-near Miss-back Fire From Flash Back Arrester- - DOCX Download

Dear All,

FYI,

On 7th July 2014 at 05:10 PM, HDS, a sub-contractor of XYZ Gas Cutter, Mr. Chandra Pal, was engaged in Chanel cutting with a gas cutting set in ABC Fabrication yard at ground level. Flashback arresters (FBA) were fixed on both sides (cylinder and torch). During the gas cutting job, unfortunately, the Oxygen Hose pipe blasted with fire due to backfire from the torch. The distance was approximately 1.5 meters from the torch. Immediately, the gas cutter controlled the situation by releasing all pressure gauges and releasing the pressure of the hose pipe from the torch. Fortunately, nobody was injured. (Photo Attached)

Investigation Report:

After opening the FBA-Flashback Arrester, we found that the backfire control system of the FBA was not proper. The spring and nozzle, which control the backfire, were not provided by the manufacturer in the FBA.

Action Required/Taken:

- Use Only ISO Marked FBA and all gas cutting set materials.
- All Flashback Arrester-FBA working systems should be checked before issue from the store.
- Awareness training should be conducted for all gas cutters by the HSE Department and, if possible, by the manufacturer.
- Check all FBA backfire control systems at the site/plant that are in use.

If you have more ideas for backfire protection, please input your suggestions.

Dear C.R.Siani,

Your clearly addressed on your investigation report that 100% its happened because of manufacturer defect.

Did you notice this issue to manufacturer?

Did you read the manufacturer O&M manual for FBA?

Did you have the proof of training documents that you provided to your employees on this equipment?

Are you sure it will not happen in ISO marked FBA’s?

How do you check the FBA working system – Who is responsible to check?

For your info - FBA’s are generally reliable in performing the intended function so long as the device is used according to the manufacturer’s instructions. If an end-user neglects or ignores the manufacturer’s stated or published safety and maintenance recommendations, that person is an accident waiting to happen and no accessory safety device will prevent all possible accidents. As one who has handled accident litigation cases for the past several years, I can state unequivocally that most oxy-fuel accidents are caused not by equipment malfunction, but by user neglect, impatience or lack of experience in using equipment safely.

Do me a favor provide me a details of FBA that you used on your plant/work site. I will talk to the manufacturer get some information which will help to educate ourselves.

According to your report - Action required should include the below points:

Manufacture manual should be available on-site or practically accessible; whoever operating the equipment should go through the O&M manual prior to operating the equipment – (It should be supervisor and EHS personnel’s responsible).

Appropriate training should be provided to all personnel’s whoever involve with this task – As per manufacturer requirement (Its should be management and safety responsibility).

Choose the right materials for the task

manufacturer instruction should be followed whenever operating the equipment

I don’t think it’s a small issue if it’s really a manufacturer defect am sure I’ll bring that issue to next level without involving you please provide me a details that’s what I need from you.

I’m eagerly looking forward your reply if you’re not comfortable to share the info in social network – I’m available at [Login to view]

Thanks in advance.

Dear All,

FBA should comply with IS 11006-1984, but I have never seen any IS certified FBA in India. Most of us are using FBA, which normally acts just as an NRV. Some of the branded items comply with EN 730. At the same time, they are manufacturing the product with different serial numbers that do not comply with IS or EN codes. Therefore, we should be aware and careful when selecting a product.

Thanks

Dear Raghu,

I would also like to add one more point here which I doubt might have also been there. It is also to be investigated whether it was repaired in-house or by anyone who is not authorized to do so. Its maintenance history should also be checked along with the points that you mentioned above.

Also, if you have an FBA of the same make used by other contractors, it should also be checked for the same.

Regards,
Hansa Vyas

Dear Hansa,

Welcome back! You're right. I spoke to some technical experts back in the States. I wrote an email to Mr. Saini, and he provided manufacturer details. However, I am not able to find them online, so I will need to get more details from him again as quickly as possible. Once I have the necessary information, I will contact the manufacturer to find out the real cause of the accident. If it's a manufacturer defect, I am certain I will take it to the next level and have that product banned from the market. We will see...

