2.

0 Analyze the root cause of accidents at workplace

2.1 Inherent properties

In all truthfulness, there are many different situations which can lead to a plant explosion;
however, some have been noted as occurring more often than others. For example, simple fires
can quickly spiral out of control, causing large explosions. According to OSHA.gov, a
PETRONAS Petroleum could be exposed to any of the following, “Flammable gases, such as
well gases, vapors, and hydrogen sulfide, can be released from wells, trucks, production
equipment or surface equipment such as tanks and shale shakers” that can cause many health
risks. Ignition of these items doesn’t require an open flame either, frictional heat, welding tools,
or even just hot surfaces can create a risk of fire in any environment.

Workers in PETRONAS petroleum industries face the risk of fire and explosion due to ignition
of flammable vapors or gases. Flammable gases, such as well gases, vapors, and hydrogen
sulfide, can be released from wells, trucks, production equipment or surface equipment such as
tanks and shale shakers. Workers might be exposed to hazards from compressed gases or
from high-pressure lines. Internal erosion of lines might result in leaks or line bursts, exposing
workers to high-pressure hazards from compressed gases or from high-pressure lines. If
connections securing high-pressure lines fail, struck-by hazards might be created. Several of
these hazards are highlighted below which are accepted or related as root causes for a gas
flange at the PETRONAS PETROLEUM INDUSTRY COMPLEX, KERTEH, and TERENGGANU
in 2012.
  Chemical hazard

In this case the main hazard lead to this explosion is because of chemical hazard. Improperly
stored chemicals include acids, pesticides, carbon monoxide, flammable liquids, welding fumes,
silica dust and fiberglass fibers are leading to this explosive incident at PETROLEUM Petronas
at Kerteh, Terengganu. By the creation of gases, the build-up of heat, and the reaction, a
chemical plant can become the source of serious and debilitating explosion. The chemicals
produced at PETRONAS plant are done so through the use of a broad range of equipment and
tools. This equipment requires both specialized training and properly maintained in order to
perform its purposes efficiently and safely. When the petroleum processing plant operators fail
to comply with maintenance and safety regulations concerning their equipment, the risk of
disaster is heightening dramatically. Workers assigned to maintenance are expected to inspect
and replace outdated or worn equipment, especially those that may pose a risk if overlooked,
such as catalysts, reagents, and boilers.

A chemical explosion is a result of applying an external force to a chemical compound which

causes the compound to undergo a structural change, releasing high amounts of heat and gas.
The force is known as a catalyst. While catalysts are utilized to force the processing or
production of new chemical compounds, catalysts can also cause unintended explosive
reactions through actions that may accidentally accelerate. Catalysis, the process of
accelerating a chemical reaction, can be unintentionally caused at a chemical plant by poorly
maintained equipment, an unclean work environment, or simply negligent behavior. When the
equipment used to produce and process these chemical compounds is not properly cleaned,
foreign elements easily skew the process and cause a chemical accident at PETRONAS
Petroleum at Kerteh Terengganu. Furthermore, contaminated in the plant warehouse itself can
serve as a catalyst when the elements in the contaminated air combine with the chemicals
being produced on the plant. The workers play a key role in promoting safety but one negligent
act, such as an improperly discarded cigarette, can set off a destructive event.

Moreover, corrosion is a natural process that occurs whenever machinery is exposed to oxygen
on a petroleum plant refinery. It is a distinct hazard because of the nature of the work that is
being completed. In order to complete the process of refining crude oil, this plant utilize extreme
heat. High temperatures aid in the fractional distillation that is necessary to complete the
process of refining oil. Unfortunately, this process naturally creates corrosion, most of which
cannot be seen by the common eye. Unseen corrosion has been described as a silent killer. Its
dangers are so easily unnoticed that it can be missed even when machines have been
thoroughly inspected. Alkaline sodium chromate or sodium nitrate has been found to be an
effective inhibitor for corrosion of domestic fuel oil tanks. Internal corrosion of product pipelines
can be controlled with coatings and inhibitors such as amines and nitrites. Corrosion does not
stand for a single phenomenon but is a generalized term to cover a destructive attack on a
metal as a result of either a chemical or electrochemical reaction between the metal and various
elements present in the environment.

For instance, iron is converted into various oxides or hydroxides when reacting with the oxygen
present in air or water, when in contact with a more noble metal such as tin or when exposed to
certain bacteria. Corrosion of a metal occurs either by the action of specific substances or by
the conjoint action of specific substances and mechanical stresses. Depending upon
environmental conditions, corrosion can occur in various forms such as stress corrosion, pitting
corrosion, embrittlement and cracking and it be the reason for explosion at PETRONAS
Petroleum at Kerteh, Terengganu.

One of the most applicable elements using in PETRONAS Petroleum processing plant is
nitrogen. Nitrogen is found in many of the most important industrial compounds such as
ammonia, nitric acid, propellants, and explosives. Synthetic chemicals such as ammonium
nitrate are key elements found in industrial fertilizers; their use is largely due to the chemical
structure of nitrogen. These conversions and productions are some of the processes that take
place at the most common chemical plants and can include the use of other reactive chemicals
such as ammonium nitrate, phosphorus, and potassium. However, because of the sensitivity of
the compounds and elements being handled, such as nitrate gases, one slight factor can quickly
precipitate an unforeseen explosive catastrophe.
  Physical hazard

Next, we analyzed that physical hazard also one of the reasons for happened this explosion at
PETRONAS Petroleum Industry Complex, Kerteh, Terengganu. A physical hazard is an agent,
factor or circumstance that can cause harm with contact. Physical hazards include ergonomic
hazards, radiation, heat and cold stress, vibration hazards, and noise hazards. Physical hazards
are a common source of injuries in many industries especially in gas and oil industry like
PETRONAS petroleum industry. There are some classes of physical hazard in PETRONAS
Petroleum namely Explosive, Flammable, Oxidizing and Gases under Pressure. Every
explosive has two main characteristics when it comes to output, brisance and force. Brisance
relates to the shockwave and, therefore, to the velocity of detonation of the explosive. On the
other hand, force relates to the increment in pressure, provided by the rate in which gaseous
products are created. Furthermore, since the seismographic operation requires shockwave
propagation and not an increase in pressure, the explosive used should move towards a high
detonation velocity possible at the same time as keeping the pressure at a minimum. To
achieve a minimum pressure, two aspects of the chemical composition should be dealt with
heat temperature and moles of gaseous produced per mass of explosive.

