Articles

Bayer Crop Science Was Running People Past Their Breaking Point

One element that figured prominently in the 2008 explosion at the Bayer Crop Science facility in Institute, West Virginia, was a lack of operator training for the new DCS that had just been installed at the methomyl production unit. While this was undoubtedly …

Bayer Crop Sciences Operators Running Without Training

Prior to the 2008 incident, the methomyl unit at the Institute facility had been shut down for two major equipment upgrades: the DCS had been replaced and the old carbon steel residue treater vessel had been replaced with a new stainless steel pressure vessel.…

Bayer Crop Sciences Poses Equipment Problems Share the Blame

Bayer Crop Sciences Poses Equipment Problems Share the Blame Bayer Crop Sciences Poses Equipment Problems Share the Blameacceptable levels. When the two operators who were killed went to the vessel, the expected to find this vent was simply blocked and were go…

Bayer Crop Science Under Pressure to Start Production

Bayer Crop Science company procedures called for a PSSR (pre-startup safety review) to be run for the methomyl unit before it was restarted. This was a complex process that was supposed to prove that all the equipment and safety devices were in order, allowing…

Bayer Crop Science: Pushing Process Beyond Personnel

History has shown that industrial disasters are rarely the result of some single failure in a plant environment that is otherwise carefully operated and scrupulously maintained. In most situations, an incident, large or small, is the logical and inevitable res…

Is your safety system compliant with today's safety standards?

Operational aspects of safety systems are under increased scrutiny throughout the automation industry these days. Beyond the pure financial benefits, which focus on reducing operational cost throughout the system lifecycle, the real driver is safer operations…

The Safety Fitness Test

The first step in any athlete’s performance improvement plan is a thorough assessment of his current fitness level. In the case of our plant’s safety systems, the assessment phase begins with a thorough updating of process conditions and risk factors.

Integrated SIS Perfect Companion for Batch Processes

It is often perceived that the continuous and batch process industries are different manufacturing worlds. Certainly there are notable differences, but on many levels they are the same. But one element that is often perceived as being the same is functiona…

Human factors and the impact on plant safety

Operating procedures should clearly lay down instructions for operation of the process plant. The procedure needs to represent a best practice that should occur at all times. Process operators should have guidance concerning the required operating philosop…

Essentials of Safety Instrumented Systems

Throughout the global process and energy industries, the safety instrumented system (SIS) plays an essential role in protecting workers and equipment as well as nearby communities and the environment from harm. Much has changed in the several decades since the…
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