Process Safety Management (PSM) is a regulation issued by the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA). The regulation is designated as OSHA 1910.119, Process Safety Management of Highly Hazardous Chemicals. Its purpose is to prevent or minimize the consequences of releasing hazardous chemicals in a facility or the environment surrounding a facility. Hazardous chemicals are those that may be toxic, reactive, flammable, explosive, or a combination of these properties. Industries handling hazardous chemicals are required to develop an effective PSM program that protects employees, contractors, and visitors of the facility. These industries include: petrochemical, pharmaceutical, paints, adhesives and sealants, food processing, industrial organics and inorganics, and paper mills.
How do companies know they are complying with the OSHA regulation when implementing a PSM program? To answer this question, companies should be familiar with the following 14 elements that are required for PSM program compliance. These elements are the minimum requirements extracted from OSHA 1910.119 [1]. All information (date, equipment, personnel, process safety information, and process hazard analyses) should be recorded and stored in the event that future audits need to refer back to historical information about the facility and equipment.
All employees that play a role in facility operations should be involved in a PSM program. Each of the following elements requires a competent and experienced team of individuals. Ideally, a team should include at least one person who specializes in the specific process being used.
The PSI element requires that employers collect and document highly hazardous chemical (HHC) information before conducting a process hazard analysis. This information pertains to the chemicals, technology, and equipment used in the process. Furthermore, the information should be accessible to all employees in order to understand the HHC related risks they may face during the job.
A PHA is performed by a team of engineering and maintenance experts that are able to identify, evaluate, and control hazards. PHAs can be conducted using a number of techniques, including:
Additionally, it’s important to make sure PHAs are performed in a timely manner as teams are expected to complete a certain amount of the analysis by specific deadlines. PHAs should be performed at least every 5 years [1].
Companies should document all operational procedures involving initial startup, normal operations, temporary operations, and emergency shutdowns. Operators should be aware of the operating limits of the process, the consequences if the process deviates from normal conditions, and be prepared to correct deviations when necessary.
Employees should be trained on procedures, safety factors, and health hazards specific to the job task. Certification programs may help ensure that individuals are competent in specialized areas relative to their practices. Additionally, some practices require on-going training as methods and best practices continue to develop.
Companies should evaluate a contractor’s safety performance prior to starting a project (e.g. repair, turnaround, or renovation). Once a contractor passes clearance requirements, it is the responsibility of the company to inform the contractor of potential risks and health hazards related to the contractor’s project. The contractor’s responsibility is to inform the incoming contracted team of risks and health hazards and to ensure contracted employees have received and understood necessary training.
Companies are required to perform a safety review before new or modified facilities begin production. The pre-start up safety review confirms that an initial PHA has been performed and that all safety, operating, maintenance, and emergency procedures meet the requirements of codes, standards, and specifications [1].
Routine inspections are required for major process units and equipment, such as pressure vessels, storage tanks, piping systems, relief and vent systems, emergency shutdown systems, control systems (e.g. monitoring devices and sensors), and pumps to ensure the mechanical integrity of the component meets requirements. All inspections and tests need to be well-documented and must follow recognized and generally accepted good engineering practices (RAGAGEP).
This mandate requires that employers issue hot work permits for personnel performing high-temperature operations on equipment (e.g. welding).
A company needs to have an organized and efficient process for managing procedural changes regarding process chemicals, technology, and/or equipment. Under the OSHA 1910.119 standard, each change requires that the following considerations be addressed:
Investigations should be performed on incidents that resulted in (or could have resulted in) catastrophic HHC release. Incident investigations should report:
Companies are required to develop and implement emergency action plans for the entire facility. Emergency plans include procedures for mitigating large and small releases of HHCs.
Individuals should recertify their credentials at least every three years to keep up-to-date with evolving practices and technology. This element also states that companies should retain the 2 most recent compliance audit reports.
This mandate ensures that employees involved in elements 2-13 have access to the information about the process and health risks they may encounter during the job.
Is this definition incomplete? You can help by contributing to it.
