Designed to Fail: Chemical Release at LyondellBasell

Introduction

This tutorial aims to provide safety guidelines and lessons learned from the tragic incident at the LyondellBasell La Porte Complex, where a chemical release of acetic acid resulted in fatalities. By understanding the key factors that contributed to this event, we can better advocate for safety measures in industrial settings.

Step 1: Understand the Risks of Acetic Acid

• Acetic acid is a corrosive substance that can cause severe burns and eye damage.
• It can be harmful if inhaled, emphasizing the need for proper safety protocols when working with it.
• Ensure that all workers are aware of the properties and dangers associated with acetic acid.

Step 2: Implement Effective Valve Design

• Review existing plug valve designs and identify areas that can be improved to prevent human error.
• Redesign valves to make it difficult to inadvertently remove pressure-retaining components.
• Use color-coded paint or warning signs to clearly mark pressure-retaining components on existing valves.

Step 3: Conduct Thorough Risk Assessments

• Before any maintenance work, perform a comprehensive risk assessment to identify potential hazards.
• Determine if equipment needs to be depressurized or de-inventoried before removal of actuating equipment.
• Ensure that all risk assessments are documented and accessible to all personnel involved.

Step 4: Develop and Follow Written Procedures

• Create clear, step-by-step written procedures for tasks such as removing actuators from plug valves.
• Ensure these procedures are readily available and communicated to all workers involved in maintenance.
• Verify that all procedures are understood and followed during the maintenance process.

Step 5: Provide Comprehensive Training

• Ensure all contract personnel and workers are adequately trained on the specific tasks they will perform.
• Include training on safety protocols, procedures, and the correct use of tools and equipment.
• Regularly update training materials and sessions to reflect any changes in procedures or equipment.

Step 6: Maintain Oversight During Maintenance Activities

• Ensure that experienced personnel oversee maintenance tasks, especially those perceived as simple.
• Have a system in place for verifying the competency and qualification of contractors before they begin work.
• Encourage open communication between workers and oversight personnel to address any uncertainties or risks immediately.

Conclusion

The tragic incident at LyondellBasell highlights the importance of robust safety measures in industrial operations. By focusing on valve design, thorough risk assessments, clear procedures, comprehensive training, and effective oversight, we can significantly reduce the risk of similar incidents in the future. Implementing these steps will not only enhance workplace safety but also protect the lives of all workers involved in potentially hazardous tasks.