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Explosion in a Gas Processing Plant

Fire and Explosion in a Gas Processing Plant

What happened?

Fire and explosion has occurred in the Storm Water Drain (SWD) in a gas processing plant that resulted in one fatality, 32 workers hospitalized and damages to the SWD structure. Fire occurred while a worker was testing his welding equipment (amperage test) on a working platform about 6 meters above the SWD. Investigation revealed that the fire was initiated from the welding sparks, which fell into the SWD that contained flammable hydrocarbons [fuel] in excess quantity and led to an explosion and fire.

 
Picture 1 : A: Working Area; B: Condition inside SWD with burnt marks after the explosion and fire

What went wrong?

• The plant owner failed to identify hazards and risk of hydrocarbons in the SWD;
• Tests to confirm that the plant is hydrocarbons free does not include SWD;
• Failure of the owner to carry out periodic maintenance work on the SWD;
• No safety procedure in carrying out welding work;
• The scope of the gas measurement is not carried out properly because it does not consider risk assessment of welding work’s surrounding;
• Communications breakdown within organization during safety management implementation; and
• Measurement of Lower Explosion Limit (LEL) for hydrocarbons in the SWD was not carried out by the owner.

Lessons Learnt

• Identification of hazards and risk must be done thoroughly, including SWD;
• Test shall be taken to ensure SWD is hydrocarbons free;
• Periodic maintenance work should be carried out on the SWD to ensure no presence of hydrocarbons in it;
• Provision of safe work procedures for welding work;
• The scope of the gas measurement should take into account the environmental risk assessment for welding work;
• Effective communication in the organization is upheld during the implementation of safety management system and
• Measurement of Lower Explosion Limit (LEL) for hydrocarbons in the SWD should be carried out by the owner.

References

1. Bjerketvedt, D., Bakke, J.R., Wingerden, K.V. 1997. Gas explosion handbook. Journal of Hazardous Materials 52: 1-150
2. Lees, F.P. 1996. Loss Prevention in the Process Industries – Hazards Identification, Assessment And Control, Volume 2, 2^nd edition, Butterworth-Heinemann, Oxford, United

SPESIFIKASI GAS - SEMENANJUNG MALAYSIA, SABAH DAN LABUAN

INFORMATION

Fire on Liquefied Petroleum Gas (LPG) Decanting Process Premise

Fire on Liquefied Petroleum Gas (LPG) Decanting Process Premise

On the night of February 28, an explosion and fire occurred at a premise where the illegal transferring operation of Liquefied Petroleum Gas (LPG) took place (Figure 1). It believed to be caused by gas leakage during the transferring work (decanting process) from domestic cylinder to industrial cylinder (Figure 2). Fire has destroyed entire processing area on the premises. No casualties reported.

                          Figure 1 : Scene of the accident
 

Figure 2 : Pile of cylinders damage by the fire

Suggestions for Improvement:

1. Owner should ensure that the operation of his establishment has taken into account all the safety precautions required during the decanting process including safety signage, impact and fire protection as well as potential ignition sources
2. All equipment used in the process must be checked and confirmed to be safe to use (not substantial) and will not cause any risks to employees and also public's.
3. All employee engaged in the decanting process should undergo the instructional training and be able to demonstrate competency in the filling, emergency procedures and use of personal protective equipment associated with the task

NOW SOLENOID VALVE & GAS DETECTOR COMPULSORY IN MALLS

The Energy Commission has released a directive to shopping mall owners and tenants with piped gas supply to install solenoid valves on their networks. Especially when it comes to in-mall restaurant kitchens with cooking stoves, gas leak detector systems must be installed in order for these valves to shut supply off upon detection of leakage.

This was revealed at the recent Planning, Managing & Enhancing Building Safety seminar, organised by Building Management Association of Malaysia.

According to the directive, mall owners and occupiers must employ one full-time staff to oversee gas safety. This staff must ensure that all gas valves are closed and recorded as such by the end of the day’s operations.

"The directive said immediate action must be taken but we know that this requires some time and investment, so the tenant will be given some grace period of, I think, some months to comply," said the Energy Commission’s head of gas safety, Yusni Sharif. "Definitely, we have to ensure we do something since gas leakages have been rampant." Gas explosions within malls have occurred over the last few years in Maju Junction, KL, Empire Shopping Gallery, Subang, as well as Aeon Jusco, Malacca.

More than five months after the gas blast at Empire Gallery, in fact, investigation results into the cause of the incident are yet to be released.

The time frame given by the commission to do so was in fact three months after the incident.

While unwilling to make any statement, experts from the commission indicated that the investigation has concluded and that the results are now in the hands of the Energy Commission’s lawyers.
- The Sun, Malaysia - 30 Mar 2012

Explosion of Liquefied Petroleum Gas (LPG) in a Supermarket 2011

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