Safety Reflections










Thursday, January 20, 2011

COSH Names Top 10 Workplace Tragedies for 2010

By Laura Walter
The year 2010 was a bad one for workers: An explosion on a an off-shore drilling rig killed 11 workers and triggered the worst oil spill in U.S. history; a catastrophic mine disaster killed 29 coal miners; and an oil refinery explosion caused multiple fatalities – and those were just the incidents you heard about.
“In 2010, we saw some of the deadliest workplace disasters in recent history,” said Tom O’Connor, executive director of the National Council for Occupational Safety and Health (COSH), “but the sad fact is, thousands of Americans were killed on the job in accidents that got very little, if any, attention at all. Unfortunately, because Congress failed to act this year on legislation that would have protected American workers, we can expect more of the same next year.”
Nearly 5,000 workers died on the job in 2010. Despite their diverse nature, the vast majority of these accidents – including the incidents that made the top 10, O’Connor said – were easily preventable.
“In most cases, workers at these sites where people were killed were aware that there was something wrong in their workplace,” O’Connor said. “But workers on these and far too many other worksites feared for their jobs if they talked too openly about safety hazards on the job. This year, if we learned nothing else, we learned that when workers lack the security and confidence to speak up about life-threatening hazards on the job, catastrophic incidents are inevitable.”
Unfortunately, O’Connor said, while cases like the Gulf of Mexico explosion and resulting oil spill and the West Virginia mining disaster grabbed the headlines, a quiet epidemic of job fatalities continued throughout the country. Few people heard about the thousands of deaths from falls from roofs, trench cave-ins and other “routine” incidents on jobsites throughout the year.
“The solution to the problem of worker safety in our country is not complex,” O’Connor said. “Fines for serious hazards, currently averaging only about $400, need to be greatly strengthened. Workers who fear for their safety on the job need to be given real ‘whistleblower’ protections, so that they can warn others about serious hazards without losing their jobs. OSHA needs far more resources in order to be able to inspect workplaces more than once every half-century or so on average, and employers who knowingly and recklessly place their workers’ lives in danger should face more than misdemeanor charges with a maximum sentence of 6 months in jail that current law provides for.”
 
Top 10 Deadliest Workplace Tragedies
According to COSH, the following workplace tragedies made the top 10 list for 2010:
 
1. April 20, 2010 – Deepwater Horizon explosion. An explosion at the Deepwater Horizon offshore drilling rig in the Gulf of Mexico killed 11 workers, injured 17 others and resulted in the largest oil spill in the history of the petroleum industry. Media reports indicate that management knew key safety equipment had been compromised in earlier incidents, but chose to ignore the significance and continue operations.
 
2. April 5, 2010 – Upper Big Branch mine explosion, Montcoal, W.Va. An explosion at the Upper Big Branch mine in Raleigh County, W.Va., killed 29 workers. The accident represents the worst mining disaster in the U.S. since 1970. Public documents show that the mine’s owner, Massey Energy, has a long record of safety violations at the Upper Big Branch mine.
 
3. Feb. 7, 2010 – Kleen Energy Power Plant, Middletown, Conn. Contract workers at the Kleen Energy plant were performing a “gas blow,” a procedure that uses natural gas at very high pressure to clean pipes of debris. During the process, the gas encountered an ignition source resulting in a massive explosion, killing six workers and injuring 30 others. Following its in-depth investigation, the U.S. Chemical Safety Board (CSB) called natural gas blows “inherently unsafe practices” and called for the immediate ban on the procedure.
 
4. April 2, 2010 – Tesoro Refining & Marketing Company, Anacortes, Wash. A ruptured heat exchanger at the Tesoro Refinery caused an enormous explosion that rocked the plant and killed seven workers. A 6-month long investigation by Washington state OSHA personnel determined that the explosion could have been prevented if the company had carried out proper testing and maintenance of the equipment.
 
5. Dec. 9, 2010 – AL Solutions Plant, New Cumberland, W.Va. An explosion of undetermined origin killed two brothers working at the plant and injured a third worker. According to media accounts, the AL Solutions plant has earned a reputation as a “dangerous place to work” and the deaths of the two brothers represent the third and fourth deaths, respectively, at the plant in the last 15 years.
 
6. March 2, 2010 – Northwest Insulation, Artesia, N.M. Four contractors were installing insulation on top of a new crude storage tank. Workers were welding when a fire ignited. Two workers were injured when they fell while a third remained on top of the tank and was fatally burned. A fourth worker was confirmed dead more than a week later. An OSHA investigation into the cause of the accident is ongoing.
 
7. May 5, 2010 – Amtec Corporation, Huntsville, Ala. Two workers were killed in a violent explosion at a plant that manufactures rocket fuel. Federal investigators later cited the plant’s owners for six serious violations and willfully exposing workers to fire and explosive hazards without proper protection.
 
