Chemical Process Safety (PSM/RMP)

JFK Airport fueling accident (drive off w/ video)

On my soapbox again, regarding the catastrophic hazards associated with load/unloading/transferring large volumes of hazardous materials. via temporary hose hook-ups. Three weeks ago, I posted about the fatality event when a driver pulled their truck forward for unknown reasons, severing the LNG hose, and was killed as he entered the LNG cloud when it was…...

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FATAL Start-Up of Gas Plant kills 15, 39 hospitalized

Last week, 8/25/26, during the initial start-up of the Amur Gas Chemical Complex in Russia’s Far East, has so afr claimed the lives of 15 workers, mostly contractors and sent 39 to the hopsital. The facility is a huge polyethylene/polypropylene project being constructed by Sibur and Sinopec and had not yet entered production. Equipment was…...

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“Farmer’s leak test” vs. industrial leak test

I have mentioned “farm leak testing” several times in my ramblings, and every time I caution against industrial facilities, especially those falling under OSHA’s PSM or EPA’s RMP. Essentially, a “farmer’s leak test” uses NH3 as the leak-test medium before using their implement to knife the NH3 into the ground as a fertilizer, as this…...

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CSB Discovers that Nippon Dynawave Packaging Company Was Told in July 2025 that the Tank Was Not Fit for Continued Service and Could Fail (MI Failures w/Video)

NOTE: I normally remove company names, as I am not about name shaming, but this company has earned its shame! The U.S. Chemical Safety and Hazard Investigation Board (CSB) today released an update on its investigation into the deadly May 26, 2026, catastrophic failure of a 1.2-million-gallon atmospheric storage tank at the Nippon Dynawave Packaging…...

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Leak testing our hazardous material storage/process vessels BEFORE placing them into service

I talk a lot about “pressure and leak testing” our piping systems before they are put into service or returned to service after breaching the pressure boundaries, but the same practice should apply to our process vessels/tanks. But I almost always get the “you must be on drugs” look when I ask about this in…...

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Control Portable Electronic Device Use to Prevent Ignition Hazards Offshore (BSEE Safety Alert)

Recent Marine Minerals Administration inspections identified unsafe use of portable electronic devices (PEDs) – including pagers, cell phones, cameras, video equipment, and radios – in hazardous areas offshore. During one inspection, MMA observed a wireline operator using a cellphone on a mobile offshore drilling unit during active wireline operations. This use violated facility safety procedures…...

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Line Break Gone Bad (Natural Gas)

In winter 2026, a small gas explosion and fire occurred in a Dawson Creek home, causing two workers to sustain burns. The incident also damaged a furnace, hot water heater, and the home’s interior.   Two (2) unqualified workers were disconnecting gas piping while the gas supply was still on in order to remove a…...

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Six-figure fine for a petrochem facility after five (5) piping leaks of extremely flammable hydrocarbons (CUI piping failures)

Five leaks of extremely flammable hydrocarbons occurred at the plant between February 2018 and September 2019, including one that lasted four months. The leaks were discovered after Health & Safety Executive inspectors detected a strong smell of flammable gas on a routine inspection – all five leaks were attributed to Corrosion Under Insulation (CUI). An…...

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Did the state of GA have a fire code that addressed the use of Liquid and gaseous nitrogen in the workplace in 2021 when the FFG accident happened?

The simple answer is yes. Georgia had a state fire code regulating liquid and gaseous nitrogen in January 2021, when the Foundation Food Group (FFG) accident occurred in Gainesville, Georgia. What was in effect in January 2021?… Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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CSB Releases Foundation Food Group’s Fatal N2 Accident Safety Video

Today, the U.S. Chemical Safety and Hazard Investigation Board (CSB) released a new safety video on its investigation into the deadly January 28, 2021, liquid nitrogen release at the Foundation Food Group (FFG) poultry processing plant in Gainesville, Georgia, that killed six people and seriously injured three others. The release occurred when the bubbler tube,…...

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How do I pressure-test/leak-test my new process piping equipped with HRV/TRVs?

This is another very common question for those getting into PSM/RMP, where their RAGAGEP requires the piping to be protected from a “blocked-in liquid” scenario, such as Liquefied Petroleum Gas (LPG). Many realize the dilemma only after installing their HRVs/TRVs; unfortunately, they have to go back and remove these relief valves to perform the “Pressure…...

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Does ASME B31.3 require hydrostatic leak testing to be the first option unless it creates a greater hazard?

Yes. Under ASME B31.3, hydrostatic leak testing is the default and universally preferred method for verifying the integrity of a piping system. The code mandates it as the primary option, and alternative methods are permitted only when the owner explicitly deems hydrostatic testing “impracticable.”… Membership Required You must be a member to access this content.View...

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