Chemical Process Safety (PSM/RMP)

What happens when the NH3 release inside the engine room exceeds 40,000 ppm?

UPDATED on 8/21/2019 with the 2018 IFC Commentary… I am guessing that someone has published a technical paper or article stating that an “electrical shunt” is no longer a code requirement for ammonia refrigeration engine rooms.  This has caused several of my clients and subscribers to ask me if this is true as this goes…...

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How to annually verify my flammable liquid(s) processing area mechanical exhuast ventilation is functioning as designed

This $50 device is priceless in validating that the ventilation system is functioning as designed Verifying that a mechanical exhaust system provides sufficient airflow is critical for preventing the accumulation of flammable vapors. The use of a Vaneometer™ is ideal for monitoring low-velocity air currents (typically 25 to 400 feet per minute) at the face…...

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2019 edition of the National Board Inspection Code (NBIC) summary of major changes

The 2019 edition of the National Board Inspection Code (NBIC) has been available for purchase since July 1st, 2019.   Here is a summary of the major changes:… Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Anhydrous Ammonia hydrostatic expansion event?

This is another picture that was shared with me and is making the rounds on social media.  It certainly appears to be a liquid (hydrostatic) expansion event on a stainless steel pipe.  The story goes and I can certainly see this happening…  Valve installed when hot out. Valve didn’t fully seat and allows vapor to…...

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Hazards of Improper weld repair and failed hydrostatic pressure testing?

I have many questions about this picture but was told this was the results of a failed hydrostatic pressure test after a non-certified repair was made.  Has anyone seen this picture before?  Got an incident report to go along with the image?  My source is very trustworthy, but I just would like to have an…...

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EPA RMP GDC citations @ windshield wiper fluid manufacturing facility (Methanol & $197K)

PLEASE NOTE this case is significant in that many facilities in the OSHA arena will EXEMPT their “methanol” from PSM coverage using the “Atmospheric Storage Tank” exemption (e.g. 1910.119(a)(1)(ii)(B) or called the “Meer Decision”).  EPA couldn’t care less about this OSHA exemption, as is evident in this case! There is NO EPA RMP exemption for flammable liquids stored…...

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Benchmarking Risk by Whole Room Scale Leaks and Ignitions Testing of A3 Refrigerants

The objective of this project was to conduct refrigerant R-290 (propane) leak and ignition testing under whole room-scale conditions to develop data and insight into the risks associated with the use of Class A3 Refrigerants and to generate technical data to support revisions of relevant safety standards.       The entire project included parametric testing…...

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Hazardous Materials and Chicago Coupling(s)

Most anyone who has spent a day inside an industrial facility has seen a “Chicago Coupling” or as some may call it, a “crows-foot”, although they may have never heard the phrase that describes this device… Photo Source: chicagocoupling.com Having been raised as a safety engineer in the petrochem industry I learned early on that…...

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Hazardous Materials and Chicago Coupling(s)

Most anyone who has spent a day inside an industrial facility has seen a “Chicago Coupling” or as some may call it, a “crows-foot”, although they may have never heard the phrase that describes this device… Photo Source: chicagocoupling.com Having been raised as a safety engineer in the petrochem industry I learned early on that…...

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Piping Corrosion (External – Outside/In)

This is WATER damage!  It is on an NH3 process, but this was found to be external damage from treated water with an incorrect water treatment “recepie”.  The condenser was not being maintained properly either and the two failures produced this corrosion and a tad bit of erossion as the water was dripping down from…...

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Piping Corrosion (External – Outside/In)

This is WATER damage!  It is on an NH3 process, but this was found to be external damage from treated water with an incorrect water treatment “recepie”.  The condenser was not being maintained properly either and the two failures produced this corrosion and a tad bit of erossion as the water was dripping down from…...

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Current National Enforcement Initiative (NEI), Ammonia Refrigeration – What To Look For

Here is a nice presentation from on EPA’s National Enforcement Initiative (NEI) on Ammonia Refrigeration with pictures of some of their findings involving: Housekeeping as a leading indicator Corrosion and CUI Deadman Valve issues (missing deadman, missing plugs, handle manipulated) Hose Failures SAFTENG members can see the images and download the ppt file… Membership Required You...

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