Thank you.

That's the reason we are insisting on using the standard product of Flashback Arrester while performing cutting and welding activities. If the flashback arrester is not working properly, it may endanger the lives of many people working around the area.

To the extent I know about FBAs, I think Hansa Vyas's hunch is right — more of an O&M issue than related to the manufacturer. We Indians are known world-over for what we call 'Jugaad' — improvising. But I know that many times, we go overboard even when the necessary tools, systems, and SOPs are in place. Anyway, let's wait for Raghu's inputs.

Best regards,
TS

Team,

I can't find the vendor contact details through the product name. However, I chatted with Mr. Siani as per our conversation on this issue. They contacted the service engineer who came to visit the site, but I haven't received the service engineer's comments from Mr. Siani yet. As soon as I get that report, I will obtain the service engineer's contact number from Mr. Siani, which will make it easier to communicate and move forward on this issue.

Additionally, I spoke to Mr. Suman Das, who works for HIND MEDICO PRODUCT. He offered a site visit to his factory as well.

HIND MEDICO PRODUCT (An ISO 9001:2000 Certified Company)

3/1, Ashutosh Mukherjee Road, Belurmath, Howrah, West Bengal, India 711202

Contact: 91-9836848888, 91-33-26548185, 26544766

Fax: 26542251

Email: [Login to view], [Login to view]

Website: Gas Cutting Equipments, Welding Gas Equipment Manufacturer, Personal Protective Equipments Supplier

I will provide further updates on this subject matter.

Dear Members,
FYI,We have changed all FBA at site ,
Thanks to All, and special thanks to Mr.Raghu, who did investigation deeply.
I have discussed to our Project head for send MOM copy to our team for more investigation, He is not allowing for MOM & visit another agency at site .We have limitations.
So sorry I can’t send Company’s document.(I have given company name ABC in Report)
Thanks to all again……………………………………………………………..

Dear Raghu,

The FBA shown on the website is not an FBA. It is just an NRV, and I am sure it is not ISI certified. The FBA should have:
1. Flame arrestor
2. NRV
3. Temperature-sensitive cut-off valve
4. Pressure-sensitive cut-off valve

Please let me know if I am wrong. I am looking forward to comments from our senior members.

Hello Everyone,

Since I mentioned "Jugaad" in my earlier response in this thread, I just thought this could be of interest to all—though not connected with the subject of the thread.

With the hackathon, GE wants to partner with other stakeholders to develop low-cost devices - The Economic Times

This only shows that Indians seem to get only better at 'Jugaad.'

Regards,
TS

Hi Mr. Vijay,

You're right. I am not sure about what's available on their website. Additionally, I went through the product description on their website, which is not clear. I wrote an email to clarify the product description, as usual, like some manufacturers - They simply ignored my email.

Team,

Do any of our members have the details of the manufacturer providing the IS standard FBA in India? If so, please share it with us; it will benefit a lot of our people.

Thanks, Mr. Vijay, for driving this question to our board.

Dear Raghu,

You can share the good practices being followed in your project regarding this subject matter.

Dear Vijay,

Apologies for being late in response. You know very well most of the peoples in this universe are more advanced than us specially in safety - They having equipment and strengthen regulation. We do have a strengthen regulation compare to other’s but enforcing authority are failed in India.

When I’m worked in India in my earlier days - I don't have that much opportunity to move forward and learn something; when i went through this topic only thing blinks in my mind why we need to go beyond FBA and Check Valves why? Just buy a torch handle with built-in flashback arrestors and check valves which is safe and easy for everyone.

I expect some of our members will put this comment that's the reason i waited but over 300+ views even no comments - very few participated on this thread.

Share your knowledge guyz that's the only thing you can give to your next generation.

Thanks you guyz who participated on this thread.

See the attached - This is what am using in my site :) - It's meets all the required international standards.