Chemical Process Safety (PSM/RMP)

There are very good reasons why workers are required to be a “safe distance” from equipment that is being “pressure tested”. These safe distance requirements apply to BOTH pneumatic and hydrostatic pressure testing. Had these distances been honored/respected, a component failure during the pressure test may cause damage, but not an injury! On August 26,…...

On April 21, 2020, Employees #1 and #2, 37 and 63, were conducting a pressure test on a chiller. Employees #1 and #2 were unaware there was pressure in the chiller. When they began removing the 1/2″ nuts off the bolts holding the flange in place…… Membership Required You must be a member to access...

On February 28, 2020, an employee, 36, was tasked with replacing a gasket in a 6-inch bolted flange on top of the Platformer Heater at an Oil Refinery. The employee was working in a man basket on top of the Platformer Heater. The employee loosened the bolted flange while using hand tools to remove a…...

EPA Region 7 developed several RMP training modules that are available to download. Topics include:… Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

SPECIAL NOTE: the Cl2 was generated by a truck unloading incident that was a WRONG CHEMICAL-WRONG TANK event (phosphoric acid to sodium hypochlorite) which produced 973 pounds of Cl2. Respondent owns and operates two amino acid manufacturing facilities located near each other (the Facilities). One Facility specializes in food and beverage industries (Foods), and the…...

Up to 100 pounds of ammonia was released outside a public athletic club with indoor ice facilities. The leak happened during decommissioning work of an ammonia refrigeration condenser by a refrigeration contractor and resulted in the facility enacting their Ammonia Release Emergency Protocol. Multiple workers and members of the public were in the area at…...

Those who follow my posts closely know I am a massive fan of bollards for physically protecting hazardous materials processes. These simple and inexpensive posts have saved my butt over my career more times than I can count, and yet so many still are unaware of their need and requirements. But these bollards are for…...

In light of the recent HSE video showing a 30′ silo exploding and going airborne for 9 seconds, I thought it might be fitting to offer some guidance on how to SAFELY perform HW on these “used containers.” OSHA’s 1910.252 standard provides no advice other than to say that we must be “absolutely certain” that…...

As you know, I am a big fan of the International Fire Code and utilize it more than outdated OSHA standards. One requirement the IFC has that OSHA does not is that “conspicuous signs shall be posted to warn others before they enter the hot work area.” Such signs shall display the following warning:… Membership...

On 20 September 2017, two employees of were using a grinder to cut and replace pipework at the top of an 11-metre (40’) high metal tank containing waste slurry. They were not using harnesses. Sparks from the grinder ignited flammable gasses causing the tank to explode. The slurry vessel was airborne for 9 seconds and…...

On March 20, 2024, at noon, an employee, 34, was pneumatically leak-testing a newly installed 56-inch drainpipe. The pipe extended from one side of the street to the other, roughly 150 feet. They placed a rubber pressure plug on one side and another on the testing site across the street. At about 30 minutes into…...