Safety Info Posts

OSHA rescinds and replaces the memorandum dated January 26, 2023, on “Violation Grouping and Discretionary Ungrouping”

/ OSHA Compliance /

This memorandum rescinds and replaces the memorandum dated January 26, 2023, on the same subject. This memorandum further clarifies the policy described in the earlier memorandum. Under this policy, Regional Administrators and/or Area Directors may refrain from grouping violations where the violations are separate and distinct, even if other OSHA policies or directives recommend grouping…...

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What is it about a disgruntled employee and their safety

/ Human Factors Engineering, Motivational Safety Materials, Safety Management System /

It has taken me 20 years to truly understand what Clive Lloyd said in his book “From Compliance to Care.” One of my top five safety books I recommend for every safety professional and front-line manager. “Behaviors are NOT the problem – they are expressions of the problem.” I have conducted over 100 safety assessments…...

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H2S has has claimed eleven (11) souls in 7 days (3 different events)

/ Hazardous Materials, OSHA Compliance, Permit Required Confined Spaces /

In less than one (1) week, Hydrogen Sulfide (H2S) has claimed eleven (11) souls: Six (6) at a Dairy in CO Three (3) in a sewer in TX Two (2) in a Sewage Treatment Plant This chemical has a long history of killing workers: (Note: SAFTENG membership required to access article)… Membership Required You must...

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EPA RMP Citations @ Power Plant (NH3 & $8K)

/ PSM and RMP Citations/Analysis /

Respondent is a power gas-fed generation facility, utilizing Anhydrous Ammonia in its SCR. It shares its ammonia with a neighbor who uses the NH3 in its refrigeration process. (Don’t ask me how I know) ALLEGED VIOLATIONSFollowing its February 5th, 2025, inspection, EPA alleges Respondent’s failure to:… Membership Required You must be a member to access...

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Catastrophic Failure of NH3 Cold Storage Vessel = 14M pound release & 7 Fatalities

/ Chemical Process Safety (PSM/RMP), Hazardous Materials /

A liquid ammonia NH3 tank failed catastrophically at the Azotas fertilizer plant in Lithuania in 1989. During maintenance on the boil-off system, operators accidentally created a backflow of liquid warm NH3 to the tank. Potentially after a “role-over”, NH3 evaporated quickly, creating pressure that could not berelieved by the PSV. The tank was lifted, releasing…...

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WRONG Chemical – WRONG Tank (HCL to Nitric acid tank – Video)

/ Hazardous Materials /

The chemical reaction event at the Friesland Campina site in Borculo early last month (July 2025) was caused by an error in the unloading of hydrochloric acid. The explosion released toxic smoke, chlorine, and nitrogen dioxide. A truck driver reported to the wrong unloading point at the dairy company in Gelderland on Friday afternoon, July…...

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The real role of the “buddy system” in OSHA/EPA’s HAZWOPER

/ Emergency Response, OSHA Compliance /

Almost everyone involved in emergency response is aware of the “buddy system” (e.g., 2 in-2 out rule); however, many merely treat this as a “check box” approach as compared to having real rescue capabilities for the entry team. I always ask my students if they believe they could lift and carry a grown adult in…...

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Triple H2S Fatal Event in Sewer (Single Entrant & 2 would be rescuers)

/ OSHA Compliance, Permit Required Confined Spaces /

RIP 🙏 Another H2S PRCS event claimed three (3) souls This was also a SINGLE ENTRANT with two (2) “would-be rescuers”… Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Human Error leads to Cl2 exposoures during truck loading

/ Chemical Process Safety (PSM/RMP), Hazardous Materials /

At 4:00 p.m. on May 10, 2021, an employee working for a chemical supplier was transferring chlorine-containing product from a storage tank into a tanker truck. A valve intended to direct the displaced contaminated air to be scrubbed of chlorine was accidentally left CLOSED. The chlorine-containing air was then not scrubbed and was allowed to…...

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Line Break Gone Bad (Cl2)

/ Chemical Process Safety (PSM/RMP), Hazardous Materials, OSHA Compliance /

This event is a perfect example of why all piping openings are hazardous. At approximately 7:00 p.m. on November 15, 2006, Employee #1 was a process operator at the Chlorine Liquefaction Unit, Block A-19. He was preparing to bleed off chlorine on a process line to clear the line for maintenance work. The valve handle…...

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OSHA issues Facility Siting citation under 5(a)(1) rather than PSM

/ Chemical Process Safety (PSM/RMP), Hazardous Materials, OSHA Compliance /

NOTE: these are from the fatal 2014 NH3 Truck Unloading accident, where the “bleed tank” (which was a plastic IBC) catastrophically failed because a liquid NH3 valve was left open. I have no idea why this 5(a)(1) was not issued as a RAGAGEP citation using ANSI K61/CGA 2.1, which is where the facility siting requirements…...

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OSHA Willfuls for PRCS accident ($252K)

/ OSHA Compliance, Permit Required Confined Spaces /

OSHA has cited a commercial laundry company for alleged workplace safety hazards after an employee injury. OSHA opened an investigation following a referral from the local Police Department. OSHA inspectors determined that on Jan. 18, 2025, a worker suffered serious injuries while performing maintenance on an industrial dryer.  The agency issued three willful and nine…...

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