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Blog
January 3, 2019 By Nick Schmoyer at Inspectioneering
The U.S. Department of Labor provides a vast amount of raw data related to OSHA activities (inspections, violations, etc.) through their website. What follows is a quick summary of 2016-2017 OSHA violation data pulled directly from the DOL. |
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November/December 2018 Inspectioneering Journal
By Efrain Rios at Fortress Oil & Gas, LLC
This article describes how an international oil and gas company built an inspection data management program for its U.S. operations yielding improved confidence in decision-making information, cost savings through increased efficiency, and an overall improvement in the asset integrity program’s performance. |
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November/December 2018 Inspectioneering Journal
By Mike Asquini at T.A. Cook
This article discussed the importance of an asset management philosophy that integrates software, maintenance tools (RCM, FMECA, RBI, PM, and PdM), data collection, and analytics to improve and optimize asset management through emerging technologies and methodologies. |
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November/December 2018 Inspectioneering Journal
By Tim Hill at Quest Integrity Group
This article provides an overview of the key components in establishing IOWs, the levels of IOW limits, and the basic principles and application of API Recommended Practice 584 to achieve reliable fired heater performance. |
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September/October 2018 Inspectioneering Journal
By James "Chezo" Cesarini, PE at Pro-Surve Technical Services, LLC
The most valuable unit of measure within a turnaround is not money, but time. Successful turnaround planners are now integrating the Detailed Inspection Planner (DIP) within their teams to increase the accuracy of planning and reduce the time required to complete the turnaround. |
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July/August 2018 Inspectioneering Journal
By Stephen J. Thomas at PK Technology
Advancements in technology offer organizations huge opportunities for improvement. However, adoption of new tools can change the way an organization functions. If not properly managed, these changes can lead to wasted time and money and ultimately, failed initiatives. |
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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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May/June 2018 Inspectioneering Journal
By James R. Widrig at Quest Integrity, and James Wilson at Quest Integrity
As assets age and production demands grow, it becomes increasingly critical to implement sustainable long-term AIM strategies and programs. This article dives into the elements that will help ensure the successful management of assets throughout their life-cycle. |
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May/June 2018 Inspectioneering Journal
By Dheeraj Narang at Haldor Topsoe India Pvt Ltd.
This article intends to use a top-down approach of describing RBI methodology and how it fits in a facility management system. The main idea of this article is to provide a comprehensive picture of RBI methodology in terms of basics, technology trends, implementation guidance, and evaluating a potential RBI technology partner. |
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January/February 2018 Inspectioneering Journal
By Mohamed Attia at Saudi Aramco
This article, the first of a multi-part series, discusses the methodology and need for establishing an integrated and holistic framework for managing asset integrity on a day-to-day basis. |
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Partner Content
Industrial Rope Access is a proven method of achieving a safe work position at elevated heights or areas that are difficult to access. When combined with advanced NDE technologies, rope access technicians can substantially reduce the cost of inspections and maintenance activities by virtually eliminating the need for fixed scaffolding. |
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Blog
February 7, 2018 By Daniel J. Grucza at Hunton & Williams LLP
Last October, we saw the State of California implement its “PSM for Refineries” standard and now the State of Washington’s Division of Occupational Safety and Health (DOSH) appears to be following suit, releasing draft language to adopt a rule of its own. This new chapter will only apply to Process Safety Management (PSM) for petrochemical refining facilities. |
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September/October 2017 Inspectioneering Journal
By Daniel Cypriano at Petrobras, and Henrique Ventura at Petrobras
Although value-drivers often differ between facilities, all can agree that effective asset management strategies should lead to better decision making. In this case study, the authors detail how process-based risk management strategies can make for improved use of equipment. |
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September/October 2017 Inspectioneering Journal
By Tata L.N. Murthy at Gujarat State Petroleum Corporation Ltd
Ensuring the integrity of oil and gas assets is a challenge for oil and gas operators. This article discusses several “pillars” of asset integrity management on which successful O&G operations rely, including Material Selection, Process Safety, Inspection, and more. |
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Blog
September 13, 2017 By Jeremiah Wooten at Inspectioneering, LLC.
