Chemical Process Safety (PSM/RMP)

My hi level interlock just tripped on my vessel – can I count this trip as the scheduled quarterly/annual PM test?  This question is maybe in the top 10 questions we get from PSM/RMP clients and friends and without a doubt one of the top 5 MI questions of all time.   There is no argument…...

12/13/12 – I uploaded the full video (1:45) to my YOUTUBE account rather than the members’ area.  This full version includes a 2nd view from a different camera and shows the full impact and size of the explosion and the tank fires resulting from the blast. WARNING!  This video will be UPSETTING to many, especially the…...

If you spend any time around Anhydrous Ammonia, you know how easy it is to detect its presence; however, if you have ever tried to find the leak causing the issue, it can be extremely difficult. One method that is by far the most common, most simple, and one of the easiest and cheapest methods…...

UPDATED FM Data regarding Contractors and Hotwork… 3.1.8 Outside Contractors Many hot work operations are performed by outside contractors, these include cutting, welding, joint soldering, paint removal, reroofing, etc. The tendency is to relax rigid procedures for contractors assuming they know their jobs. However, this practice has produced a discouraging loss history. Hot work by itself is…...

Not many know this dirty little secret about overpressure protection on ASME-coded vessels (formerly called “code case 2211”), but I will let the cat out of the bag… Not all ASME pressure vessels have to have a pressure relief device, and I am not talking about those very small vessels, but any size vessel. No,…...

NONMANDATORY APPENDIX S – DESIGN CONSIDERATIONS FOR BOLTED FLANGE CONNECTIONS S-1 BOLTING The primary purpose of the rules for bolted flange connections in Appendices 2 and Y is to ensure safety, but there are certain practical matters to be taken into consideration in order to obtain a serviceable design. One of the most important of…...

OSHA has cited a specialty chemical manufacturer for 20 safety violations following a plant explosion that resulted in the hospitalization of approximately 40 employees of other companies, working in the surrounding area, for decontamination. The May explosion was caused by a runaway reaction from an overheated reactor. During the production of a compound used in water…...

OSHA has cited a fertilizer producer with 40 safety and health violations following the deaths of two workers in separate incidents.  On May 22, an operator attempting to start up a steam turbine in sulfuric acid plant No. 2 was struck by flying metal debris when the turbine housing ruptured due to apparent overpressurization. In a…...

There are several codes and standards that call for the use of Hydrostatic Relief Valves (HRV) and often times the implementing organization fails to meet these requirements fully.  As for propane systems, both OSHA and NFPA, require the installation of HRVs EVERYWHERE there is a chance that liquid propane can be trapped, but as this…...

ASME Section VIII, Division 1 has special design and construction requirements for vessels that will be used in “Lethal Service.”  Sounds logical and easy.  Logical – yes, Easy – not so much!  Section VIII mentions the term “lethal service” dozens of times. Still, it is Subsection B – Requirements pertaining to Methods of Fabrication of Pressure…...

The IIAR is proposing a new standard to specify the minimum criteria for developing operating procedures for closed-circuit ammonia mechanical refrigerating systems. IIAR has designated the proposed standard as BSR/IIAR 7-200X. Upon approval by the ANSI Board of Standards Review, the standard will receive a different name that reflects this approval.  The 45-day public review…...