On July 14, 2009, Employees #1 and #2 were performing a pneumatic test to verify leak tightness of a new pipeline meter station. The test medium was nitrogen gas, and the system being tested included piping and two (2) pressure vessels. Numerous leaks were found in the system during the test. The system reached the required test pressure of 2225 psig at approximately 3:25 p.m., and Employee #1 observed...

At 3:00 a.m. on February 19, 2020, Employee #1, 30, was using a torch to “dry” his shirt after spilling isopropanol on it. The employee’s shirt caught on fire, and the employee picked up the shirt in an attempt to extinguish the flames. The employee started to spin the shirt in his left hand and, in the process, caught the back of his pants on fire. The employee was doing this...

On July 23, 2020, an employee, 30, was looking into a vessel being filled with chemicals, including Isopropyl alcohol, to ensure the level of the mixture was above the blades before turning on the mixers. The access port was mounted with one bolt so the employee could rotate the cover to look in. The employee turned on a small flashlight and was looking into the access port when a chemical explosion...

On July 12, 2024, an employee, 74, at a campground resort was attempting to add sodium hypochlorite to a bulk supply container to recharge the swimming pool. The employee added sodium hypochlorite to a container of sulfuric acid and was overcome by the vapors generated by the mixture. The employee was killed due to the inhalation of chlorine gas vapor generated by the mixture. … HomeRead...

On July 13, 2024, Employee #1, 41, entered a manhole to tape piping in preparation for pouring concrete inverts. Shortly after entry, a coworker stationed topside observed that Employee #1 appeared pale and profusely sweating. When asked, Employee #1 indicated difficulty breathing. As Employee #1 attempted to climb the steps to exit the manhole, he experienced a medical incident, lost consciousness,...

The Facility is a colloidal and polymer blend manufacturing facility. The Facility has used Epichlorohydrin and Dimethylamine to manufacture chemicals on site since at least 1999. The Facility maintains a maximum inventory of 235,000 pounds of the regulated toxic substance Epichlorohydrin, as determined under 40 C.F.R. § 68.115, which exceeds the threshold quantity of 20,000 pounds of Epichlorohydrin...

I have limited experience with this method of isolating piping, but it is fairly often used to isolate large-diameter piping. OSHA’s investigation found that a drainpipe cleaning and maintenance company could have prevented an explosion at a Port Saint Lucie worksite in June 2024 that claimed a 24-year-old worker’s life by implementing proper safety measures to address the hazards of inflatable...

The termination of the rulemaking is effective January 15, 2025. Basis for Terminating the Rulemaking … HomeRead More »

I have these debates on a regular basis: ” We can not put an isolation valve before or after a Pressure Relief Device (PRD).” And that would be an incorrect statement. Yes, placing an “intervening valve” in a PRD path (before or after the PRD) can be risky; however, in some situations, these valves are necessary for maintenance on the PRD without having to drain the entire system...

In 2025, one would hope we would be beyond these failures. But when the price is more critical than UL/FM approval or even an attempt to comply with Fire Codes and OSHA, we will inevitably end with a chuck of metal rather than a functioning flammable liquids storage cabinet. See if you can spot the deficiencies in this brand-new cabinet: … HomeRead More »

PPE is our LAST LINE of defense, and this means we better have the BEST PPE available and be trained in its care, use, donning/doffing, and limitations. Just because it’s last in the Hierarchy of Controls does not mean we can overlook its significance. … HomeRead More »

A soap and detergent manufacturer faces $161,310 in federal penalties after an OSHA investigation of a chemical gas release that sent a dozen workers to the hospital in July 2024. OSHA initiated an inspection on July 11 after being notified by the Pennsylvania Emergency Management Agency and the facility’s operator about an incident involving a release of nitrogen dioxide gas. The release occurred...