained by other five workers.
20th September 2023 - Explosion in Plastic Waste Handling content media
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Parithi
Jul 31, 2023
In Lessons Learnt (OHS)
Moving on from exploding fire extinguishers, lets ponder upon exploding oxygen cylinders. Thinking about explosion it is very confusing to grasp. Because the phenomina of explosion and our basic understanding of explosion is very different. I have seen explosion in fire crackers. It had fuel, oxidizer, catalyst in the required ratio with sufficient confinement and with a source of ignition it produced an explosion. But a fire extinguisher does not have fuel nor does it have oxygen inside it. But it exploded. Why ? For that you would have to go to my previous post. Similarly an oxygen cylinder has oxygen and does not have fuel but it still explodes. Before going deep into the mechanics. Let us look at some case studies and understand the situations in which explosions have occoured and see if we can get a meaningful conclusion. Case 01: Cement factory in Hirmi village 18th July , 1510 hrs  | (Link to article)                     The incident took place around 3.10 pm. Three men who had come to a cement factory for some pipeline repair work. The three deceased a welder and two helpers, had gone there with the oxygen cylinder to do the work. They were killed after the oxygen cylinder brought by them exploded due to an unknown reason.The impact was such that one of the workers was thrown 20 feet away from the spot. Case 02: Two killed, six injured in oxygen cylinder blast in Lucknow 05th May 2021  | (Link to article) Two persons have been killed and six others injured in a blast at an oxygen refilling station in Lucknow on Wednesday. According to initial inputs, the blast took place while the workers were refilling an oxygen cylinder. Case 03: Oxygen cylinder explodes while refilling at Kanpur plant, 1 dies Apr 30, 2021 Case 04: Uttar Pradesh: 2 people died in oxygen cylinder blast in Chandauli Dec 30, 2022 | (Link to article) Oxygen cylinder blast occurred in Chandauli district of Uttar Pradesh on December 30, in which two people died on the spot. While speaking on this incident, SP Chandauli Ankur Aggarwal said, “Two people died after an oxygen cylinder exploded when they were unloading it from a vehicle in Dayal Hospital in Ravi Nagar of Mughalsarai Kotwali. Police reached the spot, we are searching CCTV visuals. The number of case studies goes on, there are mulitple conditions and multiple angles which leads to explosion of a cylinder. Each case is somwhat unique and covers a particular aspect or safety aspect which needs to be updated. Now that i think about it, a case by case study with a compiled CAPA will the most apt option. So thats what we will do.
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Parithi
Jul 17, 2023
In Lessons Learnt (OHS)
For the past couple of days, incidents related to trucks have caught my eyes. All accidents involving trucks had two things in common. It has something to do with either the load carried by the vehicle or Drowsiness at the wheels. Pondering over both the causes, it seems one can be easily addressed but the other cannot. Or Can It ? Case Study 01: A lorry driver in China had a lucky escape when seven massive concrete pipes slammed through the back of his cab when he performed an emergency stop. The truck's cargo - weighing several tons - left the driver trapped in horrifically mangled wreckage. Case Study 02: Steel coil crushes truck cabin in southern Vietnam. An improperly attached steel coil being transported on a tractor-trailer rolled over and crushed the truck's cabin in Dong Nai Province when the vehicle stopped suddenly. Amazingly, no one was hurt in the accident, including the truck driver.   Direct Cause: · Crushing of the cabin by the loaded material. Root Cause: · In-adequate securing of the Loaded Materials. · Sudden and harsh braking. · Lack of protective devices like Head Board. · Damaged Rigging tools and tackles.   Top Contributing Factor Analysis When a load is incorrectly secured, this can have disastrous consequences, such as, but not limited to: 1. Cargo can break through the front wall of a truck, causing severe or fatal injury to the driver 2. Load can fall from the vehicle, causing severe or fatal injury to other road users 3. Load can fall from the vehicle, causing environmental problems 4. Load shift can result in damage to cargo and cargo of others sharing the vehicle   Corrective and preventive actions: Proper securing of the load with tested slings and ratchets Ensure that the load does not shift by providing dunnage bags, anti-slip mats ( friction co-eff > 0.6)  and sufficient restraints. Ensure that the cabin of the truck is protected by head board of sufficient strength. Choosing the correct anchor points for securing the load & uniformly distribute load on the truck bed . Provide training in defensive driving techniques to avoid sudden breaking.   Following these thumb rules are expected to lower the incidents to a great effect. But still I am not satisfied with the simple CAPA, may be I have to go though some more literature and a few more interviews and we will update this as we go !
