Bryan Haywood

Establishing our “Battery Limits”

A term not even mentioned in OSHA’s 1910.119 or EPA’s Part 68, but a term that has huge impacts on process safety. So what is a “Battery Limit” in the context of Process Safety? I use the definition provided by AICHE… The perimeter of a specific manufacturing process area. It is often defined by the…...

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CNG Bus falls from lift leading to catastrophic explosion (Video + SFM Report)

The examination of the scene was conducted using a systematic approach using a basic method of fire investigation and scientific methodology outlined by the consensus committee of the 2024 edition of NFPA 921, “A Guide for Fire Explosion Investigation,” and the 2022 edition of NFPA 1033, “Professional Qualifications for Fire Investigators,” and other treatises as…...

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Pros of Hydrostatic Leak Testing

The old argument that we cannot do Hydrostatic Testing on our piping and must do Pneumatic Testing is as old as I have been dealing with process piping (32 years and counting). I was raised in the process and semiconductor industries, where we ALWAYS did hydrostatic testing, and pneumatic testing was our last resort. But…...

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Establishing Pipe Class for PSM Flammable Liquid Process

Using the piping inspection RAGAGEP API 570, one of the first steps in our piping inspections/testing is to establish the “Class” our piping fits into. In most cases, I advise my clients to classify their PSM/RMP-covered piping as Class 1. However, there is a possibility that some flammable liquid piping could be classified in a…...

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Controlling hazards associated with mobile equipment around processes

Those who know me or have been following my rants for years know my love of Bollards and Jersey Barriers. These simple devices (e.g., PASSIVE engineering controls) can prevent a lot of contact between mobile equipment and process/equipment. But as shown in the image below, Aerial Devices such as JLGs can reach OVER safety barriers,…...

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Facility Siting 101 – 25′ safe distance – vapors travel along ground (Video)

Take notice… single hose. Means liquid gasoline is going in the tank, but where are the vapors going if there is not a vapor return hose back to the truck? ALSO, the tank has an atmospheric vent pipe somewhere so as to vent vapor pressure should the tank get warmer and the gasoline Vp increases…....

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Are we missing the mark when it comes to 1910.120(q)(3)(vi)

Most response groups practice the 2-in/2-out rule during a HAZMAT response. But the devil is in the details when complying with 1910.120(q)(3)(vi). How many have attempted to pick up a grown man, weighing 200+ pounds, while they are donned in a wet Level A suit and carry them out of the Hot/Warm Zone? I can…...

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Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alterations

This can be a sensitive topic at many facilities. I was raised to believe that whenever the pressure-retaining boundary is physically broken during line or equipment opening tasks, the line or equipment MUST be pressure- and leak-tested before being returned to service. I get a lot of hate mail and even more weird looks when…...

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A useful interpretation of ASME B31.3 Pressure/Leak testing

Does the fabricator of a B31.3 piping system still have to pressure test components that are manufactured to a standard listed in Table 326.1 when that standard states that the component is hydrotested as a requirement of the standard?… Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log...

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