Car Seal Program and Training Presentation UPDATED 2/2025
I have upload my REVISED Car Seal Program and the PowerPoint that goes with it to the Document Library – Chemical Process Safety folder.
When you see it… (Not a Car Sealed Valve!)
I just uploaded my newest version of the SAFTENG Car Seal Program that reflects the code requirements in 2025. A client has learned they need to car seal some valves that are “intervening valves” after a PRD and before a header. The OEM commissioning the process stated they had a Car Seal Program and would
CSB Releases New Safety Video on the 2020 Fatal Propylene Release and Explosion
Three People Died Due to the Blast The U.S. Chemical Safety and Hazard Investigation Board (CSB) released a new safety video on its investigation into the January 24, 2020, fatal propylene release and explosion at the Watson Grinding and Manufacturing Company facility in Houston, Texas. The massive explosion resulted in the death of two workers
Managing Pressure Vessels and their Pressure Relief Devices is more than just PSM/RMP
With the recent catastrophic and fatal pressure vessel (PV) failure in KY, I have to speak up and point out a very dangerous and unfortunately common failure we see in our work. Far too often we visit a facility under the guise of doing process safety work and we typically find the PSM covered PVs
Chemical Exposures from Industrial Valve and Piping Systems
Fundamentally, employers and employees must be alert to the fact that working with a “closed system” does not always ensure safety. Operations involving the opening of valves or pumps on otherwise closed systems or working on such equipment that is not isolated or locked/tagged out are particular sources of danger. When a normally closed system
Hazards of Pneumatic Pressure Testing Piping with Nitrogen
At 8:04 a.m. on May 11, 2023, an employee, 58, working for an oil and gas support services company was found dead. On 5/10/23, the night before, the employee had instructed his coworkers from other contractors to go home, and he would finish the job up. This was the last time anyone had spoken to
Line Break Gone Bad (Flammable Gas)
At approximately 9:20 a.m. on December 1, 2010, Employee #1, #2 and #3 were working on the barge of an oilrig (Rig Number 1). They were removing a Christmas tree flange, an assembly of valves, spools, and fittings used to control the flow of oil or gas out of the well, with a cutting torch.
Line Break Gone Bad (Installing blinds to isolate a PRCS)
When we think the task is to improve safety for an entry, we may lose sight of the risks associated with opening process equipment, specifically flanges in the event. On July 23, 2009, Employee #1 and a coworker, both contract employees specializing in preparation of refinery equipment for entry, were installing blinds in piping preparatory
Steam belongs in our Line Break Program
At 9:00 a.m. on October 6, 2019, an employee was attempting to open a flange. Steam released, burning the employee’s legs and lower body. The employee was hospitalized. 29 CFR 1910.269(d)(2)(iv)(D): The procedure did not clearly and specifically outline specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout
Leak Testing per ASME Section V, Article 10 – Leak Testing
I see many contractors still arguing that Pressure Testing and Leak Testing are the same test. This is incorrect, as I have often discussed in my ramblings on this website. This post breaks down the requirements of the most common “leak test,” called the “bubble test.” ASME B31.3 refers us to ASME BPVC Section V
Dawn dish soap may be great for dirty dishes and birds, but NOT for our “bubble test”
I see this often, a contractor wants to save some $ so they think they can make up their own “bubble-test” solutions. However, not only is this a very bad idea from a QA perspective, it is actually NOT TO CODE, as ASME Section V, MANDATORY APPENDIX I BUBBLE TEST — DIRECT PRESSURE TECHNIQUE, I-1032
Preparing for a piping leak test (B31.3)
B31.3 imposes the following requirements, which are only a few of the elements of a leak testing plan: