Chemicals are forms of matter with a constant composition and properties. Virtually everything that physically exists is made up of chemicals, or a mixture of multiple chemicals. For this reason, chemicals are incredibly important in the process industries. Along with virtually every other industry in the world.
Chemical processing describes the process by which one chemical composition is transformed into another. The multi-billion dollar Chemical Processing Industry manufactures, processes, and produces various types of chemicals, chemical substances, and products. These include petrochemical and inorganic chemicals, pharmaceuticals, industrial gases, plastics, rubbers, detergents, paints, coatings, pigments, and many others. The chemical processing industry is essential to the modern global economy and plays a vital role in almost every other industry in existence.
In 1992, OSHA issued the Process Safety Management of Highly Hazardous Chemicals standard (29 CFR 1910.119). This regulation contains requirements for the management of hazards associated with processes using highly hazardous chemicals. Among other things, it requires operators to keep written safety procedures when dealing with dangerous chemicals. It also requires they create and implement an action plan in case of emergencies.
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Blog
August 27, 2020 By Inspector Frank
Who is Inspector Frank? It is a valid question but I don’t want it answered specifically for some obvious reasons. I will share what I can though... |
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June 25, 2020 By Inspector Frank
Trying too hard to bring attention to the myriad concerns of a robust equipment integrity program can end up backfiring on you. You don’t want to be the “inspector who cried wolf” with no one listening when you actually have a problem. |
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Blog
April 3, 2020 By Frank-Uwe Hess at T.A. Cook Consultants
COVID-19 is disrupting all industries including asset management. Here are 6 recommendations to help you align your asset management according to new requirements and turn the challenges into opportunities. |
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Blog
February 27, 2020 By Inspector Frank
In a nutshell, Schwerpunkt means focusing your force in the area it will be the most effective. As a strategy, it means overall strategic intent has to be known and understood by everyone. All levels know their part in the plan. |
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Blog
February 11, 2020 By Abby King at Becht
When paired with the right software, the RBWS process can lead to significant reductions in turnaround work scopes. However, some software tools have distinct advantages over others. |
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December 26, 2019 By Inspector Frank
I once worked with a chief inspector who refused to hire anyone who had any National Board inspection certifications. “Why?”, you might ask. I had the same question, and his response was “Because anyone with National Board is gunning for my... |
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December 9, 2019 By Calvin Jory at Olympus America
This article discusses two common challenges for inspectors taking thickness readings in high temperature environments and ways to overcome those challenges. |
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October 31, 2019 By Inspector Frank
Critical things often get missed in facilities but are these things being owned and fixed? We get good at reactively solving problems as they appear, but are we proactively working towards examining and fixing the potential larger issues? |
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October 3, 2019 By Arcot (Radha) Radhakrishnan at Becht
Developing a comprehensive turnaround (TA) work scope for process equipment is a critical step for achieving a facility's business goals. Risk Based Work Selection is a proven process for prioritizing and optimizing planned work for an impending TA. |
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Blog
September 17, 2019 By Arcot (Radha) Radhakrishnan at Becht
Risk Based Work Selection (RBWS) is an industry best practice used to help refiners better-manage the safety and reliability of operations for a facility. When properly conducted, RBWS can help refiners optimize major turnaround projects. |
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August 29, 2019 By Inspector Frank
Just because you have a technical expert does not mean they will be an expert at managing people. Like any skill set, it takes training, time, and mentoring to become a good personnel manager. |
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May/June 2019 Inspectioneering Journal
By Andres Salazar at WorleyParsons
This article details an experience assessing the mechanical integrity of a feed pressure vessel, and describes the methodology carried out for detecting CUI and how results were managed for this pressure vessel. |
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Blog
June 27, 2019 By Inspector Frank
This is the first article in a new column. In each article, the author will share technical, thought-provoking, and sometimes humorous or emotional experiences garnered in a career that spans over 20 years inside the gates of facilities. |
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May/June 2018 Inspectioneering Journal
By Chad Patschke, CPSA at Ethos Mechanical Integrity Solutions
According to API 570, facilities must have a mechanical integrity program in place for critical check valves. But what criteria determines whether or not a check valve is critical in your process? How should check valves be inspected and by whom? |
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March/April 2018 Inspectioneering Journal
By Simon Yuen, P.E. at Suncor Energy Inc., and Ken Gottselig at BP America Production Company
Hot spots – localized areas of overheating in pressure equipment – can lead to deformation or even loss of process containment. It is important to understand the effects of elevated temperature caused by hot spots on the mechanical integrity of... |
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March/April 2018 Inspectioneering Journal
By John Reynolds at Intertek
This article is designed to help the reader better communicate their FEMI Mission, Vision, Core Values and Responsibilities to all stakeholders at their site. |
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January/February 2018 Inspectioneering Journal
By Kyle Dunn at Dunn Heat Exchangers, Inc.
