Importance of proper Gas Monitors proved in Bayer Cropscience incident

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By now, all of those of you in industry must have heard about the Bayer Cropscience incident that took place in August 2008 in Institute, W. Va. There was an explosion in the Methomyl unit and two workers were killed. Several lapses were pointed out by the US Chemical Safety Board that led to the unfortunate incident. One issue however that was not highlighted by the board but emphasized by local investigative reporters, was the non working of several toxic gas detectors in the facility. The management claimed that the detectors were disconnected from the monitoring system due to maintenance, but this itself seems wrong. Generally only one detector is removed at a time for maintenance or calibration. The next one should be removed only when the first is in place.
Secondly there were no such toxic gas detectors placed along the western side of the plant. The wind direction unfortunately on that day was from the plant's western side to its neighbors (communities staying near the plant).
The explosion that took place was very close to a tank containing the extremely toxic chemical Methyl Isocyante (MIC), the same that caused the now infamous Bhopal disaster.
All in all it just shows how seriously companies should take the selection, installation and proper operation and maintenance of gas detectors and gas monitors in their plants. If not then disasters may be looming!