The U.S. Occupational Safety and Health Administration (OSHA) recently released a new guide to help petroleum refiners comply with its Process Safety Management (PSM) standard (1910.119). The guide presents lessons learned from the petroleum refinery Process Safety Management National Emphasis Program. |
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July/August 2017 Inspectioneering Journal
By Richard W. Prugh at Chilworth Technology (a DEKRA Insight company)
In deflagration incidents, electrical arcs and electrostatic sparks are often considered to be primary ignition sources. However, there are a variety of other ignition sources. Do you consider mechanical equipment and the significant non-electrical ignition hazards they may present? |
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Blog
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 asset’s reliability or performance. |
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January/February 2017 Inspectioneering Journal
By Chuck Provost at Sentinel Integrity Solutions
Some facilities lead the industry with streamlined RBI/IOW programs, and some facilities are just implementing standard calendar-based programs. Both are still susceptible to inspection interval gaps. |
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November/December 2016 Inspectioneering Journal
By Blake Stermer at Sentinel Integrity Solutions
As the industry strives to maintain PSM/OSHA compliance through owner/user mechanical integrity programs, inspection professionals should fully understand technical standards to generate an adequate repair recommendation or request further inspection and testing |
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May/June 2016 Inspectioneering Journal
This paper identifies the attributes and benefits of a data and metrics-driven management system focused on process safety design integrity and reliability relative to loss of primary containment (LOC). This management system process focuses on the four key business drivers of risk (i.e. regulatory compliance, operations, and profits), and involves several distinct business methods involving people, processes, and tools/technology. |
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November/December 2015 Inspectioneering Journal
By Ralph E. King P.E. at Stress Engineering Services Inc., and Brian Olson at Stress Engineering Services Inc.
To ensure the mechanical integrity and fitness-for-service (FFS) of equipment, facility managers, reliability engineers, and inspection technicians must understand the HTHA damage mechanism. |
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September/October 2015 Inspectioneering Journal
By Marc McConnell, P.E. at Pro-Surve Technical Services, and Nolan L. Miller at SASOL North America
If we could measure, understand, mitigate, and most importantly, control corrosion, we can do a better job of keeping the product in the pipes. To accomplish this task, we needed to know what is causing the corrosion and how to control it. |
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Blog
August 10, 2015 By Linda Otaigbe at Jackson Lewis P.C.
OSHA has recently issued three memoranda updating guidance on its Process Safety Management (“PSM”) standard. |
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Blog
June 29, 2015 By Nickole C. Winnett at Jackson Lewis P.C.
A new memorandum released by OSHA provides a list of 16 enforcement considerations that will be considered by an inspector when evaluating whether an employer is meeting the RAGAGEP requirements under the PSM standard. Here are 8 tips for addressing OSHA's new enforcement guidance. |
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Partner Content
Offshore platforms are exposed to some of the roughest conditions on earth and require regular attention to ensure they are structurally sound and safe for continued operation. With so many components and major joints at elevated locations, it is clear why a well-trained rope access technician can be an invaluable resource for offshore operators. |
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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 Plants, August 4-6, 2015 in San Antonio, TX. Here is their exchange. |
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March/April 2015 Inspectioneering Journal
By Walt Sanford at PinnacleART
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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November/December 2014 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal, and Michael O. Nichols at Marathon Petroleum Company
Key Performance Indicators or KPIs are important for businesses to track measurable progress, or a lack thereof, as compared to pre-defined goals or benchmarks. For those of us in the inspection, fixed equipment reliability world, the same holds true. Often the efficacy of our inspection programs is measured against such goals. |
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Blog
December 1, 2014 By John Reynolds at Intertek
One of the reasons we continue to have too many fixed equipment mechanical integrity (FEMI) events in the refining and process industries is the lack of understanding and appreciation by site management for the hazards posed by the 101 FEMI issues. |
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Blog
November 24, 2014 By Nick Schmoyer at Inspectioneering
For over 20 years, OSHA's process safety management (PSM) standard worked to guarantee safe and healthy workplaces in industries that use hazardous chemicals. For most of that time the standard had remained largely unmodified. This all changed last year. |
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July/August 2014 Inspectioneering Journal
By Jeremiah Wooten at Inspectioneering, LLC.