Cleaning of heat exchangers and other process equipment is typically done with the use of pressurized water (e.g., hydro-blasting). However, in some situations thermal decomposition, a technique that utilizes heat rather than water to break down... |
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January/February 2018 Inspectioneering Journal
By Phillip E. Prueter at The Equity Engineering Group, Inc.
Given the concern throughout industry regarding the potential for brittle fracture failures, PWHT guidance to address potential issues arising from the recent changes in PWHT code requirements for carbon steel is examined in this article, and... |
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December 19, 2017 By John Reynolds at Intertek
Industry SME John Reynolds provides his bi-annual updates from the API Standards Meeting and discusses developments related to the 2019 API Inspection Summit, SCIMI codes, standards, and recommended practices, and the API Individual Certification... |
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May/June 2017 Inspectioneering Journal
By Ryan Myers at Pinnacle, and Brian Marino at Pinnacle
Effective condition monitoring location selection is a key component of a best-in-class mechanical integrity program. Learn how moving beyond traditional qualitative approaches to optimized CML selection can reduce risk and maximize the value of... |
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May/June 2017 Inspectioneering Journal
By David E. Moore at Becht, PONO Division
Read a firsthand account of how organizing Process, People, Plant, and Performance can reveal breakdowns in your corrosion management practices and drive down corrosion related leaks. |
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June 1, 2017 By Nickole C. Winnett at Jackson Lewis P.C.
The U.S. Occupational Safety and Health Administration (OSHA) has issued two reports on the safe management of hazards by small businesses and storage facilities that use highly hazardous chemicals in business processes. |
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March/April 2017 Inspectioneering Journal
By Fernando Vicente at ABB, and Laza Krstin at ABB
Myths, challenges, and good practices related to process piping integrity management activities that help inspection and maintenance managers make the right decisions to develop cost-effective piping inspection plans without compromising the... |
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January/February 2017 Inspectioneering Journal
By Edwin A. Merrick, PE at The Augustus Group
This article presents a perspective on the human factor and emphasizes the value of using risk tools at all levels in the organization to help provide management focus during times of severe economic pressure. |
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January 3, 2017 By Jeremiah Wooten at Inspectioneering, LLC.
At the end of every year, the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA) releases a list of the 10 most frequently cited safety and health violations for the fiscal year, comprised from approximately 32,000... |
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January/February 2016 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal
The enormous decline in oil prices over the past 14 months has definitely slowed projects and changed the energy and production landscape. Despite this, refineries, petrochemical plants, and chemical facilities must continue to run safely,... |
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January 4, 2016 By Jeremiah Wooten at Inspectioneering, LLC.
We at Inspectioneering would like to take this opportunity to thank all of our subscribers, followers, clients, and industry partners for a great 2015, and wish every member of the Inspectioneering community a happy and healthy 2016! |
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July/August 2015 Inspectioneering Journal
By John Reynolds at Intertek
Rarely is there a new and unknown cause of a major Fixed Equipment Mechanical Integrity (FEMI) failure in the petrochemical and refining industry. This article briefly summarizes five major fixed equipment mechanical integrity (FEMI) failures from... |
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May/June 2015 Inspectioneering Journal
By Amanda Nurse at BP, and Josh Havekost at BP
Assessing risk is an integral part of working at a refinery. Infrastructure supporting the miles of piping, process vessels, and the platforms and ladders used in daily unit operations are often taken for granted. The Civil Structures Management... |
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Online Article
Michael Heard, Risk Engineering Advisor, Process Safety / Technical Safety / Environmental at Hess Corporation recently spoke with marcus evans about key topics to be discussed at their upcoming Facility Siting and Risk Mitigation for Processing... |
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March/April 2015 Inspectioneering Journal
By Walt Sanford at Pinnacle
Today, many managers are finding that they can address the reliability of all types of assets by combining RBI and Reliability Centered Maintenance (RCM) processes together into one comprehensive reliability management process. |
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March/April 2015 Inspectioneering Journal
By Andy Kates at Versa Integrity Group
Rope access allows for a wide variety of work to be performed at high elevations or other hard to reach areas without the use of scaffolding or heavy equipment. It has evolved from techniques used in rock climbing and caving to become an extremely... |
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March/April 2015 Inspectioneering Journal
By Jeremy Wimberly at Sentinel Integrity Solutions
Refractory materials have significantly evolved during the past 15 years, testing technology is much more sophisticated, and the need for test technicians to be properly trained and experienced to use that technology is much more important than it... |
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March/April 2015 Inspectioneering Journal
By A.C. Gysbers at The Equity Engineering Group, Inc.
