Kleen Energy Explosion-CSB issues report

By Rick | Feb 26, 2010

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Feb 25, 2010- The CSB has released a preliminary report about their findings in the Kleen energy power plant explosion that caused fatalities and injuries. Here is the text of the news conference.

The gist of the findings are that companies must take sufficient care to ensure that gas or explosive/inflammable vapors do not happen at all and if they do, they should not meet an ignition source. This is well known to engineers and technicians in the process industries, but apparently it took actual explosions to bring home the truth.

KleenEnergyLeakPhoto

CSB Statement

Good morning I am CSB Lead Investigator Don Holmstrom; thank you for coming to this CSB news conference. The Chemical Safety Board is an independent federal agency that investigates and reports to the public on the causes of major chemical accidents at industrial sites across the country. The CSB is headed by five board members appointed by the president and confirmed by the Senate.

The CSB’s reports and safety recommendations to Congress, federal and state regulators, and industry are widely followed and applied throughout the United States. Our mission is to prevent disastrous accidents of the kind that occurred here less than three weeks ago.

The safety issues raised by this accident are not limited to Connecticut. These issues are larger than any particular company, facility, or individual. The U.S. has embarked an ambitious construction effort for new natural gas power plants. Thousands and thousands of workers across the country will be involved in constructing these plants. The safety of these workers and the nation’s energy independence are at stake as these gas-fired plants are built over the next 20 years.

The CSB has a team of ten here investigating at the Kleen Energy accident site. On behalf of all of us at the CSB, we extend our deepest condolences to the families of Ronald Crabb, Peter Chepulis, Raymond Dobratz, Kenneth Haskell, Christopher Walters and Roy Rushton. The goal of the CSB investigation is that terrible accidents like this will not happen again and that no families will suffer such tremendous losses in the future.

The CSB team arrived at the site on February 8th. Since that time, the CSB team has conducted a large number of interviews, reviewed documents, and closely examined the accident site on numerous occasions. We appreciate the outstanding cooperation from the workers at this facility, who despite living through such a horrible ordeal have provided valuable information to CSB investigators.

This accident occurred during a planned work activity to clean debris from natural gas pipes at the plant. To remove the debris, workers used natural gas at a high pressure of approximately 650 pounds per square inch. The high velocity of the natural gas flow was intended to remove any debris in the new piping. At pre-determined locations, this gas was vented to the atmosphere through open pipe ends which were located less than 20 feet off the ground. These vents were adjacent to the main power generation building and along the south wall. The open pipe ends are visible here in the photographs.

You can actually see the high-pressure gas venting out of one of these open pipe ends in this photograph taken a short time before the accident on February 7.

This cleaning practice is known within the natural gas power industry as a “gas blow.” Industry personnel have indicated to CSB investigators that gas blows are a common practice during the commissioning of new or modified gas pipes at their facilities.

CSB investigators have reviewed gas utility records for the morning of the accident. These records together with written pipe cleaning procedures and witness testimony confirm that the gas blows occurred intermittently over the course of the morning. At the same time that gas blows were underway, there were potential ignition sources present in the surrounding area, including inside the power plant building. There were many construction-related activities underway inside the building.

Determining the exact ignition source is not a major focus of our investigation at this point. In most industrial worksites, ignition sources are abundant and efforts at accident prevention focus first and foremost on avoiding or controlling the release of flammable gas or vapor.

Initial calculations by CSB investigators reveal that approximately 400,000 standard cubic feet of gas were released to the atmosphere near the building in the final ten minutes before the blast.

That is enough natural gas to fill the entire volume of a pro-basketball arena with an explosive natural gas-air mixture, from the floor to the ceiling.

This gas was released into a congested area next to the power block building. This congested area likely slowed the dispersion of the gas. The gas built up above the lower explosive limit of approximately 4% in air and was ignited by an undetermined ignition source.

