At approximately 9:30 a.m. on October 3, 2002, an employee who worked for a company that provided vehicle maintenance such as car washes, detailing, fueling, and lube and oil servicing, inadvertently drank acid from a plastic spray bottle while he was on a rest break. The employee, feeling very ill after ingesting the contents of the quart bottle, asked his coworkers to transport him to the hospital. He was taken to San Antonio Community Hospital where he was pronounced dead at 11:49 a.m. from internal injuries. Laboratory analysis indicated that the acid solution in the plastic bottle contained hydrofluoric acid and phosphoric acid with a pH of less than one.

CLICK HERE for case file

On April 15, 2014, Employee #1, a maintenance technician employed by Solarworld Industries America Inc., and Coworker #1, a tool operator in the plant's fabrication area, were working at the employer's solar cell manufacturing facility. Coworker #1 had submitted a work order to repair a leak of liquid hydrofluoric acid (HF). HF is used in the manufacture of solar cells in a process similar to that for making semiconductor wafers.

18010724This week we saw a construction vehicle strike a fill valve of an underground propane tank.  The valve was not only unprotected, it was actually camouflaged by a large plastic trash can that sat over top of it.   The valves for the 1000 gallon tank were struck by a construction vehicle which led to an active and significant leak.  


  1. A breakdown of the Atlas Foundry LPG BLEVE (2007)


  3. Another WRONG CHEMICAL to WRONG TANK incident (Reaction making Chlorine)

  4. Underground Storage Tank raises its ugly head, literally (video)


  5. PHMSA Issues Safety Advisory on Use of DOT-39 Cylinders for Liquefied Flammable Compressed Gas

  6. When BOLLARDS work! (Video)

  7. 2015 International Fire Code (IFC) and Vehicle Impact Protection

  8. Another "Vent & Burn" used on Cat 1 Flammable Gas(s) Transport Containers

  9. DOT Requirements for Loading/Unloading LPG and NH3

  10. NTSB releases PRELIMINARY findings on Chlorine Railcar leak in WV

  11. What OSHA's GHS Means for Fire and Building Code Officials (Fact Sheet)

  12. Who said diesel was not explosive?

  13. PHMSA Proposes to Harmonize Hazardous Materials Regulations to International Standards

  14. Did the Federal Motor Carrier Safety Administration (FMCSA) just declare e-cigs an "ignition source"?

  15. REVISED Safety Advisory: Emergency Discharge Control Equipment Installation on Cargo Tank Motor Vehicles Resulting in the Potential Loss of Vehicle Control (FMCSA 2016)

  16. HAZMAT Safety Advisory: Immediate re-inspection and retesting of certain cargo tank motor vehicles required (FMCSA 2016)

  17. Fisher PRD Recall Safety Notice (DOT) FREE Ohio Fire Code Training Modules - Update from State Fire Marshal's Office (July 2016) EPCRA Revisions to Hazard Categories and Minor Corrections: Technical Amendment Ammonia is not suppose to behave that way

    HAZMAT Guys discuss two major Ammonia Releases

  18. IL has another TOTAL LOSS of NH3 from MC331 during loading/unloading @ fertilizer facility

  19. Callaway, MN MC331 Tanker vs. Train incident does NOT appear to have been a BLEVE

  20. FREE ACCESS to the 2015 International Fire Code (IFC)

  21. 2nd BLEVE in as many days??? (MC331 - Propane)

