Chemical Plant Safety Resources

Last June 20, 2009, a maintenance worker was killed when a high-pressure refrigerant line ruptured and four other employees were injured, at a poultry processing plant in Lumberton, U.S (fayobserver.com). The refrigerant was ammonia. The Department of Labor then found some safety violations that lead to the accident.

At least 20 serious safety violations were found. These findings made the states to fine the company by penalties of $73,325. (more…)

Combustible dust hazard control is the key to prevent combustible dust deflagration and explosion. Combustible dust hazard control includes dust control, ignition (heat) source control, operation control and workplace or space control. Proper controls can prevent dust explosion.

Once the initial dust explosion occurs, the secondary explosion seems likely to take place. The secondary explosion can be far more destructive than the primary explosion due to the increased concentration of combustible dust in the surrounding air. (more…)

In the previous post, I have posted about Chemical Safety Board report on explosion at Imperial Sugar Company, USA. Combustible dust sugar was related to that accident. Then, what does a dust explosion mean actually? According to wikipedia, a dust explosion is the combustion of a particle(s) of dust suspended in the air in an enclosed location, resulting in overpressure, thermal radiation, and ensuing projectiles.

From the basic point of view, a fire can only exist whenever an oxidant (oxygen), a combustible material and a source of ignition come together. The three components are famously called by the fire triangle. Meanwhile, in the case of dust explosion, it requires not only the fire triangle components but also combustible dust material must be in an enclosed space or confined space and suspended in the air at the certain concentration.  (more…)

I still commit to post about incident and accident news related to chemical plant operation. This is intended to remind you how accident or incident can happen in various ways and conditions. Here is my accident news record in August 2009.

Fire at Scrap Metal Reprocessing Plant in New Cumberland

Three Workers Treated after Nitric Acid Spill in Savannah

Fire at Chemical Factory Complex in Detroit

Monomethylamine Leak at Dupont Plant During Pumping in Belle

Chemical Fire at Fuel Storage Tank Area

Explosion When Transferring Methanol, One Injured

Boiler Explosion At Chemical Plant in China Killed 3 People

Anhydrous Hydrogen Chloride Leak at Bayer Plant

I read at least 16 accidents news story in July, where most of the plant accidents were fire accidents. The other reasons were chemical leakage, construction accident and falling accident. Here is the list:

Chemical Fire during the Process of Tank Cleaning

Evacuation after Toxic Ethyl Acrylate Fumes Released

Electrical Short Caused Fire at Chemical Plant

Plant Leaked, Released Strong Ammonia Smell

Flash Fire Caused One Man Died

Flash Fire Occurred at a Chemical Unloading Area, One Man Dead

Hexane Fumes Caused One Man Died

Falling Accident at Industrial Area, One Man Died

Construction Accident in Tennessee, 2 Workers Crushed

Chlorine Gas Leaked Forced Water Filtration Plant Shut Down

Wet Concrete Spilled on top of Workers at a Construction Site

Ammonia Leak from a Chemical Plant Caused a Woman Died

Chloro-benzene Explosion Killed 7 Workers in China

A Pressurized 55-gallon Drum of Cleaner Exploded

2 Workers Injured When Glycerin-Sulfuric Acid Mix Sparked Blast

Steam Cracker Exploded during Shut Down Process

This accident video shows a chemical plant explosion at Lodi chemical plant. Such explosion was real and this event has to become the main reason why safety should always be in the first priority. Safety cost is nothing when it is compared with the explosion impacts. Do we care enough to workplace safety?