The Province of Alberta has a long history of pressure equipment safety dating back to 1897 when the first boiler laws were introduced to regulate the new technology of steam boilers. Boiler inspectors were hired, and soon thereafter the Alberta Boilers Branch was established as the government organization that administered those laws. |
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July/August 2014 Inspectioneering Journal
By Jerry Crawford at TGC Engineers
Piper Alpha is an offshore oil and gas platform that suffered an explosion in July 1988, still regarded as the worst offshore oil disaster in the history of the United Kingdom. The 25th anniversary of the disaster was commemorated across the country in July of 2013. The accident killed 165 out of 220 crew members, plus two crew from the standby vessel Sandhaven. |
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Blog
July 28, 2014 By John Reynolds at Intertek
Fixed equipment mechanical integrity (FEMI) failures are not caused by damage mechanisms; rather, they're caused due to failure to create, implement, and maintain adequate management systems to avoid failures. Nearly all failures that have occurred in our industry could have been avoided if these human systems were more robust and sustainable in providing the primary layers of protection for FEMI. |
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November/December 2013 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal
It is with sadness that I learned of the passing of one of the world’s greatest authorities on chemical process safety, Dr. Trevor Kletz; a man I deeply respected and admired for his commitment to improving safety, preventing accidents, and saving lives. Although I never met Dr. Kletz, I certainly wish I had. He was a pioneer in the discipline of process safety management, and had the courage and conviction to speak up about industrial shortcomings at times when others would not. He wrote and spoke candidly on causes of industry incidents and provided insight on how to prevent them... |
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September/October 2013 Inspectioneering Journal
By Jeremiah Wooten at Inspectioneering, LLC.
Earlier this year, our friends at Pinnacle Asset Integrity Services hosted a webinar entitled Mechanical Integrity Assessment: Why Bother? The broadcast included discussions on the history and value of asset integrity programs, as well as the evolution of the processes and methods necessary to ensure these programs achieve the objective of decreasing risk to improve safety. We have selected a small sample of these exchanges to present to you because we feel they provide important information regarding the need for mechanical integrity assessments in our industry. |
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Online Article
Though new regulations have changed the way offshore companies operate, the need to make safety part of an enterprise sustainability management strategy has never been more important. As accountability moves higher up the chain of command, operators are coming under increasing pressure to place an emphasis on HSE - especially with regard to human factors and workforce training. At the same time, juggling compliance efforts with daily safety concerns has forced a re- thinking of how to evaluate SEMS and training systems for overall safe operation and to drive strategic decisions. David Munzenmaier, HSE&S Director GOM at Baker Hughes, recently spoke with marcus evans about key topics to be discussed at the upcoming 3rd Annual Offshore Safety & Workforce Capability Assurance Conference, October 2-4, 2013, in Houston. All responses represent the view of Mr. Munzenmaier and not necessarily those of Baker Hughes and its subsidiaries. |
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Online Article
Though new regulations have changed the way offshore companies operate, the need to make safety part of an enterprise sustainability management strategy has never been more important. As accountability moves higher up the chain of command, operators are coming under increasing pressure to place an emphasis on HSE - especially with regard to human factors and workforce training. At the same time, juggling compliance efforts with daily safety concerns has forced a re-thinking of how to evaluate SEMS and training systems for overall safe operation and to drive strategic decisions. Del Forbes, Worldwide Corporate HSE Auditor & Culture Assessor at Noble Drilling, recently spoke with marcus evans about key topics to be discussed at the upcoming 3rd Annual Offshore Safety & Workforce Capability Assurance Conference, October 2-4, 2013, in Houston. All responses represent the view of Mr. Forbes and not necessarily those of Noble Drilling and its subsidiaries. |
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July/August 2013 Inspectioneering Journal
By John Reynolds at Intertek
IÂ have written numerous technical articles addressing how to improve your fixed equipment mechanical integrity (FEMI) program. This time I will deviate from the FEMI technologies and methodologies to address a topic that may be equally important to improving your FEMI program – managing your manager(s). |
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July/August 2013 Inspectioneering Journal
By Holly F. Baker at Baker Inspection Group, L.L.C.
