PGR, ARE YOU STILL ALIVE ?
In 1997 I joined SAFCO (Saudi Arabian Fertilizer Company) and was posted in Ibn Baytar Plant (One of the plants of SAFCO named after Arabic botanist and herbalist Ibn Al-Baytar) as an Ammonia plant process engineer. A problem that I initially encountered as an expatriate was communication with police and government agencies in Jubail as their spoken English was simply awful. In Baytar plant building where I had my office, I had a young and dynamic Saudi Technician named Essa Habib Al-Khalaf who worked in our Inspection department. His job involved helping and assisting our Inspection Engineers in process Inspection of vessels and equipment during normal activities and Plant turnaround (A major plant maintenance activity under taken every 2-3 years after full shut down of all process plants). Essa Habib became my lingua franca and intermediary whenever I had needs to communicate with government agencies.
He was an amazing young Saudi Boy of 27 years and bore a cheerful countenance for everyone in Baytar building irrespective of caste, creed and nationality. Since I didn't have any car during my early days, Essa took it as an honour to ride me in his car whenever my errands required him to do so. He respected educational qualifications, admired degrees and often taunted me to give him an engineering degree certificate so that he could pursue a more prosperous career. Essa was a dynamite of energy and enthusiasm and had a curiosity to learn more from whoever worked with him. He knew how to put his mind, heart, soul and intellect even in the smallest task and was loved by one and all.
Often during office hours, he would knock at my door holding a cup of tea in his right hand and shout from there with winking eyes and waxing lips '"PGR, Are you still alive!". If I showed an inviting tone, he would enter my room and I too joined him for a tête-à-tête with a tea. Sometimes his teasing incantation "PGR, Are you still alive!" annoyed me a bit and I used to shout back'"I will follow you". We became very close and talked about family matters and I often enjoyed this cross-cultural interaction with an open heart to empathize with his concerns. One good routine habit Essa had was that he rang his wife at regular intervals during office hours. He was a totally committed husband and family man.
In the year 2004, Ibn Baytar plant turnaround was in full progress. All of us were on 12 hours duty and were steeped in our scheduled tasks which included process Inspection, catalyst change out, cleaning of Heat Exchangers, Columns etc. Essa was assigned the inspection of some equipment in Ammonia plant. We were veering towards the end of the tiring turnaround and were boxing up many opened equipment for plant start up activities.
On March 1st 2004, a telephonic message came to the control room of Ammonia plant from Essa 's wife at 8 PM that her husband didn't call her at their normal appointed hour of 7 PM. The operator who himself was busy consoled her that possibly he could be in the thick of some tasks in hand. At 9 PM, his wife called up again with concern and urged the attendee that she needed to talk with Essa immediately. Pager system sounded all over the plant asking Essa to report to control room. There was no answer. A bit concerned, some operators and his colleagues made a search around the plant and they couldn't locate him. Security people checked the computerized plant entry-exit punching system and confirmed that he had not gone out of the plant.
Now there was a real alarm. His colleagues confirmed that he was assigned inspection duty for the 60 M high CO2 Absorber column meant for absorption of CO2 during the purification step of our synthesis gas. There was no permit issued on this vessel in the afternoon for any inspection activities though one of the middle manways (Manhole for man entry) was still open pending clearance for closure. An operator with the assistance of safety personnel climbed up the absorber to have a look inside the open manway. They entered the vessel wearing breathing apparatus and search light. To their horror, they found Essa lying inside the vessel unconscious bearing a blue face. Emergency rescue acted fast in lifting him down. Doctors declared him as dead.
Investigations revealed that nitrogen from the downstream nitrogen filled methanator reactor (connected to the absorber by a control valve) had backed up into the absorber column during start up activities and filled the whole CO2 absorber. Confined space vessel entry into absorber was normally permitted only after a permit, ascertaining oxygen level in the absorber and under the presence of a hole watch. My friend Essa in his over enthusiasm and curiosity to know the progress of the work assigned to him had entered the vessel without communicating to control room, without a work permit and without an oxygen meter mandatory for all equipment entry and had thus made a tryst with terminator Nitrogen.
Nitrogen is a silent killer gas. Though the normal air we breathe contains 78 percent nitrogen and 21 percent oxygen, nitrogen is not a benign gas. After just one or two breaths of nitrogen, the oxygen concentration (or partial pressure of oxygen) in our lungs would fall so low that all our oxygen already in the bloodstream rushes into the lungs in a sacrificial act to maintain oxygen supply to brain but alas that too would soon be exhaled out. As a result, we simply stop breathing. Since nitrogen is odorless and colorless, our senses provide no protection against nitrogen-enriched atmospheres. This was what had happened to Essa . As pure nitrogen is heavier compared to air, it had just stayed inside the absorber. He simply didn't realize that he was navigating in nitrogen when he made that deadly entry in the dark.
The fatality made 2004 a watershed year for SAFCO breaking its impeccable safety records. A loving family lost its lone supporter and SAFCO lost a soul that stirred with passion and compassion.
Many a day, drowned in the drudgery of daily routine, I hear a knock on my door and a naughty voice-"PGR, Are you still alive ?"
Yes, my buddy, with a lake in my eyes.