  22. IL Fire Marshal explains state codes and NFPA Life Safety Code

  23. Ohio is revising the State Fire Code for 2017

  24. Another WRONG material to WRONG tank incident 

  25. Metallurgical Evaluation of a Nurse Tank Cracked Head (Failure was SCC)


  27. 2015 Lessons Learned with HAZMAT UNLOADING accidents

  28. Cryogenic tank for liquefied carbon dioxide ruptured (Lack of Car-Seal Program)

  29. PHMSA to Hold Advisory Committee Vote on Rulemaking Proposal for Excess Flow Valves

  30. Dramatic Explosion @ Natural Gas Processing Plant (Video)

  31. Chlorine Institute offers HCl DVD Now Available for FREE

  32. Chlorine Institute offers New HYPO DVD Now Available for FREE

  33. SAFETY NOTICE: Welding on Cargo Tanks

  34. DOT issues warning about some nurse tanks (SP-16239)

  35. FAMOUS Cargo Tank Failure (Safety Alert)

  36. Forearmed is Forewarned, REVISING the NFPA 704 may make sense!

  37. New Edition of CI PPE Pamphlet 65 Available

  38. Review of HAZMAT Unloading/Loading risks (PHMSA)

  39. Unloading HAZMAT accident - WRONG TANK (NTSB DCA99MZ006)
  40. Unloading HAZMAT accident - WRONG TANK (NTSB DCA99MZ003)
  41. Receiving and unloading bulk hazardous liquids in Kentucky
  42. Hazardous Materials: Flame Arrestors (USFA)
  43. Cargo Tank Motor Vehicle (CTMV) Loading/UnLoading operations: Recommended Best Practices Guide
  44. Recommended Non-Destructive Testing to Improve Nurse Tank Safety, Phases I and II
  45. Nitrogen Cylinder Failure Incident (TX FM Report)
  46. States and US Territories that have adopted International Codes (IMC, IFC, IBC, etc.)
  47. Industrial Commission of North Dakota Adopts New Standards to Improve Oil Transportation Safety
  48. Sulfuric Acid into Hydrochloric Acid tank (Unloading Incident)
  49. Is your propane cylinder SAFE? (PHMSA)
  50. Hazardous Materials: Harmonization With International Standards (RRR)
  51. Detonation or Deflagration? (USFA)
  52. Did you know... Ammonia (and Propane) gas is NOT white?
  53. HAZMAT Awareness - PLACARDS (video)
  54. How NOT to haul an industrial LPG tank! (Video)
  55. Ammonia Explosion 30 years ago this week
  56. 2013 HAZMAT Loading/Unloading Incidents
  57. NIOSH launches the NIOSH Center for Direct Reading and Sensor Technologies (NCDRST)
  58. U.S. DOT Announces Comprehensive Proposed Rulemaking for the Safe Transportation of Crude Oil, Flammable Materials (Releases new data on Bakken crude oil to support increased safety measures)
  59. BLEVE or Diesel Tank Exploding??
  60. OSHA’s TECHNICAL MANUAL on the LIMITATIONS of Explosibility (combustible gas) Sensors
  61. Commissioning of a LNG Storage Tank (Video)
  62. 2014 Video of the Week #16 (The power of NH3 inside a pressure vessel)
  63. Nurse Tank Safety and Compliance Advisory letter (2008 Reminder)
  64. Hazardous Materials: Cryogenic Fluids (USFA)
  65. Why ice accumulates on cryogenic system vaporizers (USFA)
  66. Hazardous Materials: Cargo Tank Motor Vehicle Loading and Unloading Operations
  67. PHMSA issues Safety Alert regarding crude oil being transported from the Bakken region
  68. Adoption of ASME Code Section XII and the National Board Inspection Code
  69. Company failed to report CL2 release in timely manner ($42K - truck unloaded to WRONG tank - reaction)
  70. CFATS FAQ: What is a thermal radiation zone?
  71. Safety and Security Plans for Class 3 Hazardous Materials Transported by Rail
  72. Improving Chemical Facility Safety and Security: Listening Sessions
  73. Vehicle impact protection for liquefied petroleum gas (LPG) exchange cages
  74. Natural Gas Line Excavation ignition caught on camera
  75. Pipeline Safety: Notice to Operators of Hazardous Liquid and Natural Gas Pipelines of a Recall on Leak Repair Clamps Due to Defective Seal
  76. Ammonia Engine/Machinery Rooms and Hazardous Locations is NOT driven by PSM/RMP alone
  77. Reading Codes and Standards: Part 3
  78. Federal Railroad Administration Issues Emergency Order to Prevent Unintended Hazardous Materials Train Movement
  79. Reading Codes and Standards: Part 2
  80. Safety Alert: Risks Associated With Liquid Petroleum (LP) Gas Odor Fade (PHMSA)
  81. Pipeline Safety: Reminder of Requirements for Utility LP-Gas and LPG Pipeline Systems
  82. Fire Code Permits (USFA)
  83. Liquefied natural gas road tanker explosion (BLEVE incident)
  84. Preliminary Findings of the U.S. Chemical Safety Board from its Investigation of the West Fertilizer Explosion and Fire
  85. Method of Measuring Nanoparticle Penetration through Protective Glove Materials under Conditions Simulating Workplace Use
  86. Guide for Safe Use of Isocyanates - An Industrial Hygiene Approach
  87. The mistakes made in West (Not OSHA's or EPA's)
  88. FREE Resources for Ammonium Nitrate Safety (NO EXCUSES!)
  89. Bulk Liquid Oxygen Separation (USFA)
  90. House Dems Ask GAO to Examine Oversight Gaps at West, TX & Similar Facilities Nationwide
  91. Has your state adopted the International Fire Code (IFC)?
  92. Storing Ammonium Nitrate in Ohio
  93. Ammonium Nitrate Sensitization (explaining one West, TX scenario)
  94. Increased Civil Penalties Take Effect for Those Who Knowingly Violate Federal Hazmat Laws and Regulations
  95. 2012 HAZMAT Loading/Unloading Incidents
  96. BLEVE - Cause and Effect
  97. UNLOADING HAZMAT to the wrong tank (CL2 Incident)
  98. Pipeline Safety: Reporting of Exceedences of Maximum Allowable Operating Pressure
  99. NEW DOT Shipping Papers REQUIREMENT EFFECTIVE 1/1/13
  100. The DOT 25' Attendant Rule
  101. FRA Safety Advisory - 2003-02 (Excess Flow Valves)
  102. Update on CL2 release @ Poultry Plant
  103. New Reports Recommend Improvements for Acute Exposure Guideline Levels Documentation     
  104. NH3 Fertilizer Compliance info from State of MI
  105. Revisions to the Tier I and II Emergency and Hazardous Chemical Inventory Forms
  106. Compressed Gas Cylinder Color Coding
  107. Odorant Fade in Railroad Tank Cars (Safety Advisory 2012–01)
  108. Ammonia kills woman driving thru cloud (Video - News Account)
  109. Albert City, Iowa Chicken Farm BLEVE (NFPA)
  110. MAJOR Bromine Rail Car Release (Video)
  111. ANOTHER Acetylene cylinder stored in a car
  112. Cylinder Transport
  114. Morris missile: Anhydrous ammonia nurse tank explosion
  115. FREE Training Resources for Responding to Ethanol Incidents
  116. Chlorine Institute offers FIVE more FREE Technical Publications
  117. Chemical Reactivity Worksheet
  118. DOT Revises the Requirements for Emergency Response Telephone Numbers
  119. DOT final rule sets design standards for PIH-carrying tank cars
  120. DOT issues a Nurse Tank Safety and Compliance Advisory letter
  121. Chemical Plant Security
  122. BLEVE Response and Prevention (Mechanical Engineering Queen’s University)
  123. House subcommittee sends chemical security bill, H.R.2868, to full committee
  124. PHMSA is amending the HAZMAT Regulations to maintain alignment with international standards
  125. DOT to Improve Safety Around Hazardous Material Loading and Unloading Operations
  126. Does the fuel inside generators being transported from one site to the next have to meet DOT HAZMAT requirements?
  127. DOT CHANGES the Security Plan Requirements (Revised List of Materials)
  128. HAZMAT UPDATE on Railroad Tankcar Designs
  129. Propane Cylinders - Important Pressure Relief Valve Information
  130. Storing forklift propane cylinders PROPERLY
  131. Acetylene Cylinder Safety