Next, workers in the PETRONAS industry face the risk of fire and explosion due to ignition of
flammable vapors or gases. Flammable gases, such as well gases, vapors, and hydrogen
sulfide, can be released from wells, trucks, production equipment or surface equipment such as
tanks and shale shakers. Ignition sources can include static, electrical energy sources, open
flames, lightning, cigarettes, cutting and welding tools, hot surfaces, and frictional heat.
Oxidizing materials are liquids or solids that readily give off oxygen or other oxidizing
substances such as bromine, chlorine, or fluorine. They also include materials that react
chemically to oxidize combustible (burnable) materials. This means that oxygen combines
chemically with the other material in a way that increases the chance of a fire or explosion. This
reaction may be spontaneous at either room temperature or may occur under slight heating.
Oxidizing liquids and solids can be severe fire and explosion hazards.

Gases under pressure are gases which are contained in a receptacle container at a pressure of
200 kPa (kilopascals) or 29 psi (pounds square inch gauge) or more, or which are liquefied or
liquefied and refrigerated. This includes compressed gases, liquefied gases, dissolved gases,
and refrigerated liquefied gases. Compressed gases can be toxic, flammable, oxidizing,
corrosive, or inert. In the event of a leak, inert gases can quickly displace air in a large area
creating an oxygen-deficient atmosphere, toxic gases can create poison atmospheres, and
flammable or reactive gases can result in fire and exploding at the industry. In addition, there
are hazards from the pressure of the gas and the physical weight of the cylinder. When a gas
cylinder falling over can break containers and crush feet. The cylinder can itself become a
missile if the cylinder valve is broken off. Compressed gases can cause fires, explosions,
oxygen deficient atmospheres, toxic gas exposures as well as the innate physical hazard
associated with cylinders under high pressure. Gases under pressure will release large amounts
of gas into the workplace air very quickly which could result in health and or fire hazards
depending on the properties of the gas. So, when the gas started to release deliberately from an
accidentally a broken or leaking valve, its spin out of control with great force and become a
reason for happen explosion at this petroleum processing plant industry.

 Mechanical hazards

Apart from the both hazards, mechanical hazard is also becoming a reason for to this explosion
happened at PETRONAS petroleum Kerteh, Terengganu at 2012. Amongst all the industries
that use hazardous machines and equipment, the oil and gas industry arguably rank first. Many
of these machines operate in unguarded areas which further endangers the workers using
them. This means operations such as traveling derrick, heavy lifts and hoists, spinning chain,
loading and unloading materials, and drilling should be conducted with care by competent
operators, states Oil Pro.

Using welding tools near flammable substances at processing plant can create also sparks and
ignite highly flammable chemicals at this industry complex. With the number of flammable
materials on and near the rig, workers must be extraordinarily cautious and follow proper safety
protocols when performing "hot work" such as welding, cutting, and grinding. If a single spark is
exposed to the fuel on an oil platform, it can start a rapid-fire breakout Petronas processing
plant.

Oil rig blowouts can occur when the rig applies too much pressure during the drilling, causing
the pool of underground oil to erupt. When the drill encounters a pressurized zone underground
and the gravity of the drilling mud fails to counteract the pressure, it causes a sudden rush of
pressure up the system.

 Electrical hazards

Last but not least, electrical hazards also have led to this explosion incident. In electrical
substations, accidents are often caused by more than one contributing factor, such as design
defects, sudden power surges, winding failures, insulation oil leaks, and the formation of
ignitable mixtures. Electrical hazards occur with exposed wiring, overloaded outlets or circuits
and extension cords. Overheating of transformer cooling fluids presents a serious hazard.
Workers at PETRONAS processing plant at Kerteh, Terengganu might be exposed to
uncontrolled electrical, mechanical, hydraulic, or other sources of hazardous energy if
equipment is not designed, installed, and maintained properly. The most common electrical
hazard is a lightning strike, which can damage wires and or equipment and cause too much
electricity to flow into the transformer, leading to explosion at this PETRONAS petroleum
industry complex.

In this complex work, the risk of fires and explosions due to vaporization of the hydrocarbon
components of mineral oil, which is used as a transformer cooling fluid in electrical substations,
was investigated. The compositions of new and used mineral oil from an electrical substation in
Riyadh were analyzed using gas chromatography mass spectrometry, and C6 to C41
hydrocarbons were detected. The majority of the components were alkanes, alkenes, or
alkynes; some ketone, alcohol, aromatic, and anhydride species were also detected.
Approximately 25% of the compounds comprising the new oil sample were alkanes, whereas
more than 33% of the used oil sample components were alkanes. The lower and upper
flammability limits (LFL and UFL) of the mixtures were found to be 0.88 and 5.75 vol.% for the
new oil and 0.47 and 3.05 vol.% for the used oil, respectively. These values were used to
construct a flammability diagram. The results indicated that the new and used oil vapor mixtures
were not flammable at 25 °C and 1 atm, but would become flammable at 77 and 115 °C.