The Process Safety Management Rule (29 CFR 1910.119 - PSM) has long been recognized as a collection of interdependent requirements. In recent reviews of PSM programs by OSHA, it has been shown that two of the most cited elements in agency audits tend to be Mechanical Integrity and Process Safety Information. |
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July/August 2013 Inspectioneering Journal
By Dana Schmidt at STI/SPFA
Tank inspectors and owners, did you know? Each year about 14,000 oil spills are reported, according to the EPA website. It is estimated that there are 618,000 facilities that are regulated under EPA SPCC in the United States. |
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Blog
May 13, 2013 By Greg Alvarado at Inspectioneering Journal
This is my third of three posts on Key Performance Indicators (KPIs) based on requests and discussions on the issue. |
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March/April 2013 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal
A pattern of requests for key performance indicators (KPIs) related to equipment integrity management (IM) programs has appeared on Inspectioneering’s LinkedIn group discussion as well as other industry forums. Furthermore, the topic came up numerous times at the recent API Inspection Summit. Performance is the key. |
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May/June 2012 Inspectioneering Journal
The Mary Kay O'Connor Process Safety Center is currently seeking nominations for the annual Merit Award and Harry West Memorial Service Award, to be presented at the 2012 Annual Symposium. |
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September/October 2011 Inspectioneering Journal
By Barry Snider at Small Hammer Incorporated
Maintenance has been around since prehistoric man fixed a broken, trusted spear instead of fashioning a new one. One concept of maintenance is any activity that extends the useful life or enhances the performance of an item of interest. A broad concept for sure but for most of recorded history, maintenance has been synonymous with fixing or repairing. |
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May/June 2011 Inspectioneering Journal
By Paul F. Schubert, Ph.D. at SGS North America Industrial Services, and Travis Keener, P.E. at SGS North America Industrial Services
Putting off the initial inspection (i.e. baseline) of piping and vessels in a new process unit is both common and problematic. The tendency of owners is to rely on the nominal thickness because the actual original thickness was either not measured or not recorded for calculating corrosion rates after the first wave of thickness readings are taken with the equipment having been in service for some period of time. |
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March/April 2005 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal
We are happy to announce the 10-year anniversary of the inaugural issue of the Inspectioneering Journal! |
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March/April 2005 Inspectioneering Journal
By John Reynolds at Intertek
One of the more important uses of the 99 Diseases of Hydrocarbon Process Equipment is to determine how to safely operate process pressure equipment. Such a work process thereby minimizes the impact of any potential degradation mechanisms (the 99 Diseases), by establishing the appropriate boundaries for long and short-term safe process operation. Such boundaries are called Integrity Operating Windows (IOW's). |
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July/August 1998 Inspectioneering Journal
By Roy Schuyler at DuPont DeNemours, Inc.
Regulatory, civic and competitive pressures require we change to a proactive, rather than a reactive culture or environment with a supportive infrastructure. The concurrent evolution of cultural and infrastructural change relies upon effective leadership, communication and commitment (both philosophically and financially) to create an environment which not only promotes but supports/facilitates (no mixed signals) “healthy” progress, that can be measured. |
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May/June 1996 Inspectioneering Journal
By Rolland E. Stroup at JBF Associates, Inc.
Since OSHA began issuing citations under the Process Safety Management (PSM) standard (29 CFR 1910.119), the relative frequency of citations related to some subsections of the regulation has increased dramatically, while the frequency of others has decreased just as dramatically. Has OSHA changed its focus over time? Will there be new trends in the future? These issues can be better understood by looking at citation history and the continuing deadlines built into the regulation. |
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May/June 1995 Inspectioneering Journal
By David A. Moore, PE, CSP at AcuTech Consulting, Inc., and Dana P. Albert at Acutech Consulting, Inc.