8. June 12, 2010 – Top Notch Cleaners, LLC, Valley, Ala. Two employees were buffing floors during the night at a mental health outpatient facility with machines that use propane gas. An employee of the outpatient facility discovered both men dead the next morning. Both the employee and the police who responded to the incident smelled gas when they entered the building where the men were working. Investigators believe carbon monoxide poisoning and inadequate ventilation contributed to the deaths.
 
9. July 22, 2010 – Horsehead Corp., Monaca, Pa. An explosion at the Horsehead zinc refinery, a facility with a long history of safety violations and OSHA citations, killed a pair of workers and injured two others. Although investigators have still not determined the cause of the blast, the company has a long history of safety violations.
 
10. July 23, 2010 – Northeast Energy Management Inc., Cheswick, Pa. Two workers engaged in arc welding were burned to death when the tank they were working on exploded, throwing their bodies approximately 60 feet away from the site of the ignition. The explosion and fire that killed the workers was the third involving Northeast Energy Management since September 2007, when one employee was severely burned in an explosion at a gas and oil well.
 
O’Connor stressed that national political leadership needs to recognize that, after 40 years, the outdated Occupational Safety and Health Act needs a major overhaul. Only then, he said, can the families of the nearly 5,000 workplace victims in 2010 feel that their loved ones did not die in vain.
 
Augie Rincon, ConocoPhillips

Monday, January 17, 2011

Sunday, January 16, 2011

What are the biggest problems you are faced with in your company?

- Lack of management commitment
- Lack of enforcement of rules and regulation
- Lack of buy-in from employees
- Lack of budget

Most of the problems encountered in a company boil down to lack of management commitment. If management is not totally committed to safety, the grassroots appproach will only take you so far. A lack of budget may indicate that in this economy your company may be short on cash and is focussed on keeping the company afloat, but if there is no safety budget it may also be because management has not deemed safety important enough to plan ahead for any possible safety expenses that may arise (new equipment, cost for training, etc). Although the cost for safety is substantially lower than the cost for a lost time accident or a fatality (which could actually put a smaller company out of business), cost still has to be planned into the project. If management thinks they can do without any safety budget, it only shows that they do not understand the cost of working unsafe.

Lack of enforcement of rules and regulations: Have you ever worked in a company where there seem to be several standards for different employees, that the employee who has been with the company for 25+ years can get away with more than the employee who just started? Maybe you have realized that certain sections of the Safety & Health program collect dust because not even verbal warnings are issued? Workers will realize very quickly that there are different standards and that enforcement is only lip service.

If employees don't buy into safety, it is mostly because they see that management does not buy into safety either or that management does not walk the talk. Can we change that? Hopefully by being knowledgeable, persistant and passionate about your job.

Meike Patten, MPSafety Training

Tuesday, January 4, 2011

Vapor Cloud Explosions

The Beacon

A vapor cloud explosion occurs when a sufficient amount of flammable or combustible material is released, mixes with air, and is ignited. Some causes of the release of the vapor or gas fuel include:
• Loss of process containment from failure of a pipe, reactor, storage tank, or other process vessel  
  containing flammable or combustible liquid, or a flammable gas.
• Rapid discharge of flammable vapor to the atmosphere through a pressure relief system.
• Release of flammable liquid stored under pressure – for example, Liquefied Petroleum Gas (LPG). The
  discharged liquid will rapidly boil at atmospheric pressure, forming a flammable vapor cloud.

If the flammable vapor cloud is ignited, it can explode, producing a blast wave which can cause major destruction at a large distance. This is particularly true for releases in congested or confined areas,
for vapor clouds that have drifted into such areas, and for reactive materials. In addition, heat from the fireball can cause significant injury or damage. Some of the worst disasters in the history of the process industries have been vapor cloud explosions. Some examples include:
• June 1974, Flixborough, England (28 fatalities)
• October 1989, Houston, Texas (23 fatalities)
• March 2005, Texas City, Texas (15 fatalities)
• December 2005, Buncefield, England (no fatalities but 43 injuries
and major damage)
• October 2009, Jaipur, India (12 fatalities)

What can you do?

Make sure that piping and equipment inspections and preventive maintenance tasks are completed as
required to ensure mechanical integrity of process equipment. Containment of fuel is the best way to prevent
vapor cloud explosions. Ignition sources for flammable vapor clouds – for example, heaters, vehicles,
unclassified electrical areas, hot work, static discharge – are difficult to control.

Ensure that safe work practices are followed, including hot work procedures in areas near flammable
inventories.
If you detect any leak, no matter how small, on equipment containing flammable or combustible liquid or
flammable vapor, report it immediately and know how to initiate emergency procedures.
If your plant contains flammable or combustible materials, you should have written emergency procedures
for a leak. Review and understand these procedures, participate in drills, and know what you must do to
protect yourself and others in case of a leak. Know when and how to use appropriate personal protective
equipment (for example, flame resistant clothing) and leak detection equipment such as portable flammable
material detectors.

