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 Session No. 543 - Process Safety Management Best Practices, Lessons Learned and Enforcement Trend
 
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33 incidents & 0 updates (4/15/14)
Safety Info Posts - Incident Alerts
Written by Bryan Haywood   
Tuesday, 15 April 2014 18:54
Last Updated on Tuesday, 15 April 2014 19:01
 
2014 Photo of the Week #15 (Hearing Protection)
Safety Info Posts - Photo of the Week
Written by Bryan Haywood   
Saturday, 12 April 2014 17:42

Your guess is as good as mine!!!  I am merely guessing, but I would imagine this is TRYING to say that DUAL HEARING protection is required in the area.  Instead we ended up with... Like I said last week, it is all in how you SAY IT (or in this case SPELL IT).

duelHP

Last Updated on Saturday, 12 April 2014 17:52
 
Ammonia behaving badly... it is suppose to rise! (Video)
Safety Info Posts - Emergency Response
Written by Bryan Haywood   
Saturday, 12 April 2014 00:00

MEMBERS UPDATE on 4/12/14 from Minnesota Department of Agriculture (MDA)... On October 31, 2012 at 6:00 p.m. while anhydrous ammonia (ammonia) field application assembly was making a turn at the end of the field, the hitch connection between the application/toolbar unit and the nurse tank failed. The break-away coupling device failed to disengage, causing the threaded fitting at one end of the withdrawal hose to fail resulting in the air release of ammonia.  The video illustrates the ammonia release.

Last Updated on Saturday, 12 April 2014 22:30
 
2014 Video of the Week #15 (Power of a Vacuum)
Safety Info Posts - Video of the Week
Written by Bryan Haywood   
Saturday, 12 April 2014 00:00

So often we hear about the vessels that go BOOM, it never hurts to remind us what can happen when we create a vacuum in a vessel.

Last Updated on Saturday, 12 April 2014 21:31
 
The Value of Self Assessments
Safety Info Posts - Motivational Safety Materials
Written by Bryan Haywood   
Friday, 11 April 2014 08:15

A little boy went into a drug store, grabbed a stool at the counter and pulled it over to the telephone. He climbed onto the stool so he could reach the buttons on the phone and proceeded to dial someone. The store-owner observed and listened to the conversation.

Boy: ‘Lady, Can you give me the job of cutting your lawn?’

Woman: (at the other end of the phone line): ‘I already have someone to cut my lawn.’

Boy: ‘Lady, I will cut your lawn for half the price of the person who cuts your lawn now.’

Woman: ‘I’m very satisfied with the person who is presently cutting my lawn.’

Boy: (with more perseverance): ‘Lady, I’ll even sweep your curb and your sidewalk, so on Sunday you will have the prettiest lawn in town.’

Woman: ‘No, thank you.’

With a smile on his face, the little boy replaced the receiver. The store-owner, who was listening to all this, walked over to the boy.

Store Owner: ‘Son… I like your attitude; I like that positive spirit and would like to offer you a job.’

Boy: ‘No thanks.’

Store Owner: ‘But you were really pleading for one.’

Boy: ‘No Sir, I was just checking my performance at the job I already have. I am the one who is working for that lady I was talking to!’

How is your performance these days? Take time, every once in a while, to gauge your job performance. Too many times we blame others for our mistakes or the situations in our life rather than ourselves. We need to take a close look at who we are and how we do what we do. And it pays to have the valuable input of those we work for and with. Then, once we have identified our strengths and weaknesses, we can consciously work on both as needed. Honest, hard work and dedication always pay off in one way or another. Even if our efforts go unnoticed by others, we have the pride and satisfaction of knowing we’ve done our best!

Safety Wayne

 
40 incidents & 3 updates (4/6/14)
Safety Info Posts - Incident Alerts
Written by Bryan Haywood   
Sunday, 06 April 2014 20:24
Last Updated on Sunday, 06 April 2014 20:31
 
What is your EPA Risk Management Plan “Hazard Index”?
Safety Info Posts - Chemical Process Safety (PSM/RMP)
Written by Bryan Haywood   
Saturday, 05 April 2014 16:07

One of the methods EPA uses to determine RMP inspection priorities is based on their use of the Wharton School’s Hazard Index, which is defined as 

“the sum over all chemicals of log2 (maximum quantity of inventory on-site/threshold), or, alternatively, as the number of chemicals times log2 of the geometric mean of the maximum-to-threshold quantity ratio.”

EPA has defined a “High Risk” facility as one that has:

  1. RMP WCS population ≥ 100,000
  2. Any accident meeting RMP reporting criteria within last 5 years
  3. Hazard Index ≥ 25

So do you know your facility's  "Hazard Index"?

Last Updated on Saturday, 05 April 2014 16:37
 
Yep, its JUST Anhydrous Ammonia "in Refrigeration" (Part II)
Safety Info Posts - Chemical Process Safety (PSM/RMP)
Written by Bryan Haywood   
Friday, 04 April 2014 11:23

UPDATED with the actual working EXCEL Spreadsheet so that members can sort the data as needed;as well I updated the #'s related to refrigeration below.  I had messed up my first sort and was off by a couple.  

