Details

Parent Category: Safety Info Posts

Category: PSM and RMP Citations/Analysis

Published: 04 August 2015

The respondent produces, processes, stores, and/or handles extremely hazardous substances, including hydrochloric acid (36%), due to its toxic and corrosive characteristics and propensity to volatilize in ambient air.  On July 25, 2014, there was a release of hydrochloric acid (36%) at the Facility.  An operator while on his normal rounds gauging the Boiler I house Sump, noticed an abnormal vapor cloud coining fro1n behind Warehouse #2. The operator immediately notified a Shift Leader, who identified the vapor cloud as hydrochloric acid (36%), and immediately shut down the pumping of hydrochloric acid (36%) from Line 3 through the pipe rack behind the warehouse. Facility later determined that the release was caused by a breach of a flange connection on a 2" pipe. The pipe consists of two components: a carbon steel outer structure that bears pressure and a teflon liner that protects the carbon steel outer pipe fro1n the hydrochloric acid traveling through the pipe. The carbon steel pipe had been severely corroded by hydrochloric acid that had permeated the teflon inner liner. Once the outer carbon steel pipe lost its structural integrity the teflon inner shell was unable to contain the pressure and failed at the flange connection. 3,280 pounds of hydrochloric acid (36%) were released during the incident.

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