If you really want to get a feel for the culture around safety, STOP with the surveys and get with today’s technology Three of my five bosses throughout my career all had this same practice, which is far more telling than a “survey.” And with today’s technology, such as cameras and drones, there is a far better way to gauge the “safety mindset” of our workforce. It works like this… Hire a high-tech...

“… an attitude of frustration or an internal state of distress can certainly influence driving behaviors, and vice versa. Indeed, internal (unobserved) personal states of mind continually influence observable behaviors, while changes in observable behaviors continually affect changes in person states or attitudes. Thus, it is possible to “think a person into safe behaviors” (through education,...

In process safety, we spend a lot of time discussing the PRIMARY containment systems; however, our secondary containment systems play a vital role in our PROTECTION and MITIGATION layers of protection. Of course, we want to keep the tiger in its cage, but we also need to be prepared for the day it gets loose, and this is where our secondary containment systems come into play. With all that said, let’s...

It never ceases to amaze me how businesses will cut corners in fundamental safety protections. Recently, I came across fire extinguishers that were not “approved” by a Nationally Recognized Testing Laboratory (NRTL). This was discovered during a 5-year REVAL PHA after the facility suffered a failure of one of its extinguishers that caused damage to some PSM/RMP piping. The investigation...

Following the investigation of a natural gas explosion in Loudon County, Virginia, in 1998, the National Transportation Safety Board (NTSB) recommended (Recommendation P-01-002) that PHMSA require that excess flow valves be installed in all new and renewed gas service lines, regardless of a customer’s classification, when the operating conditions are compatible with readily available valves....

When we encounter a manufacturing facility that has been pulled into OSHA’s PSM or EPA’s RMP, we are almost certain to find the same design features for the emergency stop functions (i.e., E-Stops). Most of these facilities are shocked to learn there is a big difference between the location of an E-Stop on a machine or conveyor and one on a hazardous materials process. If we think about...

I believe in Excess Flow Valves and Check Valves, even though I have seen them fail more often than work as hoped. However, these failures are “human failures” in the incorrect design (e.g., sizing and placement) of the process where these valves are utilized. The valves are highly reliable when they are DESIGNED, INSTALLED, and TESTED per the manufacturer’s requirements/recommendations....

Some Excess Flow Valves (EXFVs) models can be placed into a position that would render them useless in their intended function. I have encountered this scenario more than once during my PHAs, Investigations, Audits, etc. There are not many manufacturers that incorporate this failure mode in their designs, but there a couple that do; and for those that do, I HIGHLY RECOMMEND these valves be placed into...

What prevents excess flow valves from closing when the line breaks?  There are plenty of things that can prevent EFVs from operating as designed.  These include design failures, mechanical failures due to poor or no maintenance, and “human failures.” 1. Not a Clean Break For one or a combination of the following reasons, excess flow valves have been prevented from closing in emergencies:...

I am aware that NFPA 58 applies to LPG installations; however, with the “dumbing-down” of many RAGAGEPs, I am always looking for the BEST DESIGN for my process safety functions. I do wish the IFC would define/quantify where remote activation stations must be, as they did decades ago. But for now, I use NFPA 58, which states: 6.13.4 Remote Shutdown Station. 6.13.4.1 At least one remote shutdown...

Is your facility using Building Information Signs for emergency responders?  This requirement from the International Fire Code (IFC) is rarely adopted by states, but this is a great thing, especially when coupled with a Knox-Box access.  Here is how the Fire Service – Building Information Signs are supposed to look and say… J101.1 SCOPE New buildings shall have a building information...

The simple explanation of what is happening… Styrene (Stabilized) is shipped with an “inhibitor.” This inhibitor is TIME and TEMPERATURE dependent. Should the inhibitor expire and/or the solution exceed its safe temperature, the inhibitor weakens, and the Styrene will begin to polymerize (chemical reaction), which is an EXOTHERMIC reaction with “run-away” potential. This...