Truck Accident: Crushed by Onboard Load content media
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Parithi
Jul 15, 2023
In Lessons Learnt (OHS)
Can a fire extinguisher explode ? That is a very good question. A fire extinguisher is basically a pressurized container. A typical Dry powder extinguisher will have a pressure of 185 to 195 psi and a Carbon Di-oxide type fire extinguihser has around 825 psi. Now how high of a pressure is this. For a comparison a typical car tyre has 35 psi of pressure and a truck tyre has around 145 psi. This video of a tyre exploding should paint a clear picture of the risk involved. Has there been any incidents where a fire extinguisher exploded ? Incident 01: : 23rd June 2023 A senior high school student has died after an extinguisher exploded during a fire drill at his campus in Thailand. Twenty-one others at Rajavinit Mathayom School in Bangkok were injured in Friday's incident, said the city's governor. Seven were taken to hospital. The explosion had sent the extinguisher flying towards the victim, who was about 10 metres away. Rescuers said the extinguisher may have been defective because of sun or heat exposure. Incident 02: Feb 3, 2023 Fire extinguisher explodes in rubber factory in Greater Noida, 3 injured. The incident occurred at a rubber factory in Sector Beta-2, a fire broke out in Omfa Rubbers Ltd in Site-4 around 9.30am on Thursday. “The fire was triggered when a machine producing fan belts caught fire due to friction. The employees used a fire extinguisher to control the flames, but the cylinder exploded instead. One very important that I have noticed is that these types of extinguisher explosion incidents occour only in "Cartridge type fire extinguishers". The already weakened walls of the fire extinguisher is unable to contain the sudden release of pressure. Corrective and Preventive Action 1. Regular inspections by qualified professionals identify potential issues, such as corrosion, leakage or damaged components. 2. Pressure checks should be performed as the manufacturer recommends to ensure the extinguisher’s pressure remains within the safe range. 3. Store fire extinguishers in designated areas away from extreme temperatures and ignition sources 4. Ensure the fire extinguihser is not kept directly on the ground. 5. Fire extinguishers shall be place at a height greater than 5 feet. 6. Recognizing Signs Of A Potentially Dangerous Fire Extinguisher: 7. Operating a Fire Extinguisher 8. For rechargeable fire extinguishers, you will need to replace them if any of the following issues occur:
Fire Extinguisher Explosion !!! content media
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Parithi
Jun 16, 2023
In Lessons Learnt (OHS)
Tata Steel BSL Dhenkanal plant, also known as Bhushan Steel Ltd (BSL), Tata Steel BSL Odisha, and Tata Steel Angul steel plant, is a 5600 thousand tonnes per annum (TTPA) blast furnace (BF), basic oxygen furnace (BOF), direct reduced iron (DRI) and electric arc furnace (EAF) steel plant operating in Meramandali, Odisha, India. On 13th June 2023 ( Tuesday) at approx. 01 PM an accident was reported at a blast furnace of Tata Steel's hot rolled coil factory at Meramundali in Odisha's Dhenkanal district. The incident occoured during inspection work, Initial reports said "We are saddened to report an accident at the BFPP2 power plant due to escape of steam at Tata Steel Meramandali Works in Dhenkanal, Odisha, The accident occurred at 1:00 pm (IST) today during the course of the inspection work and has affected a few people working at the site, who were immediately shifted to a hospital for further treatment," A total of 19 personnel were injured in the accident owing to steam leak and were shifted to occupational health centre inside the plant premises and were then admitted to a hospital in Cuttack. Out of the 19 patients, 2 patients have also sustained fractures, and 6 of them are burnt above 40%. One patient has sustained burns over 70% are getting treated in the ICU". 
