On May 7, 2020, a tragic industrial incident occurred at the LG Polymers Pvt Ltd chemical plant outside Visakhapatnam, Andhra Pradesh, India. According to the government incident report, 12 people died from the leak of toxic styrene gas at the plastics manufacturing plant. Hundreds of residents also were sent to the hospital from exposure to the chemical. The gas leak could have a long-term impact on the health and biodiversity of the region. Government findings conclude the root cause of the accident was the failure of management to adhere to safety protocols.
The gas leak incident took place in the early morning hours at the chemical plant. A chemical reaction caused a sudden increase in temperature and pressure in styrene gas storage tanks, used in the production of plastics and synthetic materials. This is likely due to the refrigerating unit malfunctioning. As a result of the increase in temperature, auto polymerization then occurred, leading to vaporization and release because of a gas valve failure.
The resulting gas leak affected the surrounding areas, including nearby residential communities, and spread to an estimated distance of 5 kilometers. The incident led to the loss of several lives, including workers at the plant and residents in the surrounding area. People residing in the nearby villages and neighborhoods reported symptoms of respiratory distress, eye irritation, nausea, and dizziness. The gas leak also caused panic and significant disruption to the local community.
Following the gas leak, emergency response teams, including local authorities, police, and medical personnel, were mobilized to the affected area. They initiated evacuation procedures, provided medical aid to the affected individuals, and implemented measures to contain the leak and prevent further exposure.
The incident prompted a swift and comprehensive response from both the state and central governments. The affected individuals received medical treatment, and compensation was provided to the families of the deceased and affected individuals. LG Polymers Pvt Ltd and its management faced charges of negligence and violations of safety regulations. Local authorities and regulatory bodies then undertook measures to strengthen safety regulations, conduct safety audits of industrial facilities, and raise awareness about the safe handling of hazardous chemicals.
The Visakhapatnam gas leak brought global attention to the importance of robust safety measures, strict adherence to industry standards, and effective risk management practices within chemical plants and industrial facilities. At the time of the incident, India had no single comprehensive regulation like the Process Safety Management (PSM) regulation issued by the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA). This standard consists of technologies, procedures, and management practices collectively known as the 14 elements of PSM. We recommend following OSHA guidelines and recognized and generally accepted good engineering practices (RAGAGEPs).
Defining chemical reactivity hazards is part of the OSHA PSM Standard requirements and is highly recommended. Within the standard, the process safety information (PSI) element requires companies to provide information that may aid in evaluating reactive interactions and their potential hazards. This requirement is rarely satisfied by a safety data sheet. The information is a necessary input to completing hazard analyses, developing operating procedures, emergency relief system design, and optimal asset integrity management (also referred to as mechanical integrity) programs.
Pressure relief and flare system (PRFS) design is a keystone in achieving process safety. The OSHA PSM Standard requires companies to compile information involving the design and design basis of relief systems. Process Safety Office® SuperChems™ can model the dynamics of runaway reactions coupled with venting, heat transfer from/to surroundings and vessel walls, and the change of solar heating over time, depending on geographic location.
News and local reports about the Visakhapatnam runaway incident indicate the likely cause was a combination of cooling and loss of inhibitor associated with a prolonged COVID-19 shutdown scenario. For a case study example of SuperChems™' dynamic modeling capabilities, read this Polymerization Reactions Inhibitor Modeling white paper for a plausible scenario of this incident.
The OSHA PSM standard requires that compliance audits and assessments be conducted every three years and this practice is also highly recommended. They act as an ongoing quality assurance process to identify potential hazards and areas for improvement. Engaging with industry experts on how to adhere to relevant safety standards and guidelines can provide valuable insights and best practices outside of a company’s internal knowledge base.
Training is needed to ensure all personnel are aware of the dangers hazardous materials pose, the safety practices of your facility, and the regulations that must be followed. According to the OSHA PSM Standard, there are several elements or components that specifically require training, for example, before the start-up of a new or modified process or change. Read this article by Principal Consultant Dianne Coon to learn more about the connection between OSHA compliance and training.
ioKinetic has reduced process safety risk, maintained compliance and substantially increased peace of mind for our clients worldwide. To learn more about how we can help you manage risk, contact us today or call us at 1-844-ioKinetic.
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