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Line Break Gone Bad (Worker misidentified flange that needed unbolting)
A worker on a contracted maintenance crew at an oil refinery partially unbolted a flange on a live crude oil heat exchanger. An undetermined volume of oil was released. Another worker, a refinery employee who participated in the incident response, was exposed to the resulting crude oil vapors, which are believed to have contained hydrogen sulfide (H2S). The second worker sustained injuries from the...
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Screenshot
Acetylene inside the work van ignites
An auto repair worker was walking toward his mobile service vehicle, which contained an oxyacetylene welding system, to start work for the day. When he was approximately 32 ft. away, he clicked a button on the key fob to unlock the vehicle remotely. The vehicle immediately exploded and burst into flames. No one was injured in the explosion; however, surrounding vehicles and property were extensively...
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Cheat Sheet for PSIA, PSIG, Inches of H20, mm Hg
To accurately understand pressure measurements in industrial safety and process engineering, it is essential to distinguish between absolute pressure and gauge pressure, as well as the units commonly used for low-pressure monitoring (such as draft gauges or vacuum systems). The following table provides the conversion relationships between these units, referenced against standard atmospheric pressure...
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Hydrogen is becoming a popular fuel, and the 2024 IFC provides us with an excellent baseline design for these H2 systems
I have worked with three (3) organizations in the past 5 years on their efforts to make H2 an everyday fuel for household appliances, vehicles, and industrial fuels. Each project was a huge learning experience for everyone! But I am a lover of “codes” to establish the baseline design, construction, operation, and maintenance. I looked to my IFC for guidance, and I was not let down....
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WA Paper Mill Event
Understanding an "implosion" (i.e., vacuum) on an atmospheric storage tank
We keep hearing how the tragedy in WA state at the Papermill was some type of tank implosion and then explosion. I have serious doubts about that theory. I think this was just a simple seam/weld failure, possibly caused by Stress Corrosion Cracking (SCC), but I am sure the CSB will get to the bottom of this failure in due time. I come to this conclusion based on all the pics and videos we’ve...
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WRONG CHEMICAL - WRONG TANK event @ WTP
An odor incident at the Gallipolis Water Treatment Plant was triggered by the accidental mixing of two treatment chemicals during a delivery. The incident was isolated entirely to the plant, and officials confirmed there was no threat to the public water supply or drinking water. Incident Breakdown Date & Time: The incident was reported to 911 at approximately 11:24 a.m. The Cause: Water...
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Failure Modes for White Liquor Tank @ Papermills
So I was curious as to how a 900,000-gallon white liquor tank could catastrophically fail. I am certain we will learn how this specific failure occurred, but I am not convinced the learnings will be shared broadly if the CSB does not get involved. With this much damage to people and property, there will be a desire to contain as much information as possible, which will not be flattering to the business....
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Don't kid yourself, there is NO SMS in place if the facility is not audited on a routine basis (Learning the hard way)
In the context of a Safety Management System (SMS), auditing is the systematic, independent, and documented process for obtaining objective evidence and evaluating it against established criteria to determine the extent to which requirements are fulfilled. I recently had a lengthy discussion with the executive team regarding my PSM/RMP audits over the years. These men and women are at the highest...
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Worker burned after safety failures triggered a violent LPG release at a shipping terminal
A ship’s engineer sustained cold burns to 10–13% of his body surface after liquid propane was released without warning in the early hours of 1 November 2018 during loading operations. A flammable gas cloud could have resulted in a catastrophic explosion if ignited. The worker was treated at the hospital and subsequently repatriated to Russia, where he received further treatment. He is understood...
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Using 35°F - 50°F dew point compressed air in Hot Oil Boiler piping pressure/leak tests is a serious FAILURE
We get so much slack when we push Hydrostatic Pressure/Leak Testing vs. Pneumatic testing. So many think that pneumatic is easier and cheaper, when in reality it is NOT. In fact, the B31 series makes it clear that HYDROSTATIC is the first choice for pressure and leak testing. The code makes it clear that pneumatic is for when the piping pressure and leak test can NOT be done by the hydrostatic method...
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Preliminary Findings in Robbins Lumber Fire and Explosion Investigation
FMO Releases Preliminary Findings in Robbins Lumber Fire and Explosion Investigation FMO Investigators and ATF Special Agents worked throughout the Memorial Day weekend at the scene of the Robbins Lumber fire and explosion in Searsmont. During that time, personnel paused to honor Morrill Firefighter Andrew Cross and remember military members who made the ultimate sacrifice in service to their communities. The...
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WA Paper Mill Event
Fatal White Liquor Tank Failure at WA Papermill
Prayers to all involved, but things at the WA State Paper Mill are looking far more serious than what the media is saying. This is looking like a “white liquor tank” event based on the images I have seen (SAFTENG members can see them below). Emergency responders have confirmed: 10 individuals were transported to area hospitals:-8 employee injuries,-1 firefighter injury-1 fatality Officials...
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