The United States Department of Labor (USDOL) Occupational Safety and Health Administration (OSHA) standard 29 CFR 1910.119, "Process Safety Management of Highly Hazardous Chemicals," has been in effect since may of 1992. To enforce this standard, OSHA has targeted seven industries for which it plans and conducts routine compliance inspections. |
Pro-Surve Technical with subsidiaries ProSource Radiography and ProForce Industrial are an integrated inspection, NDT, reliability engineering, Data management and project controls service provider assisting clients across CapEx/OpEx budgeted projects processes. We concentrate on solutions provided by the integration of engineering and inspection.
Pro-Surve Technical with subsidiaries ProSource Radiography and ProForce Industrial are an integrated inspection, NDT, reliability engineering, Data management and project controls service provider assisting clients across CapEx/OpEx budgeted projects processes. We concentrate on solutions provided by the integration of engineering and inspection.
PK Technology is a full-service inspection contractor, as well as, an in-house software development company specializing in the Oil and Gas industry. PK Technology is the creator of intelliSPEC, the worlds first Digital Data Management System (DDMS) which is a robust and intelligent solution designed to digitize, analyze and realize all vital data.
PK Technology is a full-service inspection contractor, as well as, an in-house software development company specializing in the Oil and Gas industry. PK Technology is the creator of intelliSPEC, the worlds first Digital Data Management System (DDMS) which is a robust and intelligent solution designed to digitize, analyze and realize all vital data.
The U.S. Chemical Safety Board (CSB) has released a new 13 minute video detailing 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. Twenty-one people sought medical attention from reported exposures to the fumes and smoke released into the air.
The U.S. Chemical Safety Board (CSB) has released an animation detailing the events leading up to the February 8, 2017 explosion at the Packaging Corporation of America's DeRidder, Louisiana, pulp and paper mill. The incident killed three contract workers that were performing welding and grinding, referred to as “hot work,” above a tank that contained flammable materials. Seven others were injured.
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, Toxic Result" details key lessons from the CSB's investigation into the 2016 incident.
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.
The U.S. Chemical Safety Board (CSB) has released a new 8-minute safety video describing the events leading to the November 22, 2016 fire at ExxonMobil's Baton Rouge refinery, which severely burned four workers. The video, entitled "Fire in Baton Rouge," details the CSB's Key Lessons stemming from the 2016 incident.
The U.S. Chemical Safety Board (CSB) has released a 3-minute animation describing the events leading to the November 22, 2016 fire at ExxonMobil's Baton Rouge refinery, which severely burned four workers. The fire erupted during maintenance activities in the refinery’s sulfuric acid alkylation unit.
The U.S. Chemical Safety Board (CSB) has released an animation depicting the February 18, 2015 explosion and fire at the ExxonMobil (now PBF Energy) refinery in Torrance, CA.
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 CSB all together.
The U.S. Chemical Safety Board (CSB) has released a safety video detailing its investigation of the June 13, 2013 explosion and fire at the Williams Olefins Plant in Geismar, Louisiana, which killed two workers and injured an additional 167.
Those involved in the implementation or management of mechanical integrity (MI) programs understand the value of good feedback. An effective feedback loop is critical to ensuring your MI program is achieving the desired results.
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 damage. The deadly fire and explosion occurred when about thirty tons of fertilizer grade ammonium nitrate (FGAN) exploded after being heated by a fire at the storage and distribution facility.
U.S. Chemical Safety Board safety video discussing the massive 2009 explosion at the Caribbean Petroleum, or CAPECO, terminal facility near San Juan, Puerto Rico. The incident occurred when gasoline overflowed and sprayed out from a large aboveground storage tank, forming a 107-acre vapor cloud that ignited.
U.S. Chemical Safety Board safety video depicting the accident at DuPont’s La Porte facility, located east of Houston, which killed four workers and injured a fifth when methyl mercaptan, a toxic chemical used in the company’s insecticide and fungicide manufacturing process, was released.
U.S. Chemical Safety Board safety video discussing the fatal April 2, 2010, explosion and fire at the Tesoro refinery in Anacortes, Washington. A nearly 40-year-old heat exchanger violently ruptured, causing an explosion and fire that fatally injured seven workers – the largest loss of life at a U.S. refinery since 2005.
