The CSB warns about “Line Breaks gone bad”
The CSB examines two (2) high-consequence incidents in 2025 that were caused by workers mistakenly disassembling the wrong equipment.
Line Break Gone Bad – Maintenance Mechanic Dies After Being Burned by Hot Boric Acid Solution While Removing Pump
In July 2012, a 64-year-old maintenance mechanic at an aluminum foil processing facility died after being exposed to an approximately 180-degree Fahrenheit solution of boric acid and water while trying to remove a recirculation pump from its housing. The pump was part of a boric acid evaporation system. The system took several days to completely
Water hose fails during transfer, killing water truck driver
On August 19, 2019, at approximately 3:00 p.m., a 67-year-old male water truck operator, working as a seasonal employee, sustained severe head injuries when a pressurized water hose burst and he was knocked to the ground. He died two days later from his injury. The victim’s employer was a cooperative of almond growers that provided
Hydrostatic Pressure Test gone bad (49-year-old pipefitter killed)
I have written a lot about the hazards of “pressure testing” piping, and in all of those posts I have stated how much “safer” Hydrostatic Testing is, compared to pneumatic testing. But this fatal accident shows us that even hydrostatic testing comes with fatal risks. During a hydrostatic pressure test of a fire suppression system,
LNG Tanker Unloading Fatality – Unloading Hose Failure (Driver moved truck 17′)
A 62-year-old technician was killed when an LNG vapor cloud exploded while he offloaded liquefied natural gas (LNG) from a tanker semi-trailer. Heworked for his employer, a natural gas supplier, for about five (5) years. The technician was offloading the trailer at a temporary and mobile LNG transfer station. The trailer belonged to the technician’s
Which flammable gas (methane or pentane) is better to use in calibrating my direct-reading instrument? (Sweating the small stuff series)
Choosing between methane and pentane for calibrating a direct-reading combustible gas indicator (CGI) depends primarily on your specific application, the target hazards in your environment, and sensor technology constraints. But there are BOTH a “Pentane Advantage” and a “Methane Advantage” Match the Target Gas (Best Practice for Specific Hazards)
Materials of Construction for Direct Reading Instruments: Sample Tubing (Sweating the small stuff series)
When you pump reactive, highly polar, or oxidizing gases like chlorine (Cl2), chlorine dioxide (ClO2), or ammonia (NH3) through standard silicone, polyurethane, or Tygon tubing, the tubing acts like a chemical absorber/scrubber. The gas is actively consumed or trapped by the hose before it ever reaches the instrument’s sensors. This creates severe process safety and
Report on the catastrophic Explosion @ Shandong Youdao Chemical Co., Ltd. (China)
On May 27, 2025, a catastrophic explosion and fire erupted at a chemical manufacturing plant operated by Shandong Youdao Chemical Co., Ltd. (often referred to as Gaomi Youdao Chemical) in Gaomi City, Shandong Province, China. The explosion killed 12 people, injured 19 others, and caused widespread structural destruction throughout the surrounding area. In July 2026,
What is the minimum pressure for a sensitivity “bubble test” (Piping Leak Test)?
For a formal liquid bubble leak test using a detector like Swagelok Snoop, the industry-standard minimum pressure governed by ASME Section V, Article 10 and ASME B31.3 is 15 psig or 25% of the system design pressure, whichever is less. While SNOOP itself will bubble at virtually any positive pressure where gas escapes, engineering codes
Is pneumatic testing of plastic water piping acceptable under ASME B31?
As we have discussed before, the PREFERRED pressure/leak testing method is hydrostatic. This is the “rule” for all of the ASME B31 series RAGAGEPs; however, for some odd reason, many businesses believe that pneumatic testing is “easier, cleaner, and cheaper” and will just perform their testing with little to no consideration for using hydrostatic methods.
Facility Siting – Location of labor quarters in relation to the covered process
The Industrial Safety and Health Department has directed all seafood processing units to relocate labor quarters to safe locations from the processing units immediately. The order comes in the wake of the NH3 leak tragedy that left 18 workers dead, as their accommodation was in close proximity to the factory’s Engineroom. Following the incident, the
Fireproofing piping supports
Fireproofing piping supports — specifically the application of Passive Fire Protection (PFP)— is a critical mitigation strategy designed to prevent the structural collapse of pipe racks during a flammable liquid fire. In most state fire codes and the IFC, flammable liquid piping supports inside a secondary containment are REQUIRED to be protected from the effects