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SAFTENG has:
- Over 19,000 categorized unsafe acts/conditions and accident/injury photos
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On October 1, 2020, at approximately 9:00 a.m., approximately 554 pounds of chlorine gas were accidentally released. Exposure to the toxic chlorine vapors seriously injured one employee. At the time of the incident, four (4) workers (two unit employees and two contractors) were trying to stop a chlorine leak (described as a fugitive emission) from a drain valve in the company’s methyl diisocyanate...
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At the time of the event, contract workers were disassembling a 2-inch flange to remove a blind (a solid metal plate used to isolate equipment) before reinstalling a section of piping that had been removed and cleaned. This type of equipment opening is commonly referred to as a “line opening” or “performing a line break.”
The contract workers performing the line opening wore personal protective equipment...
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Scenario: Employees bring rechargeable lithium-ion batteries from home to the workplace for use in e-cigarettes, which are not used in any equipment or devices related to their work duties. You also state that, in this scenario, the battery terminals are unprotected and the employee or employees improperly carry these batteries in their pants pocket, a fire is sparked by the batteries, and that the...
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In some processes, there is ALWAYS a need to “leak test” before returning a segment of piping to service. These “leak test” pressures are done at NORMAL Operating pressures using a calibrated solution such as SNOOP. And every once in a while, I get a question about doing a “leak test” at some really low pressures. I do not usually allow these lower pressures on...
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There are limitations on even the best “bubble solutions” used for “leak testing. My favorite is SNOOPS, and as I indicated in the title, even it has limitations. There are two (2) different types of SNOOPS:
Snoop Liquid Leak Detector
Real Cool Snoop Liquid Leak Detector
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The old question… Do we need to pressure-test and leak-test our piping after we breach the pressure boundary? My response is always YES; however, the International Gas Code says something very different. Can we apply this approach to ASME B31.3 piping?
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ATF investigators determined that the fire originated in the upper level of the engine room, portside aft. A paint locker was located in the area of origin, with various combustible materials stored both inside and outside the locker. Interviews with the vessel’s engineer revealed that a boot warmer had been plugged into an extension cord a few feet from the paint locker.
The boot warmer was stacked...
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Hydrogen is finding some footing for wider use as a fuel these days, and I have seen a significant increase in inquiries from existing and new clients about process safety for H2 storage and use. I always follow Chapter 700 of the International Gas Code as my baseline code requirements and then move into NFPA 2 for a more detailed analysis of the process. In this article, we will cover the pressure...
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1) Variation in human performance is normal and not causal.
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This is a real-life story of Elimination vs. Engineering Control
We see some odd designs in our work around the world, but recently we came across a setup that defied any logic for a relief valve design basis. For some reason, the OEM and Installer of this process equipment wanted it enclosed for “efficiency”; however, they did not feel the need to vent the relief valve(s) outside of...
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I fight this battle every year! It’s usually a learning experience for people unfamiliar with chemical processing and ASME B31.3. But I do my best to ensure they understand how the 10-minute Pressure Test is done, and then how the Leak Testing is done. So today I decided I need to “test” my practice that I have been doing for 30+ years; as I began to wonder “maybe I was taught...
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Chemical and refinery facility personnel open piping and equipment to perform routine maintenance, add/replace components, or modify pipe routing. The piping may contain hazardous material, such as flammable hydrocarbons, toxic chemicals, or thermally reactive chemicals. Safe work practices dictate the removal or mechanical isolation of hazardous material from piping and equipment (e.g., using valves...
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