U.S. Chemical Safety Board safety video discussing the 2010 Macondo tragedy where a failed blowout preventer caused a sudden explosion and fire on the Deepwater Horizon oil rig, resulting in the deaths of 11 workers and causing a massive oil spill into the Gulf of Mexico.
U.S. Chemical Safety Board safety video covering the 2009 explosion at NDK Crystal in Belvidere, Illinois, which fatally injured a truck driver at a nearby gas station. The CSB found that the catastrophic pressure vessel explosion resulted from stress corrosion cracking and that the operator not only failed to inspect or test the vessels, but they failed to heed 3rd party warnings about risk to the public.
CSB video excerpts from Dr. Trevor Kletz, a world renowned expert in chemical process safety, who died October 31, 2013.
U.S. Chemical Safety Board safety video: “Inherently Safer: The Future of Risk Reduction”
U.S. Chemical Safety Board safety video detailing a 2010 hot work accident at DuPont Buffalo.
U.S. Chemical Safety Board safety video covering three accidents that occurred over a 33-hour period in 2010 at the Dupont plant in Belle, WV.
As temperatures continue to drop, it's important for process plants to be prepared for the unique safety challenges of subfreezing weather, according to U.S. Chemical Safety Board Chairman John Bresland.
Refineries and chemical plants are facing serious economic difficulties but still need to maintain their focus on process safety, according to U.S. Chemical Safety Board Chairman John Bresland.
U.S. Chemical Safety Board safety video depicts the massive explosion that killed 15 and injured 180 at the BP Texas City refinery in 2005.
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Checklist
The Mechanical Integrity Audit Checklist serves as a companion piece to the Inspectioneering webinar, Auditing My Mechanical Integrity Program, presented by Mr. Reuben Laurel. |
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News
SunHerald, October 17, 2018
A contract worker reportedly died yesterday after a fall at Chevron's 330,000 bpd Pascagoula Refinery. |
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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 solution set for the process and syngas industries. |
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News
WHNT News 19, September 26, 2018
An explosion has occurred at a chemical plant in Arab, Alabama, killing one worker. |
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News
Daily Star UK, August 23, 2018
Essar Oil's 296,000 bpd Stanlow Refinery was hit by a large explosion and fire on Wednesday afternoon. |
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Partner Content
Offshore platforms are exposed to some of the roughest conditions on earth and require regular attention to ensure they are structurally sound and safe for continued operation. With so many components and major joints at elevated locations, it is clear why a well-trained rope access technician can be an invaluable resource for offshore operators. |
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News
Reuters, June 28, 2018
An Iranian oil refinery caught fire late on Wednesday in the southwestern part of the country, the semi-official Tasnim news agency reported, leaving six people injured. |
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News
Reuters, June 11, 2018
Mexico’s Pemex said on Monday that a fire at its 320,000 bpd Minatitlan Refinery was under control and the plants were operating normally. |
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News
ABC Eyewitness News, April 10, 2018
A fire at the TPC Group chemical plant in southeast Houston kept firefighters at work for more than an hour last week. |
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News
Reuters, March 23, 2018
An explosion killed six people at a refinery in the Czech Republic on Thursday, rescue officials said. Two other people were taken to hospital with serious injuries. |
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News
CBS DFW, March 20, 2018
Five days after an explosion rocked the Tri-Chem Industries plant in Cresson, there is still an active search for one worker. |
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Partner Content
Industrial Rope Access is a proven method of achieving a safe work position at elevated heights or areas that are difficult to access. When combined with advanced NDE technologies, rope access technicians can substantially reduce the cost of inspections and maintenance activities by virtually eliminating the need for fixed scaffolding. |
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News
Hindustan Times, January 22, 2018
An explosion at a chemical plant in India on Sunday has killed at least four workers and injured nine others. |
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News
India TV News, January 22, 2018
An explosion occurred in a boiler of Indian Oil's 300,000 bpd Panipat Refinery on Monday, reportedly killing two workers and injuring at lease six others. |
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News
Beaumont Enterprise, December 18, 2017
The fire that shut down a crude unit at Exxon Mobil's Beaumont refinery was started by an open valve, the company's investigation found. |
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News
Reuters, December 14, 2017