The tubes of heat exchangers (HX), whether for a shell and tube bundle or an airfin, are typically subject to some form of nondestructive examination (NDE) to try and quantify the remaining wall thicknesses and corrosion rates to help a plant to... |
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March/April 2015 Inspectioneering Journal
By Matt Midas at GenesisSolutions
With the advancements in today’s technology and improvements to Enterprise Asset Management (EAM) systems and Computerized Maintenance Management Systems (CMMS), if we deploy them properly and in line with best practices, it is possible to reach... |
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March/April 2015 Inspectioneering Journal
By Nick Harwood at Aetos Group, and Aaron Cook at Aetos Group
The ability to gain this unique perspective has recently become easier and safer with today’s technological advancements. This new technology comes in the form of a miniature flying machine, better known as a drone or small Unmanned Aerial System... |
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January/February 2015 Inspectioneering Journal
By Pamela Hamblin at Thielsch Engineering, Inc.
Avoiding cracking under pressure when managing high-energy piping systems is common subject matter in the power industry. Just as high-energy piping can give way to pressure, stress and fatigue, so can the people in charge of operating them when... |
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January/February 2015 Inspectioneering Journal
By Harold Marburger at Dunn Heat Exchangers
Whether onsite or offsite, the methods for cleaning shell and tube heat exchangers can vary. Refining and petrochemical operators will agree that high standards must be employed with each method. Choosing the right method can make the difference... |
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January/February 2015 Inspectioneering Journal
By Fred Schenkelberg at FMS Reliability
Reliability engineering tools and concepts can be used to avoid or delay failures, thus increasing product service life. Design or maintenance teams use reliability engineering techniques to identify failures and their causes. |
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January/February 2015 Inspectioneering Journal
By Clint Rupert at Engineered Resin Solutions (ERS)
Epoxy products have gone through extensive research and development over the years, and have reached the point that when specified for the correct environment, they should perform exactly as intended. |
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January/February 2015 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal
Challenges abounded in 2014 for the process industries, and it does not look like they will let up soon. But then again, that’s life, as they say. After 40 years in the industry the old adages still ring true, “there is nothing new under the... |
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November/December 2014 Inspectioneering Journal
By Scott Corey at Sentinel Integrity Solutions Inc.
One of the major challenges inspectors and plant operators face after each turnaround is to ensure that all repair and scope work is and was completed in accordance with the client’s requirements. Sometimes that verification will be to ensure work... |
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November/December 2014 Inspectioneering Journal
By Rajesh Bose at BP, and Terry M. Webb at BP
The introduction of PAUT is a challenging effort initially, but can have a very positive impact on your first TAR and become a routine inspection for future TARs. When fully implemented, radiation safety boundaries can be reduced significantly or... |
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November/December 2014 Inspectioneering Journal
By Kelsey Hevner at Quest Integrity Group
Steam reformers are critical assets for the successful operation of hydrogen, ammonia, and methanol plants. The steam reformer is also one of the most expensive assets in these facilities. Catalyst tubes inside the reformer are one of the most... |
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July/August 2014 Inspectioneering Journal
By A.C. Gysbers at The Equity Engineering Group, Inc.
One of the more common inspection monitoring programs for pressure vessels is to perform thickness measurement at Corrosion Monitoring Locations (CMLs) to allow monitoring of minimum thicknesses and provide estimates for corrosion rates. These... |
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Blog
March 3, 2014 By Greg Alvarado at Inspectioneering Journal
In many ways, fertilizer plants are no different than most process industry plants including refineries and petrochemical facilities. Information in documents like API 510, 570, 653 and RPs 580, 581, 571, 577, 579, etc. is essential. |
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March/April 2013 Inspectioneering Journal
By Thomas Fortinberry at Quest Integrity Group, and James R. Widrig at Quest Integrity
Steam reformers are critical assets to many refining and chemical manufacturing plants and facilities, and it is well known that the reformer is one of the most challenging assets to maintain and operate. Common problems in reformer operations... |
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July/August 2010 Inspectioneering Journal
By Craig Emslie BSc at Sonomatic Ltd., and Karen Gibson at Sonomatic Ltd.
