At around 11:00 p.m., phosgene (COCl2) and chlorobenzene began leaking inside the containment building of a chlorinated chemicals plant. The leak was detected at levels between 13 and 22 ppm by analyzers inside the containment. The analyzers’ control system automatically directed the air inside the containment towards the caustic scrubber. Technicians began looking for the cause of the leak. While one of […]
The irony in this post is thick with sulfur smoke! SAFTENG Members can read my 2012 article Sulfur sticks and ammonia leaks… are you in compliance when using these leak detection devices? This video shows us what happens when we introduce a lit sulfur stick into an NH3 gas leak. Imagine someone doing this in a
Words still mean something! There is a reason why OSHA (and EPA) use the word “Management” in the titles of their process safety standards. Sorry to state the obvious, but the standards are NOT called “process safety managER” for a really good reason. I have been serious about process safety since 1993 and the one
An ammonia storage tank was taken out of service for its 10-year non-destructive examination. After the tank was purged and opened, two (2) contractors were removing two (2) relief valves for their 5-year inspection and tests. The two (2) relief valves are 8 bolt flanged connected to a wye piping fitting equipped with a selector valve (as
Back in December 2017, I wrote about a change in the Anhydrous Ammonia fertilizer industry that would most likely require the industry to perform an MOC and PSSR. (A new grade of anhydrous ammonia fertilizer means a MOC, PSSR, etc.) Now that the product has received its official approval and has found its way into the
In April 2011, an OSHA State Plan investigated a 3,600-pound ammonia release at a large warehouse where anhydrous ammonia is used in the refrigeration system in a cold storage building. In this incident, one worker was burned on the arm from the escaping gaseous ammonia. As part of the planned mechanical integrity schedule, two (2) employees
Employees #1 and #2 were draining refrigerant oil from anhydrous ammonia refrigeration system oil traps in fruit cold storage warehouse(s). They were working approximately 24 feet above floor level on a mobile scissor lift personnel platform using hand tools including a wrench, a flashlight, and a bucket. The cause of the unexpected ammonia release is
On December 26, 1989, Employee #1 was attempting to replace a leaking oil valve on a minus 30-degree freezer when a tank inside the freezer exploded. The company uses anhydrous ammonia to manufacture ice cream. The liquid ice cream mixture (at 50 degrees) is added to the tank. When the liquid ammonia changes to a
An oil separator on a two-stage ammonia refrigeration system became overpressurized and exploded, killing Employee #1. While looking for Employee #1 after the accident, Employee #2 fell into a drain. Ammonia that had been uncovered as a result of the explosion had flowed into the drain. Employee #2 was hospitalized.
At approximately 3:15 pm on May 9, 1986, employees started to charge the number 1 line Carbo-Cooler, using a cylinder containing 150 pounds of anhydrous ammonia at 129 psi (room temperature). Employee #1, in an effort to speed the charging process, was running hot water (132 degrees F) over the ammonia cylinder (to raise the internal
A pressure vessel in an ammonia refrigerator system at an ice plant ruptured under pressure of 170 psi. The explosion caused extensive physical damage and released dense clouds of ammonia gas. Employees #1 through 4 died of acute ammonia inhalation.
Employee #1 was exposed to ammonia gas on November 20, 1984, during an ammonia leak from refrigeration piping in a compressor room. A threaded joint weakened due to excess vibration and cracked. When it failed, ammonia was released. An unapproved gas mask was used by the employee. Employee #1 died the following December 16th from