Anyone who has taken one of my HAZMAT or Process Safety training courses has heard about and seen video of the Atlas Foundry LPG BLEVE that occurred back in 2007.  But in a recent process safety course, several students (volunteer FF's outside of their full time job at this PSM facility) debated on the facts of the incident, of which neither was even close to being factual.  So as we approach the 10-year anniversary of this fatal accident and BLEVE I thought it would be a good idea to set the record straight with what actually happened and how it happened.  And yes, this was another HAZMAT UNLOADING incident gone bad...

The U.S. Department of Transportation's Pipeline and Hazardous Materials Safety Administration (PHMSA) has been made aware of concerns regarding newly adopted requirements in Section 180.209(e) of the Hazardous Materials Regulations (HMR; 49 CFR Parts 171-180). Prior to a January 21, 2016 Final Rule [Docket No. PHMSA-2013-0042 (HM-233F)], the requalification period corresponding to volumetric expansion testing for certain DOT cylinders was 12 years after the initial volumetric expansion testing conducted at the time of manufacture, and 12 years thereafter. The Final Rule, in part, reduced the requalification period from 12 years to 10 years, with a delayed compliance date of January 23, 2017. On January 13, 2017, the National Propane Gas Association (NPGA) submitted a Petition For Rulemaking & Emergency Stay [of] Cylinder Requalification Requirements requesting that PHMSA initiate a rulemaking to replace the requalification requirements established in HM-233F with the former requirements in 49 C.F.R. § 180.209(e). PHMSA hereby gives notice that while it reviews the NPGA Petition for Rulemaking, it will not take enforcement action against a person who requalifies DOT cylinders using volumetric expansion testing pursuant to a 12-year requalification period, as previously authorized by § 180.209( e) in effect on January 22, 2017. We will allow the use of either a 12 or 10-year requalification period for volumetric expansion testing until this notice is rescinded or otherwise modified. This notice is limited to the requirements recently adopted in 49 C.F .R. § 180.209( e ). This notice does not affect any other obligations that offerors or carriers may have under the HMR or any other applicable law. Issued March 17, 2017, in Washington, D.C. Acting Deputy Administrator Pipeline & Hazardous Materials Safety Administration.

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