Inspection intervals for equipment have in the past been defined in a prescriptive manner. However, industry is now embracing the Risk Based Inspection (RBI) approach which in contrast prioritises inspections based on an assessment of the risk to... |
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September/October 2000 Inspectioneering Journal
By T.C. Ridgeway & Staff at TCRI
In part 1 of this article we covered the importance of quality assurance of UT data, that is, understanding for each particular application, the accuracy required of the UT data, and new ways/graphical program to analyze and show the... |
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January/February 1999 Inspectioneering Journal
By Joseph E. Pascente at Lixi, Inc.
One of the greatest challenges facing many of refining, fossil power, and pulp and paper industries is: How to effectively examine their insulated piping? |
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September/October 1998 Inspectioneering Journal
By Bernie Weber at Det Norske Veritas
Quality failure rate data have long been needed by the Chemical Process Industry. Unfortunately, the emphasis too often has been on the collection of data rather than on its uses . One must answer the question of what to do with the data once it has... |
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September/October 1997 Inspectioneering Journal
By John Reynolds at Intertek
This is the fourth in a series of articles on piping inspection that I'm writing for the Journal. One of the previous ones dealt with improving thickness data taking accuracy with digital ultrasonic methods. This article is a "sister article" that... |
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March/April 1997 Inspectioneering Journal
By John Reynolds at Intertek
This is the second in a series of articles on piping inspection. In the last article, I enumerated four inspection issues that I believe contribute to inadequate piping mechanical integrity in the hydrocarbon process industry. |
As the United States faces this year's hurricane season, it is critical that the chemical industry understands and prepares for the potential safety hazards posed by extreme weather events.
This CSB video details the events leading up to the August 31, 2017 fire at the Arkema chemical plant in Crosby, Texas. The incident led to all employees and more than 200 nearby residents being evacuated for a week.
The U.S. Chemical Safety Board (CSB) has released a new 11-minute safety video describing the events leading up to the October 21, 2016 toxic chemical release at the MGPI Processing plant in Atchison, Kansas. The video, titled "Mixed Connection,...
The U.S. Chemical Safety Board released a preliminary animation detailing the events of the chemical fires at the Arkema chemical plant in Crosby, Texas after it suffered power loss due to Hurricane Harvey's historic rainfall.
Effective pipeline integrity management has been problematic for a large number of pipelines that were not designed for in-line inspection. Quest Integrity understands the complexities involved with this challenging segment and offers a...
The U.S. Chemical Safety Board (CSB) has released a video demonstrating the agency's positive safety impact in 2016. The video was posted just days after President Trump proposed his "America First" budget plan, which calls for the elimination of...
The U.S. Chemical Safety Board (CSB) has released a safety video into the fatal April 17, 2013, fire and explosion at the West Fertilizer Company in West, Texas, which resulted in 15 fatalities, more than 260 injuries, and widespread community...