In the days since the accident, companies and safety regulators from around the world have contacted the CSB asking about the circumstances of this devastating accident. Some companies, including a power plant here in the region, indicated that they themselves have been planning similar gas blows as part of commissioning pipes in the very near future.

A major focus of the CSB investigation is to determine what regulations, codes, and good practices might apply to these gas blows. To this point, no specific codes have been identified, but we are continuing our research.

In the meantime, we strongly caution natural gas power plants and other industries against the venting of high-pressure natural gas in or near work sites. This practice, although common, is inherently unsafe.

The CSB is investigating possible alternatives to this practice, including the use of air, steam, nitrogen, or water or the use of combustion devices to safely destroy the gas. Combustion devices like flares can safely burn up flammable gas or vapor, preventing the possibility of an explosion.

Recommending safer alternatives will be a primary focus of the CSB investigation as we move forward.

Just three days prior to this tragic accident, the Chemical Safety Board recommended changes to the National Fuel Gas Code to prevent disastrous explosions involving gas purging. We note with great appreciation that just yesterday, at a meeting in San Francisco, the NFPA panel responsible for the fuel gas code voted to move forward with the CSB’s recommendations to make purging practices safer at work sites across America. These provisions will apply at hundreds of thousands of facilities, once fully adopted.

The type of purging described in that code is different from the gas blows used in the power industry, and power plants remain exempt from the national fuel gas code. However, gas purging as defined in the code has certain similarities to gas blows, in that gas is applied at one end of a pipe and gas is intentionally vented at the other end to the atmosphere.

There is an underlying common theme among the tragic accidents at Kleen Energy, the ConAgra Slim Jim plant in North Carolina, the Ford River Rouge power plant in Michigan, the Hilton Hotel in San Diego, and many other purging-related accidents. Companies must ensure that flammable gases are not vented into close proximity with ignition sources and workers. That is a vital safety message from all these tragedies.

We encourage the gas power industry to closely study the very positive actions recommended by the NFPA and the American Gas Association committees yesterday. The CSB investigation will focus on determining what permanent changes in standards or practices are needed to prevent future accidents involving gas blows.

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A Practical Guide to Hazardous Area Classification

By Rick | Feb 17, 2010

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Miami-FL, Feb 16, 2010- If you are looking for a practical guide to Hazardous Area Classification, then look no further.There is a new ebook in a flip page format (just looks like a real book), that has all the essential information that you need to know about area classification.

As you must have known by now, area classification is very important to industries and facilities that handle, store or otherwise process hazardous (flammable liquids and vapors). Also, if a facility is handling large amounts of dusts (like grain dust or coal dust), then it needs to be classified also as a hazardous area, with the code that is applicable to dusts. This classification can be sometimes very intimidating and even confusing, what with the plethora of varying standards and codes. The IEC system and the North American (NEC) systems are covered for vapors, gases, as well as dusts. Actual real life area classification drawings are provided, that really area a help, as compared to the same stale figures that are repeated in all publications.

This guide is a fast start to your area classification exercise. It is always a good safety practice to review the hazardous area classification of an industrial facility, every few years, due to the changes, modifications in equipment or new layouts that have now become a permanent development in most plants. If the area classification was done ages ago, then it is better to review it once again, to confirm that the old classification still holds, or to change it if necessary.

This guide provides a very concise overview and even provides a step by step procedure that was followed while doing an area classification. Definitely a must have book for understanding area classification.

Also, since a trial version is available, you can download and see for yourself immediately. Click here to get it.

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Confined space entry-what to look out for?

By Rick | Feb 2, 2010

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What are confined spaces? And why should you bother about them?

Well, confined spaces are places in your workplace that are “confined” because their configurations restrict the activities of employees who must enter, work in, and exit them. A confined space has limited or restricted means for entry or exit, and it is not designed for continuous employee occupancy. Think underground vaults, tanks, storage bins, manholes, pits, silos, process vessels, and pipelines and even elevator shafts.

