Chemical Industry Digest – December 2024 Issue

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Chemingineering – Bolstering BarriersChemical Industry Digest December 2024

– K Sahasranaman, Independent Consultant

Escalation factors worsen hazardous situations by weakening or bypassing safety measures, such as technical issues, human errors, or environmental challenges. Effective Process Safety Management depends on strong, independent barriers to prevent escalation and minimize risks.

Rethinking the Accident Pyramid: A Shift Towards Proactive Integrated Safety Indicators for High Hazard Chemical Industries

– Anshulkumar Tiwari, HMEL

The article presents a six-tier integrated safety pyramid that merges personnel and process safety indicators to enhance proactive risk management in high-hazard industries. This simplifies reporting, strengthens safety culture, and drives comprehensive safety performance improvements

Functional Safety (SIL) – Do We Really Understand the Lifecycle?

–  Shivendra Kapoor, TÜV SÜD

The article simplifies the Safety Integrity Level (SIL) lifecycle per IEC 61511, covering phases from hazard assessment to decommissioning. It highlights the importance of adhering to all stages for effective functional safety in the process industry.

 How Accurate is your Safety & Risk Management System?

– Rajendra Utturkar, Independent Consultant

The SEPLO Process is a safety management approach integrating four key assets—Basic Technology, Plant Facility, Human Capital, and Organization. It addresses root causes, enhances safety, boosts efficiency, improves sustainability, and drives profitability.

In-house Root Cause Analysis Leads to Reliability Improvement of Large Steam Boiler

– Sourav Kumar Chatterjee, Independent Consultant

A root cause analysis of a large steam boiler failure revealed overheating of superheater tubes due to steam drum carryover caused by dislodged secondary separators during high drum levels at startup. Remedies include improved emergency procedures, monitoring, and separator design.

Detect and Prevent Sulfur Tank Fire

– Debopam Chaudhuri, Jignesh Desai, Ranjit Mondal, Fluor Daniel India

The article explores the causes of sulfur tank fires, traditional prevention methods, and introduces a novel solution: high-temperature internal coatings to prevent pyrophoric iron sulfide formation, reducing fire risks and corrosion.

Prioritizing Maintenance and Reliability: A Clarion Call for Sustainable Growth in India’s Chemical Industry

– Hitesh Thaker, Principal, dss+ India

India’s chemical industry must adopt risk-based maintenance strategies to enhance safety, sustainability, and operational excellence, ensuring resilient growth amid global competition and environmental challenges.

LPG Plant Fire Fighting System Maintenance

– Onur ÖZUTKU, Milangaz

Regular maintenance of fire fighting systems in LPG plants is crucial for safety, ensuring readiness during emergencies, preventing system failures, and complying with safety regulations to protect personnel and the environment.

Optimizing Asset Management and Maintenance in Crude Oil Refining Stockpiling Systems

– Dr. Marcio Wagner da Silva, Crude Oil Refining Industry, Brazil

The article emphasizes the importance of prioritizing maintenance and asset management for stockpiling systems in crude oil refineries, highlighting strategies to overcome challenges and ensure safety, reliability, and profitability.