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Parithi
Jun 09, 2023
In Incident Investigation
I was browsing the internet and found a new video, a tyre exploding on to a person. In the video the person seems to be lifitng the tyre, when it violently de-compresses injuring the personnel in the process. So this thread will be dedicated to analysis this incident and similar incidents to find the root cause and establish a safe and preventive work procedure. Requesting you to share any and all videos with relevant information so that the same can be properly analysed. Incident Number 01: Incident Number 02:
Tyre Explosion content media
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Parithi
Jun 06, 2023
In OHS Repository
World Food Safety Day on 7 June aims to draw attention and inspire action to help prevent, detect and manage foodborne risks, contributing to food security, human health, economic prosperity, agriculture, market access, tourism and sustainable development.                       There are several concerns related to food safety in India, but one of the major concerns is the prevalence of foodborne illnesses caused by contaminated food. This can be due to a variety of factors, including poor hygiene and sanitation practices during food production, processing, and handling. Additionally, the use of pesticides and other chemicals in food production can also pose a risk to human health if not used properly. Another concern is the lack of awareness and education about food safety among the general public, which can lead to unsafe food practices. These issues need to be addressed through better regulation, education, and awareness campaigns to ensure that the food we eat is safe and healthy. 1. World Food Safety Day: This is an annual event celebrated on June 7th to raise awareness about the importance of food safety. The theme for 2023 is “Food standards save lives.” 2. Food Safety Education Month: This is an annual event held in September to promote food safety education and awareness. It is an opportunity to educate people about the risks associated with unsafe food practices and to promote healthy and sustainable food choices. 3. Fight BAC! Campaign: This is a national public education campaign aimed at educating consumers about safe food handling practices to prevent foodborne illness. The campaign provides resources and information on safe food handling practices, such as washing hands, cooking food to the appropriate temperature, and storing food at the correct temperature. 4. Be Food Safe Campaign: This is a campaign launched by the U.S. Department of Agriculture (USDA) to educate consumers about safe food handling practices. The campaign provides resources and information on safe food handling practices, such as washing hands, cooking food to the appropriate temperature, and storing food at the correct temperature. 5. FoodKeeper App: This is a mobile app developed by the USDA that provides information on safe food storage and handling practices. The app provides information on how to store food properly, how long food can be stored, and how to tell if food is still safe to eat. These are just a few examples of the many awareness campaigns related to food safety. I hope this helps! Futher It is also recommended for your oganization to have a food safety plan. Below is a general guideline for the same. Food safety training is essential, to ensure that the food served is safe and free from harmful contaminants. Here are some key points to consider: 1. Identify the key personnel who need food safety training: This includes anyone who handles food, including cooks, servers, and cafeteria staff. 2. Develop a food safety plan: This should include procedures for food handling, storage, preparation, and serving. The plan should also include guidelines for cleaning and sanitizing kitchen equipment and facilities. 3. Provide training on food safety principles: This should cover topics such as handwashing, cross-contamination, temperature control, and food storage. 4. Conduct regular inspections: Regular inspections of the kitchen and food service areas can help identify potential hazards and ensure that food safety procedures are being followed. 5. Keep records: Keeping records of food safety training, inspections, and any incidents can help identify areas for improvement and ensure that food safety procedures are being followed. 6. Periodic medical exams of food handlers for any communicable diseases and vaccincations shall be ensured. Overall, food safety training is essential to ensure that the food served is safe and free from harmful contaminants. By following proper food safety procedures, we can help protect the health and well-being of ourselves and others. http://www.csun.edu/~cjh78264/foodsafety/pages/quiz.html