OSHA uses the term “permit-required confined space” (permit space) to describe a confined space that has one or more of the following characteristics: contains or has the potential to contain a hazardous atmosphere; contains a material that has the potential to engulf an entrant; has walls that converge inward or floors that slope downward and taper into a smaller area which could trap or asphyxiate an entrant; or contains any other recognized safety or health hazard, such as unguarded machinery, exposed live wires, or heat stress.

Training in confined spaces is absolutely essential for all employees who are going to work in confined spaces, as well as for those who supervise them. It’s the law! And what better and cost effective training to get than e-learning? You control the pace of the course, the time it can be taken and it costs almost next to nothing, if you factor in the yearly refresher training. An excellent choice would be a CD based confined space entry training given below. Check it out!

What is WHMIS and why should I bother?

By Rick | Jan 26, 2010

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Jan 25, 2010 - Here’s a quick heads up for those of you who are wondering about an acronym called WHMIS (sounds very close to “whims”, doesn’t it). Well for those of you who are not familiar with Canadian law (not expected anyway, unless you live or work in a Canadian facility), WHMIS is the acronym for Workplace Hazard Materials Information System. It is a comprehensive plan for providing information on the safe use of hazardous materials used in Canadian workplaces. Information is provided by means of product labels, material safety data sheets (MSDS) and worker education programs.

It is a legal requirement if you are running a factory or doing other business related to the chemical industry in Canada, formulated and enforced by Canada’s own OSHA-like body, called CCOHS (Canadian Center for Occupational Health and Safety).

The majority of the “information” requirements (and exemptions) of WHMIS legislation were incorporated into the HAZARDOUS PRODUCTS ACT and the HAZARDOUS MATERIALS INFORMATION REVIEW ACT. These apply to all of Canada.

Suppliers, employers and workers all have different specific responsibilities under these acts. For more information please visit http://www.ccohs.ca/oshanswers/legisl/intro_whmis.html

So if you are in anyway connected with the Canadian chemicals or petrochemical and allied industries, dealing in controlled chemicals, you better be familiar with WHMIS.

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ConAgra Slim Jim plant Fatal explosion-CSB to hold public hearing

By Rick | Jan 15, 2010

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Washington, DC, January 14, 2010 - The U.S. Chemical Safety Board (CSB) today announced that it will be holding a public meeting on Thursday, February 4, 2010, in Raleigh, North Carolina, to present preliminary findings from its investigation of the June 9, 2009, natural gas explosion and ammonia release at the ConAgra Food Slim Jim facility in Garner, North Carolina, that killed four workers and injured seventy others.Interior view of the ConAgra facility following the June 9, 2009, explosion and fire

The meeting will begin at 6:00 p.m. at the Raleigh Sheraton Ballroom located at 421 South Salisbury Street in downtown Raleigh. The meeting is free and open to the public.

At the meeting the CSB investigative team will present its preliminary findings on the circumstances of the accident to the three CSB board members and the public. The Board will then receive testimony from outside experts concerning safety issues raised by the accident, focusing on the topic of safe purging of natural gas piping. Following a public comment period, the Board is expected to consider draft staff recommendations for changes to the National Fuel Gas Code, which establishes gas purging practices followed across the country. The meeting will be videotaped and an official transcript will be published.

The explosion occurred during the commissioning of a new, gas-fired industrial water heater at the plant, when natural gas was purged into the interior of the building. The gas accumulated to an explosive concentration and ignited; the ensuing blast caused large sections of the building to collapse.

“This was a serious accident which claimed the lives of four workers, injured scores of others, and resulted in hundreds of job losses,” said CSB Chairman John Bresland. “The goal of the CSB investigation is to recommend measures that will help prevent other devastating accidents during gas purging operations.”

Board investigators said they have identified a number of similar gas purging accidents in recent years, including an explosion at a Michigan power plant in 1999 that killed 6 and caused $1 billion in property damge and an explosion in 2008 at a San Diego hotel that injured 14.

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