The investigation has found that the direct cause of the leak was corrosion under the insulation in a 4″ pipe for heavy naphtha from the distillation tower. The lack of inspection and repair meant that the corrosion had continued long enough for a hole to form in the pipe. Piping and equipment in a refinery […]
A Y-shaped strainer (filter) in a three-inch pipe ruptured. The failure occurred after pressure cycles induced by thermal expansion. The released isobutylene resulted in a gas cloud explosion and the company’s bankruptcy. Aspects: When a closed system filled with a liquid hydrocarbon raises the temperature, the pressure can rise above the design. Here, a brittle
Line Break is commonly associated with OSHA’s Highly Hazardous Chemicals in its PSM standard and EPA’s Extremely Hazardous Substances in its RMP rule. But SAFTENG members know I use Line Break Safe Work Practice (SWP) outside the PSM/RMP process battery limits. I apply this SWP to energy sources such as steam and even water when
How times have changed in 30 years regarding “materials of construction” in hazardous materials processes. I grew up in process safety, seeing nothing but metallic piping systems; today, I bet I see piping systems made from non-metallic products upwards of 25% of the time. This is becoming increasingly acceptable in one specific process I do
Most PSSR forms we encounter simply regurgitate OSHA’s 1910.119(i)(2). If the user is thoroughly knowledgeable of what each of these four (4) line items entails, we may be able to execute the PSSR appropriately. Let’s look at these four line items, especially the first line. 1910.119(i)(2) The pre-startup safety review shall confirm that prior to
The two (2) terms sound similar and will conjure up similar images when we hear them, but they are used in the ASME B31 piping standards in very different ways and apply to different groups. To state it very simply, the EXAMINATION is what the owner/operator does to pass the INSPECTION, which is what the
An internal failure of a heat exchanger caused ammonia gas to leak through and absorb into the circulating liquid brine for the underfloor loop. The ammonia within the liquid brine spilled out of the expansion tank, pooling within an open sump in the mechanical room. The heat exchanger needed to be replaced as it was
Facilitating Process Hazard(s) Analysis (PHA) is one of my favorite process safety skills. From having the honor to be the author of Part II in the CCPS’s Hazard Evaluation Techniques (3rd Edition) to working with several software companies on the development of their PHA products, there is nothing better than facilitating an actual PHA with
This is me doing a Process Hazards Analysis (PHA) with my non-American clients who use the metric system!Go ahead and laugh – but know the struggle is real.? ?
Not all “simple asphyxiants” are created equal; thus, not all make for good purging or blanketing. Would you believe me if I told you that one very common simple asphyxiant gas should NEVER be used for purging or blanketing flammable atmospheres? Many folks view Nitrogen (N2) and Carbon Dioxide (CO2) as very similar. This is
Some of the more eye-opening revisions: Outlining STOP-WORK procedures in Program 3 employee participation plans A justification in the risk management plan is required when: hazard evaluation recommendations are NOT adopted facility-siting hazard recommendations are NOT adopted Safer Technology Alternatives Analysis (STAA) recommendations are NOT adopted third-party compliance audit recommendations are NOT adopted A formal
At 7:30 p.m. on July 2, 2021, Employee #1, Employee #2, and Employee #3 performed two maintenance tasks in the M2 crude rectification section on the ground and second levels at tower M2-T250 and vessel V-207. On July 2, 2021, during the night shift, three (3) gas monomer chemical operators were exposed to toxic fluorocarbons
