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Visakhapatnam Steel Complex Gas Leak (2022)

Coke Oven Door Maintenance Exposure

What Happened

Aging seals broke during coke-oven door replacement under concurrent hot-work permits in the byproduct recovery section, causing a toxic compound leak of H₂S and CO. Two workers collapsed due to exposure.

Why Traditional Alarms Failed

Individual gas levels remained at 7.5 ppm H₂S (below 10 ppm alarm threshold) and 24 ppm CO (below 25 ppm warning threshold). Since no single sensor breached its individual threshold, no alarm was triggered.

SentraGrid Proactive Flag

1. Multiplied risk by 3.0x due to SIMOPS hot work permit in confined space.
2. Analyzed H₂S rising trend (+10 points).
3. Risk score hit 65 (Critical).
4. **Advantage**: Flagged alert 35 mins before the leak, suspending hot-work and ordering purging.