Safety Info Posts

Workers Hospitalized from Ammonia Leak during PRV Maintenance (Line Break/Process Opening Gone Bad @ food plant)

In April 2011, an OSHA State Plan investigated a 3,600-pound ammonia release at a large warehouse where anhydrous ammonia is used in the refrigeration system in a cold storage building. In this incident, one worker was burned on the arm from the escaping gaseous ammonia. As part of the planned mechanical integrity schedule, two (2) employees…...

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Process Opening 24′ up in a scissor lift gone bad (NH3 Oil Draining)

Employees #1 and #2 were draining refrigerant oil from anhydrous ammonia refrigeration system oil traps in fruit cold storage warehouse(s). They were working approximately 24 feet above floor level on a mobile scissor lift personnel platform using hand tools including a wrench, a flashlight, and a bucket. The cause of the unexpected ammonia release is…...

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Failure to LOTO NH3 liquid isolation valve(s) leads to cleaning contractor fatality

At approximately 9:30 p.m. on June 30, 1993, Employee #1, a cleaning contractor, was cleaning up the “cut floor” at a beef facility in Council Bluffs, IA. The facility maintenance employees were removing an ammonia valve from the refrigerant line in the ceiling and had NOT locked or tagged out the isolation valves on the roof. The…...

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NH3 Fatality after ice cream vessel (NH3 coils) catastrophically fails

On December 26, 1989, Employee #1 was attempting to replace a leaking oil valve on a minus 30-degree freezer when a tank inside the freezer exploded. The company uses anhydrous ammonia to manufacture ice cream. The liquid ice cream mixture (at 50 degrees) is added to the tank. When the liquid ammonia changes to a…...

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One Killed, One Injured Following Ammonia Vessel failure (Oil Separator)

An oil separator on a two-stage ammonia refrigeration system became overpressurized and exploded, killing Employee #1. While looking for Employee #1 after the accident, Employee #2 fell into a drain. Ammonia that had been uncovered as a result of the explosion had flowed into the drain. Employee #2 was hospitalized…. Membership Required You must be...

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UNSAFE NH3 charging practices causes catastrophic failure of 150-pound NH3 cylinder and a fatality

At approximately 3:15 pm on May 9, 1986, employees started to charge the number 1 line Carbo-Cooler, using a cylinder containing 150 pounds of anhydrous ammonia at 129 psi (room temperature). Employee #1, in an effort to speed the charging process, was running hot water (132 degrees F) over the ammonia cylinder (to raise the internal…...

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FATAL NH3 refrigeration vessel catastrophic failure at 170 psi

A pressure vessel in an ammonia refrigerator system at an ice plant ruptured under pressure of 170 psi. The explosion caused extensive physical damage and released dense clouds of ammonia gas. Employees #1 through 4 died of acute ammonia inhalation…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member?...

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Fatal NH3 release caused by threaded joint weakened by vibrations

Employee #1 was exposed to ammonia gas on November 20, 1984, during an ammonia leak from refrigeration piping in a compressor room. A threaded joint weakened due to excess vibration and cracked. When it failed, ammonia was released. An unapproved gas mask was used by the employee. Employee #1 died the following December 16th from…...

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Example of valves to Car-Seal OPEN and CLOSED on a NH3 refrigeration process

Car Seal programs have gained some attention in the refrigeration industry over the years, but there is still a significant debate over whether such a program is needed in the industry.  A past incident at a client’s facility and the root cause of that incident shine a bright light on the need for a Car Seal…...

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Car Wash Chain Conveyor sprocket guarding and employee misconduct

Although this serious injury incident occurred at a car wash, the decision of the OSHRC on guarding the chain conveyor and the workers having to work around it due to a change in work practices is an interesting take on “exposure to a hazard”.  If you have ever gone to a car wash that requires…...

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Automated External Defibrillator (AED) inspection and maintenance

AED’s have become extremely popular in the past decade; they are in just about all public places like airports, government buildings, and many private businesses.  These devices require little to no official training, as the device’s computer walks the user through the entire process of saving a life.  But these devices do NOT last forever! …...

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