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I am proud to announce that SAFTENG and The Chlorine Institute have renewed our partnership for another year (through 2026).  Members of The Chlorine Institute receive a FREE SAFTENG membership.  If you qualify, please contact me

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ISO Liquid Chlorine Tank ISO Container for Road Transport Liquid Cl2 Un1017
25-Ton Container of Chlorine dropped and catastrophic failure
Below is a video of a tragic accident that occurred today in Jordan’s Aqaba shipping port. A 25-Ton ISO Container of Chlorine (Cl2) (like the image to the left) was being lifted off a truck and onto a ship when somehow the container was dropped (too early to know the cause).  The video shows the power of a Liquified Pressurized Gas (Cl2 BP = -29F).  At this posting, there are 10 deceased...
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Sustained inattentional blindness in expert observers
This is one for all the Behavior-Based Safety Observation admirers who somehow convinced themselves their BBS process is flawless.  Most of us in the safety profession has seen the “gorilla and basketball” video.  The study used a video made famous by earlier “inattention blindness” research featured in the 2010 book “The Invisible Gorilla,” by Christopher...
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Hexane explosion in an oil extraction plant (Double Fatality - PRCS)
The accident occurred in the hexane-based rapeseed oil extraction process. After grinding the seed and obtaining meal that is then steam-cooked (100°C), pressing in a continuous screw press is used to obtain 2/3 crude oil and flakes containing 1/3 oil. This oil is extracted from the flakes in the extraction process: the flakes are transported through the extractor while a mixture of hexane and oil...
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EPA issues RMP citations @ water treatment facility (WRONG CHEMICAL - WRONG TANK incident, 2,000 lb Cl2 release & $66K)
Chlorine, CAS No. 7782-50-5, is an extremely hazardous substance regulated and listed in 40 C.F.R. § 68.130. As the owner and operator of a stationary source, with respect to the use and storage of ferric chloride and sodium hypochlorite, Respondent has a duty under the General Duty Clause, Section 112(r)(1) of the CAA, to design and maintain a safe facility taking such steps as are necessary to prevent...
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EPA issues RMP citations @ poultry processing facility (NH3 & $124K)
The Respondent processes and freezes poultry products for distribution. The Respondent has two systems which include Anhydrous Ammonia at the Facility. The Respondent had one RMP program level 3 covered process (anhydrous ammonia refrigeration systems) which store or otherwise use a regulated substance in an amount exceeding the applicable threshold. The Respondent’s poultry freezing processes...
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Cal/OSHA Cites Four Employers $1.75 Million for Safety Violations in Death of Worker at a refinery
The Cal/OSHA Process Safety Management Unit has cited a refinery and three contractors a combined $1,753,375 for serious safety violations following a confined space death of a 35-year-old worker who suffocated in a regenerator overflow well. Cal/OSHA inspectors cited three of the four employers with willful and serious violations after determining that they failed to follow confined space regulations,...
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Hierarchy of Excuses
The Hierarchy of Responses, How Hazards Sink to the Bottom
I am not sure who came up with this, but it is a classic example of far too many organizations. … HomeRead More »
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The Safety Process through the eyes of a Quality Assurance Process
As many of you know I have taken on a new client (full time) in 2022 and my role in this organization is to build a safety management system (SMS).  And let me tell you what, if you thought explaining a RAGAGEP to management was difficult – try explaining that safety is a “process” and an SMS should function just like a QA/QC process in a business.  I have written several...
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EPA issues RMP citations @ chemical manufacturing facility (Cl2, CHCl3, CH3Cl, C2H3Cl & $500K)
The respondent is the owner and operator of a chemical manufacturing facility. EPA conducted an inspection of the Facility on May 1-4, 2018, to determine the Respondent’s compliance with Section 112(r) of the CAA and 40 C.F.R. Part 68. The following chemicals are “regulated substances” pursuant to 40 C.F.R. § 68.3. The threshold quantity for the regulated substances, as listed in...
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EPA issues RMP citations @ ice-making plant (NH3 & $170K)
Respondent owns and operates an ice-making plant that uses anhydrous ammonia in a refrigeration “process”. In 2016, Respondent filed a Program 3 RMP for the Process and reported that it used 22,000 pounds of anhydrous ammonia. In accordance with 40 C.F.R. § 68.10(a) and (f)-(h), the Respondent’s use, storage, and handling of anhydrous ammonia in the Process are subject to the requirements of RMP Program...
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What do I need to do if I can't meet my vessel/PRDs inspection schedule?
Sometimes things happen that are beyond our control as Process Safety Engineers, and in reality, this is where/how we earn our keep. As our RAGAGEP (API 510) says, “Deferrals should be the occasional exception, not a frequent occurrence.” The standard provides a rational, risk-based methodology for managing an inspection that cannot be performed by its due date; however, I have experienced...
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EPA issues RMP citations @ warehouse (Flammables & $109K)
Respondent is a limited liability company that operates as a public warehousing facility.  The term “have a general duty in the same manner and to the same extent as section 654 of title 29 [of the U. S. Code]” means owners and operators must comply with the General Duty Clause in the same manner and to the same extent as employers must comply with the Occupational Safety and Health Act (“OSH...
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