Chemical Industry Digest – December 2025 Issue

Publishers Page – A Wake-Up Call for Chemical Process Safety in India

– Vinoo Mathews

The Bhopal tragedy underscores the need for uncompromising chemical process safety in India. Despite regulatory and technological progress, gaps persist.

How IoT, AI, Machine Learning and Digital Twins Are Powering the Future of Safety in the Chemical Industry – Suresh Tanwar, British Safety Council

IoT, AI, Machine Learning and Digital Twins are transforming chemical industry safety by enabling real-time monitoring, predictive risk management and proactive compliance.

The Invisible Epidemic: Why Your Plant is Burning Profits Right Now
– Rajendra Utturkar

Chemical plants lose profits to “invisible accidents” caused by misaligned technology, facilities, human capital and organisational systems. The 4th Era PSMS framework identifies and addresses these hidden issues.
Functional Safety Management [FSM] – What’s Wrong – Any Solutions?
– Shivendra Kapoor

Functional Safety Management (FSM) is often overlooked in chemical plants, leading to Safety Instrumented Functions (SIFs) that may fail in real operations. Implementing a complete FSM lifecycle ensures functional safety works effectively in the field.

A New Era in Process Safety at Oil and Gas Terminals with Artificial Intelligence
– Onur ÖZUTKU, Milangaz

AI is revolutionising oil and gas terminal safety by enabling predictive maintenance, early anomaly detection and real-time risk management. It transforms reactive systems into proactive frameworks, preventing accidents, optimising operations, enhancing
efficiency and strengthening regulatory compliance.

Managing the Threat of “Dead Legs” in Crude Oil Refineries
– Dr. Marcio Wagner da Silva, Crude Oil Refining Industry, Brazil

“Dead legs” in refinery pipelines and storage systems create stagnant zones prone to corrosion, microbial growth and hydrocarbon leaks. Effective management is essential to safeguard asset integrity and prevent process safety incidents.

Chemical Decontamination: Safe and Quick Handover of Process Systems in Turnarounds
– Ramesh Rajasekeran
Chemical decontamination during plant turnarounds safely and efficiently removes hydrocarbons from process systems using liquid or vapor phase methods. It accelerates handover, reduces
shutdown time, optimises manpower and ensures safer conditions for maintenance and inspections.
Bolt Corrosion: Causes and Mitigation – Vivek Kumar Tiwari, Smitesh Deorukhkar
Bolt corrosion, driven by environmental exposure, threatens joint integrity in industrial systems. Protection methods including coatings, inhibitors and material selection affect bolt torque and preload, but each has limitations, requiring careful application, inspection and maintenance for long-term reliability.