Chemical Industry, as is well known produces and handles some of the most hazardous and toxic chemicals. Chemical production processes need to be continuously monitored and controlled so that no runaway reactions happen. Plant and equipment health should be always in excellent operational condition and maintained optimally throughout its life cycle. Even storage, handling, and transportation of chemicals have to be as per safe practices. However, in recent times, many chemical plant fires, explosions and other accidents have taken place, despite well laid down safety protocols and strong regulations.
There are latest technologies today from processes to digital technologies that can ensure foolproof operation.
Then why do accidents happen? Chemical Industry Digest interacted with many safety experts and the first of such responses to our questions is published here.
Shivendra Kapoor, a certified safety expert with over 20 years of hands on industry experience explains from his perspective.
His views are presented here.
Chemical Industry Digest (CID): As you know, recently, quite a few very disturbing chemical plant accidents and disasters have taken place in India, mainly in Maharashtra. Despite latest technologies that give all kinds of prior warnings why are such accidents becoming frequent? Are these also due to outdated processes? To what extent do operational errors contribute to these accidents?
Shivendra Kapoor (SK): Latest technology though available and implemented in the design phase must be used correctly in the operational phase of the plant. Many forget – “What has been designed must also be maintained.” Also, safety culture of an organisation plays a pivotal role in ensuring that systems are up and running SAFELY and not just meeting production targets.
If a plant operator is burdened with too many activities at the same time, then safety will be only on PAPER and not in the FIELD. This is the harsh reality that organizations don’t realize. Projecting bar charts, pie-charts in color that we have achieved “Zero LTI Always” is misleading. Many processes are outdated, and they must be modified/ replaced with upskilling of personnel handling these processes.
(CID): Is it that there is a laxity on inappropriate maintenance of plant and equipment in general in India or not giving due importance?
(SK): To be honest the answer is Yes.It is not just the maintenance but the entire operation and maintenance phase post-handover of the plant from project phase goes for a toss. I have visited so many industries and rarely I have seen “P&ID on paper, matches what is installed and running in the field”. When the most fundamental document is in such a bad shape what can we expect? Rather I have still given an optimistic view- in most of the small sized manufacturing industries P&IDs don’t exist and unfortunately no one is bothered.
(CID): How often should chemical plants conduct safety audits and risk assessments?
(SK): Plants must conduct safety audits and Risk assessments as many times till the point they get the confidence that “Safety is really achieved in true sense- it would come from within.”
The biggest mistake that must be scrapped is’ engaging with L1 [lowest bidder] without a thorough evaluation of what he/she can actually deliver. This is a very serious problem in our industry. In the name of basic safety audits the reports are copy pasted from previous projects and Hazard and Operability [HAZOP], Safety Integrity Level [SIL] Study reports are no more risk assessments but mere paper filling work. Unless management allocates correct resources and right time required to complete these studies, the scenario will not change.
(CID): What are the key components of an effective emergency response plan for chemical plants?
(SK): Competent personnel, mock drills [with real scenarios], bringing the real issues out as to how hazardous the plant is and what could be the worst case that can happen. Organizations must think loud about the impact their organizations’ consequences may have on the community. The government must stop development of schools, malls, residential complexes, etc in and around industries. A correct and detailed Quantitative Risk Assessment [QRA]will actually open our eyes to warn us that many are actually sitting on a time bomb- ready to explode.
(CID): What technological advancements can help in preventing chemical plant accidents? How can chemical plants leverage data and analytics to predict and prevent potential accidents?
(SK): As I said technology comes later. First- attitude and cultural change is a must and that too deep rooted. Safety studies impact must be in field and not on paper.Personnel across industries need to be made competent and responsible at all positions. Technology, data analytics, etc..will easy support us for sure.
(CID): Our safety regulations are considered to be quite stringent. So, are there any identified gaps in the enforcement of these regulations?
(SK): Safety regulations must be stone-hard and all safety studies must be embedded in industrial insurance and regulatory authorities must become really very strict where they observe slip ups in any safety aspect. We need to learn some good practices from the West. Our safety regulators need to follow – ‘My way or highway approach’; else nothing is going to improve.
(CID): What preventive measures can be implemented to avoid future accidents in chemical plants?
(SK): Major 360-degree cultural change [at all levels], right work hour duration and appropriate compensation to all employees and contractors, strong safety regulations- law must instill fear in the industry, stopping of L1 bidder concept [unless it really involves deep technical and correct commercial comparison], paper to field application and definitely using the right and updated technology. There is lack of competent personnel in the industry and hence a lot of training and awareness need to be ensured before people actually practice safety in the field.
CID: How important is transparency and communication with the public regarding chemical plant operations and safety measures?
SK: It is the need of the hour. People are losing trust in the system. After every accident a compensation is announced. This cannot solve the problem. Make the processes and implementation of the laws tight in true sense; everything will fall in place.
