Bryan

Brittle Fracture (Catastrophic) Failure during HYDROTEST of Propane Bullet

I have posted numerous fatal accidents that occurred during the pressure testing of piping and pressure vessels.  Although hydrostatic testing involves less energy release should something fail vs. using pneumatic pressure, the hazard(s) are still HUGE and must be respected.  This incident involved a propane bullet built in 1994 and placed into service in 1996,…...

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Hydrostatic test of a cooling coil for an air-cooled heat exchanger fatality (OK-FACE)

A 43-year-old assemblyman died on May 26, 1999, from chest injuries he received earlier that day when struck by a high-pressure water jet emitted after the failure of a gasket during a hydrostatic test of a cooling coil for an air-cooled heat exchanger. At the time of the incident, the victim was part of a…...

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What is a process?

A process, in terms of Process Safety Management, is defined as:  “Any activity involving a regulated substance including any use, storage, manufacturing, handling or on-site movement of such substances, or any combination of these activities. For the purposes of this definition, any group of vessels that are interconnected, or separate vessels that are located such that a regulated substance could…...

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Fire Watch for your roofing contractor may have a 2-hr requirement

One of the debates we routinely have with fellow process safety professionals is the adoption of NFPA 51B vs. meeting 1910.252(a) requirements for their Hot Work safe work practice. I am a huge fan of NFPA 51B, as it is much more up-to-date than OSHA’s 1910.252, which, by the way, was based on the first…...

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Massive Leak of Liquefied Chlorine Gas (Henderson, NV 1991)

A massive leak of liquefied chlorine gas created a dangerous cloud of poison gas over the city of Henderson, Nevada, in the early morning hours of May 6, 1991. Over 200 persons were examined at a local hospital for respiratory distress caused by inhalation of the chlorine, and approximately 30 were admitted for treatment. Some…...

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The advantage of utilizing a Contractor Work Permit

Those of us living within the realm of Process Safety Management know all too well the difficulty of controlling contractor work activities to a level that we are confident they are not increasing our process risks beyond our acceptable levels. Many contractors are offended by the fact that many PSM programs have multiple layers of…...

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Sample Protocol for a Response Plan (General Outline)

Industrial Incident Guidelines for Incident Command Arrival on Scene, Initiation of Response, see: Agent Identification Quick identification by signs/symptoms: CHEMM-IST Substance identification: WISER Acute Patient Care Guidelines Estimation of Protective Distance/Threat Zone On-site Activities Triage Guidelines Hospital Activities Personal Protective Equipment General Guidelines for Responding to a Fire General Guidelines for Responding to a Spill…...

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What does “relief system design basis” mean?

Relief systems include, but are not limited to, relief valves, relief headers, relief drums, and rupture disks. Design basis means documenting how the loads and sizes of the relief system and inlet and outlet sizes were determined. This includes:… Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log...

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Key Elements of Health and Safety Observation and Feedback Processes

Behavior-Based observation and feedback processes promote desired behaviors by introducing POSITIVE REINFORCEMENT for behaving safely. The positive reinforcement is provided through POSITIVE FEEDBACK. These programs are based on the ABC behavior model, as I explain below.  The effectiveness of behavioral safety observation and feedback programs is dependent upon effective implementation. Assess Cultural Maturity or Readiness… Membership...

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Understanding the ABC Model

The core element of behavior modification is the ABC model of behavior: Antecedents                              Behavior                            Consequences The ABC model specifies that behavior is triggered by a set of Antecedents (something that precedes behavior and is causally linked to the behavior) and followed by Consequences (outcome of the behavior for the individual) that increase…...

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Albert City, Iowa Chicken Farm BLEVE (NFPA)

On April 9, 1998, two volunteer firefighters died in Albert City, Iowa, and six responders were injured when a burning LP-Gas tank exploded in a boiling liquid expanded vapor explosion (BLEVE).  CLICK HERE for this NFPA Article on the incident…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member?...

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Response to an NH3 leak leads to serious exposures and missed shifts

At approximately 9:30 p.m. on or about July 31, Employee #1, a can and bottling operation maintenance technician, responded to a possible ammonia leak during the second shift at the plant. A 2,000-lb outside storage tank pumped ammonia into the line-filled room to cool the syrups to between 35 and 40 degrees F before the…...

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