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Partner Content
Our proprietary furnace tube inspection system, FTIS is an ultrasonic inspection technology capable of rapid, automated fired heater coil inspection in refinery fired heaters. The data captured by our furnace tube inspection system is... |
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News
DuPont, April 21, 2021
DuPont is investing approximately $30 million to build a new adhesives manufacturing facility in East China to serve customers in the transportation industry. |
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Partner Content
LOTIS utilizes laser profilometry to conduct internal steam reformer tube inspections. The data captured by LOTIS is exceptionally powerful when combined with our LifeQuest™ remaining life assessment capabilities, providing an integrated... |
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Partner Content
InVista is a lightweight, hand-held ultrasonic in-line inspection tool (intelligent pig) capable of detecting pipeline wall loss and corrosion in unpiggable or difficult-to-inspect pipelines. The pipeline geometry inspection data captured by the... |
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CNN, December 9, 2020
One person died and three others were injured in an explosion and a fire that occurred in a chemical plant in Belle, West Virginia, on Tuesday night, officials said. |
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Evonik, May 14, 2020
Evonik has successfully commissioned an advanced biomaterials facility for pharmaceutical and medical applications in Birmingham, Alabama. |
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INEOS, March 12, 2020
INEOS is enacting a series of ‘social distancing’ measures in order to protect its employees who play a vital role in the production of essential products |
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Reuters, March 2, 2020
Arkema and three executives are facing criminal charges in Texas stemming from the 2017 fires at the Arkema SA plant outside of Houston. |
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Celanese Corporation, September 23, 2019
Celanese experienced a fire at its Clear Lake facility in Pasadena, TX over the weekend. There were no injuries reported in the incident. |
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Evonik Industries AG, September 19, 2019
Specialty chemicals company Evonik has officially begun construction on its largest investment to date in Germany. |
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Reuters, August 13, 2019
Royal Dutch Shell Plc will begin restarting units at its Norco, Louisiana chemical and refining facilities this week following overhauls. |
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Reuters, July 15, 2019
A unit at Royal Dutch Shell’s Pulau Bukom refinery and petrochemical complex experienced an operational upset on Sunday, a company spokeswoman told Reuters on Monday. |
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Sasol Limited, July 12, 2019
Sasol recently announced the opening of its new alkoxylation plant in Nanjing, China, which will more than double its alkoxylation production capacity in the region. |
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INEOS Phenol, July 11, 2019
INEOS Phenol has announced it will build a world scale, state of the art cumene unit in Marl, Germany, to be completed in 2021. |
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INEOS, June 3, 2019
INEOS will invest $2 billion in building its first ever manufacturing plants in Saudi Arabia, in what is believed to be one of the largest UK investments ever in the Kingdom. |
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Sasol, June 3, 2019
Sasol has announced the beneficial operation of its new ethylene oxide (EO) production facility at its Lake Charles Chemicals Project (LCCP) |
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Inspectioneering Staff, May 22, 2019
United Rentals' charity sporting clays tournament raises $20,000 for local veterans organization Fisher House. |
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WorleyParsons, April 29, 2019
WorleyParsons has officially completed its US$3.2 billion acquisition of Jacobs ECR, and adopted ‘Worley’ as its new brand. |
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Halliburton Company, February 21, 2019
Halliburton Company recently announced it will build the first oilfield chemical manufacturing reaction plant in Saudi Arabia. |
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Partner Content
Download Pinnacle's Economics of Reliability Report - Refining to see how reliability is affecting profitability. |
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News
U.S. Chemical Safety Board, August 30, 2016
An investigative team from the U.S. Chemical Safety Board (CSB) is deploying to the scene of an incident that fatally injured one worker at an Airgas facility near Pensacola, Florida. |
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U.S. Occupational Safety & Health Administration, August 5, 2016
The U.S. Department of Labor's Occupational Safety and Health Administration has found three repeat and eight serious safety violations at Solvay Specialty Polymers' chemical facility in West Deptford, New Jersey. |
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News
U.S. Chemical Safety Board, January 28, 2016
The US Chemical Safety Board (CSB) will vote on its final report and safety recommendations on the 2013 West Fertilizer fire and explosion at a public meeting at 6:00 p.m. tonight in Waco, Texas. The meeting will be available via webcast at... |
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News
U.S. Chemical Safety Board, January 15, 2016
The U.S. Chemical Safety Board (CSB) will convene a public meeting on Thursday, January 28, 2016, in Waco, Texas, at the Hilton Waco from 6 to 9 p.m. CST to present the investigation report and safety recommendations from the April 17, 2013,... |
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U.S. Chemical Safety Board, September 21, 2015
The U.S. Chemical Safety Board (CSB) will convene a public meeting on Wednesday, September 30, 2015, in Houston, Texas, at The Hilton Americas – Houston Hotel from 6 to 9 p.m. CDT to hear and vote on investigators’ findings and safety... |
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News
U.S. Chemical Safety Board, June 30, 2015
The U.S. Chemical Safety Board (CSB) has recently voted unanimously to update the status of fifteen safety recommendations resulting from nine accident investigations, including... |
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US Chemical Safety Board, December 1, 2014
Today the U.S. Chemical Safety Board (CSB) formally announced that to “Modernize U.S. Process Safety Management Regulations” is the Board’s newest Most Wanted Safety Improvement, concluding that implementation of key federal and state CSB... |
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US Chemical Safety Board, November 17, 2014
According to DuPont officials and media reports, four people were killed when methyl mercaptan, a toxic chemical used as feedstock to make insecticides and fungicide, was released into the air. |
