Chemical Process Safety (PSM/RMP)

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…...

A sixth public review of draft standard IIAR 5-201x, Start-up and Commissioning of Closed-Circuit Ammonia Mechanical Refrigerating Systems is now open for public review of the substantive changes resulting from the fifth public review. The International Institute of Ammonia Refrigeration (IIAR) invites you to make comments on the substantive changes of the draft standard. Substantive changes resulting…...

Internal combustion engines present an ignition hazard when used in facilities processing flammable liquids and gases. If flammable vapors or gases are released in these facilities, an internal combustion engine could ignite the flammable materials with catastrophic consequences. Investigations by OSHA and the U.S. Chemical Safety Board (CSB) document a history of fires and explosions…...

On the morning of June 27, 2011, human error resulted in the mixing of an acidic solution of Fresh FX, an antimicrobial used in poultry processing, with a sodium hypochlorite solution. This mixing of chemicals caused a release of chlorine gas into the plant. About 600 employees who were at work at the time of…...