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An explosion at a refinery had led to the death of one contract maintenance worker and injured four others. According to the investigation, the workers
An explosion at a refinery had led to the death of one contract maintenance worker and injured four others. According to the investigation, the workers were repairing a catwalk that had deteriorated due to acid vapours in the atmosphere around sulfuric acid storage tanks. Sparks from the welding work likely ignited flammable vapours from a tank identified TS103 that had been leak and resulting the explosion. The explosion had led to the release of sulfuric acid from other tanks TS101 and TS102, flowed into Sungai Bari causing significant environmental damage. Tank TS103 was originally designed to store fresh sulfuric acid but had been converted to store spent acid. This tank had a history of leaks and the investigation said that the company had failed to conduct inspections that may have identified the presence of these leaks. The spent acid in the tank contained impurities such as hydrocarbons which were flammable and vaporised. The company was aware the hazard of vaporised hydrocarbon and installed a carbon dioxide inert system with ventilation. However, this inert system was undersized and not implemented properly and therefore did not prevent formation of flammable atmosphere above the tank prior to the explosion. (a) Discuss the violation of Process Safety Management elements following the above incident. (10) (b) Discuss steps that should be taken to prevent similar incident in the future
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