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Parithi
Jun 05, 2023
In Psychological safety
Psychological safety is the belief that you won’t be punished or humiliated for speaking up with ideas, questions, concerns, or mistakes. At work, it’s a shared expectation held by members of a team that teammates will not embarrass, reject, or punish them for sharing ideas, taking risks, or soliciting feedback. Let us say that you are having a meeting with your boss, Without Psychological Safety: You look around and see your boss giving ideas or taking a review of the quarters performance. He points out a bottle neck where we have consistantly under performed for all three months. You see people nodding in approval as if to accept his findings, but no one dares to comment on it. When the boss pressures you to give a response you start to hear people giving commitments to achieve the goal in the next quareter and a few complaining about the next person. With Psychological Safety: Considering the same scenario, once the presentation reaches the bottle neck the leader gives an opportunity for the team to putforth their scenario. The person with the least performance comes forth and explains his constraint and support required. The boss calls for a brain storming session to analyse if the proposed system is feasible. Some tweaks are done to the proposed plan. The conclude to test the plan and get back if further discussion is required. So in conclusion psychological safety enhances the willingness to take risks, be open in meetings to put forth your ideas, Accepting your bottle necks and taking failures as learning opportunities.
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Parithi
Jun 05, 2023
In Lessons Learnt (OHS)
Under construction Aguwani-Sultanganj bridge in Bihar’s Bhagalpur collapses for the second time the bridge has collapsed. First collapse was on 29th April 2022. Further details awaited. 1700 crores were being spent on building this bridge. Work on the 3.1-km bridge to link Aguani in Khagaria district with Sultanganj in Bhagalpur. Here are three videos which describe the incident.
Under construction Aguwani-Sultanganj bridge in Bihar’s Bhagalpur collapses content media
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Parithi
Mar 27, 2023
In OHS Repository
One of the best ways to promote safety is through pre-meeting safety videos. A few minutes of a safety video will go a long way in creating awareness and communicate effectively a message. Every safety professional in their career sits and browses the web, searching for such videos. Videos that have a deep message but crisp in timing. But in a busy schedule videos are generally looked into at the last moment. Well look no further. Following are some videos organized from the web for your viewing. Bookmark the page and promote safety.
Meeting Starters ( Short videos) content media
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Parithi
Oct 21, 2022
In Lessons Learnt (OHS)
Incident Description: At 07:15 PM, 04 Nos. of workers were engaged in shifting of pulley for belt pulley replacement work. Fitter fixed a wire rope sling of 12.7 mm diameter and 1.5 Mtr. length around hydraulic cylinder at mid length to shift it using crane of 20 ton. Hydraulic cylinder was of 0.8 to 0.85 ton. To place cylinder at defined location one person was guiding it by holding the cylinder with both of his hands. When cylinder was at height of approx. one foot from ground level, to position it, he kept cylinder between his legs. Cylinder slightly got swayed and his right legs ankle got trapped between the cylinder and rail kept on ground resulting into fracture near right leg ankle. Contributing Factors: 1. Single wire rope sling used for lifting and was not properly positioned. 2. Guiding of load was done by hand not by Tag Line. 3. Non-availability of expert riggers to carryout job lifting & shifting work. 4. Lifting checklist for the job was not available. 5. HIRA /JSA was not revised as per site conditions. Corrective and Preventive Action 1. Fixing of sling with the material to be done as per the procedure. 2. Lifting job to be carried out under the supervision of Foreman & riggers. 3. Guiding of load to be done with the rope of standard length as per the site requirement. 4. HIRA to be revised & Reviewed. 5. Good Illumination level shall be maintained.
Entrapment of Leg at Ropeway Yard content media
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Parithi

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