This week I raised a red flag regarding ammonia accidents after the UNLOADING FATALITY at a fertilizer facility, only to be told that it was the wrong "forum" (e.g. ammonia refrigeration) to mention the hazards of ammonia at a fertilizer plant, after all we are "ammonia refrigeration" and not fertilizer plants.  It seems there still remains those who truly believe that Anhydrous Ammonia somehow behaves and has a different level of hazard depending on how and where it is used.  Granted, the level of risk in a process that has ROUTINE TEMPORARY connections such as a fertilizer distributor is one that is MUCH HIGHER than a closed loop refrigeration process; however, this in NO WAY implies there is little risk in such a closed loop process.  Anyone who hooks up a truck to their process can LEARN from the fertilizer accident and in truth, MOST ammonia delivered to refrigeration processes occurs in the spring and summer months as well!  So I have worked with an organization in analyzing many of the Ammonia Accidents that those of you who use the Incident Alerts have seen over the years.  Here is that accident data regarding the use of Anhydrous Ammonia in the refrigeration industry.  This data is world-wide and takes us from 2006 up to the last quarter of 2013.  This data is SPECIFIC to NH3 used in "REFRIGERATION".  In summary for the period of 2006- 3rd quarter 2013, there have been 93 fatalities from ammonia accidents in refrigeration, 877 injuries, 286 which were "severe" enough to require hospitalization, and 16,482 personnel evacuated.   These numbers correspond to minimum average GLOBAL frequencies of 120 injured, 30 severely harmed and 12 fatalities each year related to ANHYDROUS AMMONIA used in REFRIGERATION.  By comparison, a US survey (SAFTENG Members Access) on ammonia accidents showed an average frequency of 7 accidents and 2 fatalities/year between 1995 and 2006.  This article and data is for SAFTENG members and those who wish to use the data.   This is NOT a scientific study and ONLY media accounts were used in this analysis.  This means that ONLY those releases of Ammonia from a REFRIGERATION process that made the news were captured.  I will allow any deductions one comes to, to their own conclusions; however, the data is what it is.  Use at your discretion.

Last Updated on Friday, 04 April 2014 20:22
 
Why are so many fearing OSHA's I2P2
Safety Info Posts - OSHA Compliance Posts
Written by Bryan Haywood   
Friday, 04 April 2014 08:22

In the past several years OSHA has renewed their efforts in trying to get their "Injury and Illness Prevention Plan" (I2P2) on the table for discussion/rule making. To many safety professionals this may be a “new movement”, but in reality this effort dates all the way back to 1995. Recently, OSHA has said they are hoping to have a formal rule making effort going by September 2014 and this much needed "plan" is causing quite the stir in all industries and professions. It is my humble belief that in 1995 when OSHA first proposed this on the national level, that the atmosphere was just too burdened because we had just gotten PSM in 1992 and all the “higher risk” facilities were already working on a “management system” as they implemented PSM. However, most facilities in the USA do not deal with PSM so most of these businesses do not have a FUNCTIONING safety management system. If asked, most would say they DO HAVE a system in place, but as most seasoned safety professionals know this “system” is not really a living and breathing safety management system. Heck even some VPP sites struggle with an all encompassing and functioning safety management system. What OSHA is proposing is a MUST HAVE in my eyes! Whether we do it on our own using ANSI Z10 (which is OUTSTANDING by the way) or we wait for OSHA to require it, it is a MUCH need step to get us towards world-class safety. Ask yourself, or better yet ask your management team, what would happen tomorrow if the safety manager (or safety team) won the lottery and did NOT show up to work next week? What would happen to “safety”? Would anyone on the management team outside of the safety group have any idea what is “due to be done” over the next several weeks/months/quarters while they replace the safety team. If ONLY the safety team knows what is happening, what is scheduled to happen, and what has to be done to meet the “Lowest Safety Denominator” (i.e OSHA compliance) then we are just fooling ourselves into believing we have a functioning “safety management system”! I2P2 is meant to make safety a FUNCTION of “management” and not just the “safety manager” so it just makes me shake my head when I am at a safety conference and here safety professionals speak ill of the I2P2.  Here is the background of I2P2 and what we can expect…

Last Updated on Friday, 04 April 2014 11:12
 
Anhydrous Ammonia (NH3) Fatality at a NE Co-Op was an UNLOADING ACCIDENT
Safety Info Posts - Chemical Process Safety (PSM/RMP)
Written by Bryan Haywood   
Thursday, 03 April 2014 16:32

Those who read my Weekly Incident Alerts saw two (2) Anhydrous Ammonia fatalities last week:

#1 at a fertilizer facility and

#2 at an Ice Plant outside of the USA.  

BOTH of these fatalities were from OVER EXPOSURE to NH3 caused by a Loss of Primary Containment (LOPC).  The incident outside the USA was confirmed by the area coroner and I have been asking around about the incident within the USA.  The USA incident was first reported as an "explosion" so I began asking if this were a NH3 ignition event or a catastrophic failure of a pressure vessel.  It turns out there was not really an explosion at all; but something did happen that caused a pressure wave, rattling windows of nearby homes and businesses, who then reported the incident as an "explosion".  I contacted the Johnson Country Attorney as she was quoted in many of the news publications and a DOT PHMSA contact for insights as to what really happened.  Both were kind enough to respond and this is what they said:

Last Updated on Thursday, 03 April 2014 16:59
 
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