Tuesday’s blast at Austria’s Baumgarten gas hub, which killed one person and disrupted European gas flows, was most likely caused by a loose seal on a filter cap, operator Gas Connect Austria (GCA) said. |
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News
Reuters, December 7, 2017
An explosion at a Petroperu crude oil tank killed two men who had been performing maintenance work on Wednesday, the state-owned oil company said. |
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News
Reuters, December 4, 2017
A female contract worker was fatally injured on Friday while working on a construction project at ExxonMobil Corp’s refinery in Beaumont, Texas. |
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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 exceptionally powerful when combined with our LifeQuest™ remaining life assessment capabilities, providing an integrated solution set for refinery fired heaters in the refining and chemical industries. |
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News
Reuters, February 14, 2017
Russia's top oil producer Rosneft will have to spend up to $100 million to improve standards at aging refineries it bought last year |
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Reuters, January 16, 2017
Abu Dhabi National Oil Company (ADNOC) has shut half the capacity at its 800,000 barrels-per-day Ruwais refinery after a fire there last week... |
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Reuters, January 13, 2017
An accident at the Ciudad Madero refinery of Mexican state-owned oil firm Pemex killed one worker on Thursday. |
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Reuters, October 21, 2016
Saudi Aramco said on Thursday that two workers died of injuries sustained in a fire that broke out at its Wasea crude oil plant in central Saudi Arabia. |
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Reuters, October 20, 2016
Divers on Wednesday retrieved a body from the harbor at German chemical group BASF's flagship production site at Ludwigshafen, believed to be the third victim in a deadly blast and subsequent fire that occurred on Monday. |
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Reuters, August 16, 2016
Malaysia's Petronas Chemicals Group Bhd said on Tuesday that an ammonia leak at one of its plants in the eastern state of Sabah killed two employees and injured three. |
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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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U.S. Chemical Safety Board, January 13, 2016
An ongoing investigation by the U.S. Chemical Safety Board (CSB) of the February 18, 2015 explosion at the ExxonMobil Refinery in Torrance, California, has uncovered multiple process safety management deficiencies that led to the accident and a serious near miss. |
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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 recommendations from the November 2014 chemical release at the DuPont La Porte facility that killed four workers. |
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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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OSHA, May 14, 2015
Four workers killed by a lethal gas in November 2014 would be alive today had their employer, DuPont, taken steps to protect them, a U.S. Department of Labor investigation found. |
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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 safety recommendations will result in significant improvement of Process Safety Management (PSM) regulations in the United States. |
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US Chemical Safety Board, November 11, 2014
In its final Regulatory Report entitled "Regulatory Report: Chevron Richmond Refinery Pipe Rupture and Fire,” the U.S. Chemical Safety Board (CSB) proposes recommendations for substantial changes to the way refineries are regulated in California. The CSB calls on California to enhance its process safety management (PSM) regulations for petroleum refineries to ensure a more robust and adaptive regulatory regime. |
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US Chemical Safety Board, October 28, 2014
Today the U.S. Chemical Safety Board (CSB) released a safety video into the fatal April 2, 2010, explosion and fire at the Tesoro refinery in Anacortes, Washington. |
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US Chemical Safety Board, October 9, 2014
The U.S. Chemical Safety Board today released a video safety message discussing the role that the CSB recommendations program plays in ensuring that the Board’s accident investigations have a lasting impact on industrial safety. |
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News
May 7, 2014
The Ocean Energy Safety Institute will hold a Forum entitled, Risk Awareness, Risk Perception and using the Awareness and Perception in Making Operational Decisions on a Continuing Basis in Oil and Gas Operations, in Houston, TX, May 12-13. |
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United States Chemical Safety Board, November 6, 2013
CSB board members and staff are saddened to learn of the death of the one of the world’s greatest authorities on chemical process safety, Dr. Trevor Kletz. |
