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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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Water Reactive, MAQ, and Sprinklers
Make it make sense… I have a “water-reactive” chemical, and yet the IFC/IBC allows me to double my MAQ when the area is “sprinkled”. d. Maximum allowable quantities shall be increased 100 percent in buildings equipped throughout with an automatic sprinkler system in accordance with Section 903.3.1.1. Where Note e also applies, the increase for both notes shall be applied...
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Line Break Gone Bad @ Power Generation Facility (ZES of Steam could not be confirmed)
Two (2) maintenance men at an electric power generation plant removed a check valve cover from a steam system. The section of the steam line was isolated and tagged, but it could not be vented or drained first. The section was only partially depressurized when the cover was loosened. When the employees removed all fasteners holding the cover in place, it blew off, and the steam line sprayed the two...
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Line (Equipment) Opening Gone Bad (Propane)
At about 9:27 a.m. on September 5, 2008, Employee #1, was assigned to remove the cap of a check valve on a propane tank to connect a valve with a hose for a “pump down.” Instead, he removed the entire check valve, causing the rapid release of a large amount of liquid propane. The vapor cloud was ignited by a water heater located over 25 feet away, and a flash fire ensued. Employee #1...
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Performance Testing of Fraudulent Respirator P100® Filters, Organic Vapor Chemical Cartridges, and Combination Cartridges (NIOSH Study)
This report presents the results of inhalation and exhalation resistance, filtration performance, and organic vapor (OV) service life testing on NIOSH-approved and counterfeit respirator P100 filters, chemical cartridges, and combination cartridges. NIOSH’s pilot project showed: 220/240 fraudulent P100 filters 124/124 fraudulent combination cartridges 8/8 fraudulent chemical cartridges failed...
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EPA RMP GDC @ paint/coating plant (Temp-sensitive organic peroxide & $196K)
Respondent is the owner and operator of a paint facility. On August 7, 2023, an incident occurred at the Facility that EPA alleges resulted in an accidental release (the “Incident”) of byproducts from a temperature-sensitive organic peroxide, leading to an overpressure release event. EPA conducted an investigation of the Facility beginning September 12, 2023, to determine Respondent’s compliance with...
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Equipment Opening gone bad (bolts stripped - not @ a ZES)
On March 25, 2003, two employees working for an power generation facility were instructed to remove a cover plate from an electrical generator. The hydrogen gas had been purged from the generator and replaced with air pressurized at approximately 40 psi. The generator was pressurized with air so that the workers could perform a leak test on the system. The cover plate was 11.5 inches thick and 19 inches...
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Pressure/Leak Test gone bad (improper Torque)
On July 26, 2006, Employee #1 performed a pneumatic leak test on a 6-in. diameter, Schedule 40, jacketed, steel pipe, after coworkers welded sections of it. Employee #1 then secured a test tree on the end of the pipe with an adjustable wrench, then pressurized the pipe, and checked it for leaks for ten minutes. After the pipe passed the leak test, Employee #1 tried to bleed pressure from the pipe....
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This is WHY we do NOT use the Hazardous Material for our pressure/leak testing
At 2:00 p.m. on March 15, 2018, Employee #1 was conducting a leak test. Sulfuric acid sprayed out and onto the employee. He suffered chemical burns to his legs and thighs and was hospitalized. Source: https://www.osha.gov/ords/imis/establishment.inspection_detail?id=1340616.015
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Fire Watch dies from burns!
Way too many have a serious lack of respect for the hazards a “Fire Watch” may face. I say this, because in my years of experience, I almost always find the “fire watch” role is assigned to the youngest, least experienced, and lowest paid person on the job. In many situations, these workers are NOT actually trained in how to be a “fire watch”. Often times we will...
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Vessel Opening gone bad (Zero Energy State not obtained)
At about 2:45 a.m. on March 13, 2001, Employee #1 and Employee #2, two operators, and Employee #3, a maintenance mechanic, were assigned the task of cleaning out a waste vessel, KD 502A. The three employees were removing the flange to the pot, and had removed several of the 44 bolts holding the flange, when the pressure in the vessel was violently released, killing all three of the employees. …...
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14 psi can be "catastrophic" in a tanker truck
At 1:30 a.m. on December 6, 2024, a truck driver, 53, was unloading 40,000 pounds of salt from a dry bulk pneumatic trailer into salt brine tanks. The driver attached the truck’s power take-off to pressurize the trailer and connected the unloading hose to Salt Brine Tank #1. While standing near the pressure gauges on the driver’s side of the trailer, the dry bulk trailer suddenly exploded....
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Hot Work Explosion Fatality (Angle Grinder removing bolts on manway)
At 2:45 p.m. on April 17, 2023, an employee and a manager, 49, were attempting to drain a stillage tank so that repairs could be made to its internal agitator. They needed to verify the quantity level of stillage, so they attempted to remove a manway access cover on top of the tank. They encountered two bolts that were stripped, so they used an angle grinder to cut the top of the bolts off. …...
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