Chemical Process Safety (PSM/RMP)

Small cracks grow up to become big cracks and big problems (NH3 direct expansion chiller)

A new direct expansion chiller was installed at an ice arena to replace an existing chiller. After almost 20 weeks of service, an ammonia leak was detected, which released ammonia into the machinery room. The low level (25 ppm) ammonia alarm sounded and the ventilation system was activated to continuously evacuate vapors to the outdoors…...

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EPA publishes the FINAL RMP Rule (Rescinded Amendments)

The Environmental Protection Agency (EPA) has revised regulations designed to reduce the risk of accidental releases of hazardous chemicals. These regulations are part of the EPA’s Risk Management Program (RMP), which the Agency established under authority in the Clean Air Act and recently amended on January 13, 2017. After a process of reconsidering several parts…...

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CSB’s proposed chemical accident reporting rule (CFR 1604)

The CSB proposes to add a new part to title 40 of the Code of Federal Regulations, which will appear as a new part 1604. The proposed part will consist of six (6) sections. Proposed § 1604.1 states the purpose of the rule. Proposed § 1604.2 sets forth key definitions. Section 1604.3 sets forth who…...

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EPA’s RMP – Quantity of a substance in a mixture or solution toxics with listed concentration (Conc >20% Aqua Ammonia)

In EPA’s RMP standard there are four (4) TOXIC substances which have listed concentrations: Hydrochloric acid 37% or greater Hydrofluoric acid 50% or greater Nitric acid 80% or greater Ammonia 20% or greater If we have any of these four (4) substances in solution AND their concentration is LESS THAN (<) the listed concentration, we…...

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Helping lower risk through safety engineering (Chlorine and Gas Cabinets)

These days the one thing I love about my job is when a client actually asks me to lessen their risks through safety engineering. Yes, I went to school and got my BS in OSH and my MS in SE and they are stunningly different applications. With one, I help companies with their OSHA compliance…...

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FINAL REPORT on the Intercontinental Terminals Company (ITC) Tank Farm Fire

The Harris County Fire Marshal’s Office (Case Number 1903-00046) and The Bureau of Alcohol, Tobacco, Firearms and Explosives (Case Number 782035-19-0029) have issued their FINAL REPORT on the Intercontinental Terminals Company (ITC) Tank Farm Fire in La Porte on March 17, 2019.  It was observed what appeared to be studs laying in the pump housing…....

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Process opening GONE BAD with flammable vapors and a cordless grease-gun

At 10:00 a.m. on November 23, 2018, two employees were working for a firm that provided support activities for oil and gas operations. Employee #1 and Employee #2 were part of a crew that was going to launch a pig from a pig launcher on a natural gas line. There were flammable vapors present. The…...

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Diaphragm failure is caused from overpressure due to trapped liquid ammonia

Incident overview In an industrial food processing facility, an ammonia leak occurred from the thermal expansion valve diaphragm, that required replacement. Site, system and components The thermal expansion valve and diaphragm control the rate of flow of liquid ammonia that feeds the spiral freezer. The freezing temperatures are obtained when liquid ammonia evaporates to vapor…...

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Ammonia release results in facility evacuation and temporary shutdown (CUI)

Incident overview An ammonia release occurred in the mezzanine area at an industrial food processing facility, which resulted in the evacuation of the facility and temporary shutdown of the ammonia plant…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Compressor fails causing an uncontrolled ammonia release

Incident overview The bolted flanged connection on the suction of a reciprocating compressor failed causing an uncontrolled release of ammonia into the machinery room. The ammoniadetection system worked as designed activating the ventilation system and alarming the appropriate parties. The leak was isolated and no injuries resulted…. Membership Required You must be a member to...

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In Process Safety – Torquing Matters! (NH3 Leak on manway gasket)

Incident overview Manhole gasket seal on an oil separator pressure vessel failed to hold ammonia in the vessel which resulted in the exhaust ventilation system to be activated.  … Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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