Augie Rincon, ConocoPhilipps

Thursday, December 30, 2010

Safety is Free

If you get a chance, read Philip Crosby's "Quality is free" and replace the word "quality" with "safety". You will be surprised how much quality management and safety management have in common. Review especially the quality management maturity grid (1.Uncertainty, 2. Awakening, 3.Enlightenment, 4.Wisdom and 5. Certainty).

Meike Patten, MPSafetyTraining

Tuesday, December 21, 2010

Confined Spaces

September 6, 2010. NY: Two workers were killed from a possible fall and/or oxygen deficiency while entering a permit required confined space.

The hazards of confined spaces are underestimated on a regular basis as we do not see the gases that drift in a manhole or in a tunnel. The failure to recognize a confined space as such, as well as the failure to recognize the invisible but deadly hazards, almost always results in asphyxiation.

Why is it so difficult to make workers understand the incredible risk they are taking when they enter a Permit Required Confined Space? Is it complacency or the attitude that “it’ll take only a few minutes to get the job done”, do they think that simply opening the cover of a manhole or the door to a crawlspace under a building is sufficient to flush out the “bad air”?

What can we safety professionals do better? How can we change our own approach to training and make people understand that they risk their lives? And if supervisors and management do not comprehend the severity of the situation, how can we expect the workers to follow standards, regulations and safe work practices? Even if comprehensive classroom and/or hands-on training has been provided, there will still be people who will do all the wrong things a few weeks later when a PRCS is encountered. What is management’s role come in such a situation? If management does not fully understand the need to enforce the rules, and, if necessary, to draw the consequences (disciplinary actions), procedures and training will only sporadically be followed. It always comes down to management commitment and support. The grassroots approach is certainly an important building block, but it can only take you that far.

PRCS come in all sizes and shapes and the hazards are numerous. Constant training sessions are not always the solutions. Workers may over time resent being trained and guided, because they have heard it many times before. One approach may be to seek individual one-on-one communication. It is important that safety professionals have at least a basic knowledge of psychology, because at times he or she will have to “manipulate minds” – ya’know, like the clever wife who manipulates the husband and lets him think it was all his idea… Get a worker’s input. Make sure he or she understands that you really, really want to hear his opinion and how he would approach this particular hazard. Talk to the guys in the field and in the plants, make training more personal.

And never be satisfied with what you achieve. OSHA standards are only minimum requirements and we can do better than that. OSHA is not only about safety and health but also about politics (what an eye-opening statement…), which that means that safety professionals often have to be the forerunners and trailblazers and do more than just what OSHA requires in order to keep folks safe.

Meike Patten, MPSafetyTraining

Friday, December 3, 2010

I2P2

December 7th will be the first meeting of the Injury and Illness Prevention Program workgroup. The idea of the socalled I2P2 is not new. In 1991, California developed its own Injury Prevention Program, and the State of Minnesota, for example, requires "A Workplace Accident and Injury Reduction Program (AWAIR)".

In August 2010, a stakeholder meeting discussed a possible I2P2 based on OSHA's Voluntary Protection Program, Safety and Health Achievement Recognition Program, ANSI Standards and OHSAS 18001 series (by the British Standards Institution), as well as state programs such as CAL OSHA's Injury Prevention Plan. OSHA hopes to be able to present the rulemaking on I2P2 within the next three years.

Consensus standards have been developed by the American National Standards Institute and the American Industrial Hygiene Association. The ANSI/AIHA Z10 standard is based on the Deming cycle (plan-do-check-act) and the concept of continual improvement which is also major part of the ISO 14000 process standard series focusing on Environmental Management Systems. The American Industrial Hygiene Association (AIHA) believes that the component of continual improvement is beyond the statutory limits and that the I2P2 program, although based on the PDCA model, should focus on OHS management.

Another consensus standard, OHSAS 18001, provides guidelines to establish occupational health and safety management systems that can help employers to reduce risks in the workplace. Similar to the ISO standards, the ANSI Z10 standard focuses on continual improvement and employer's efforts to constantly work on further development of environmental, health and safety goals.

An ISO series in regards to occupational safety and health was never developed. In contrast to consensus standards, OSHA regulations do not focus on continual improvement or on seeking new ways to improve workplace health and safety, but to provide standards that employers and employees must adhere to. OSHA standards are, however, only the minimum requirements and leave room for improvement. Using I2P2 as a regulation to force employers to put workers' safety and health into the center of attention, will hopefully over time turn compliance into a habit and bring on permanent change.

Meike Patten, MPSafetyTraining