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Bench Testing your Relief Valves and IIAR
Safety Info Posts - Chemical Process Safety (PSM/RMP)
Written by Bryan Haywood   
Tuesday, 23 September 2014 14:40

As I have discussed many times with many clients, the practice of “bench testing” relief valves (RV) is a common practice in many industries; but in some industries the practice has been considered to be a waste of time and money. At least that was the case until now! It appears that one major trade group is taking a position that “bench testing” RV’s is not only a good safety practice, it is also GOOD BUSINESS. So maybe the days of hearing… “Bryan we are not a refinery… chemical plant… power plant… fertilizer plant… etc.” is behind us and we can move forward in improving process safety in the ammonia refrigeration industry. And yes I want to tip my hat and say THANKS to the International Institute of Ammonia Refrigeration (IIAR) for publishing “RVCalc, Using Weibull Analysis to predict valve replacement” this month (September 2014) in their “Condenser” magazine. We should not take this publishing lightly as it is a MAJOR step in the right direction and shows that IIAR is moving in the right direction. I can only imagine how this practice will be received by IIAR members, but without a doubt, it is a much needed change in this industry. To provide some contrast to how many are currently managing their RVs, consider this…

CAL OSHA's PROPOSED PSM Standard for Refineries
Safety Info Posts - Chemical Process Safety (PSM/RMP)
Written by Bryan Haywood   
Sunday, 21 September 2014 18:35

CAL-OSHA has issued a NPRM for a REVISED PSM Standard.  In addition to proposing changes to existing PSM language, the draft proposal introduces new requirements in the following areas: 

  • damage mechanism reviews
  • hierarchy of hazard controls analysis
  • human factors
  • management of organizational change
  • safeguard protection analysis
  • incident investigations
  • safety culture assessments

Here is the PSM Draft Regulation...

NOTE: the text that has been highlighted in BOLD RED represents the changes and differences in this PSM standard as compared to the existing CAL OSHA PSM standard AND the Federal PSM Standard.  Some VERY interesting proposed changes!

Last Updated on Sunday, 21 September 2014 21:32
2014 Video of the Week #38 (Forklifts, Rigging, WillFuls, etc.)
Safety Info Posts - Video of the Week
Written by Bryan Haywood   
Sunday, 21 September 2014 10:09

There is NO big surprise at the end, but watch and listen to this plan unfold!  Listen the camera guy laugh about how STUPID this act is and how he is recording it for the "failed log".  To think anyone makes the claim that "Safety is just common sense" shows that four (4) adult men can have ZERO common sense when it comes to forklifts limitations and safety and rigging.  Although they were successful in this horribly unsafe act, and sadly they have now convinced themselves this crazy stunt will work again, we can see and hear the workings of mad men in this weeks video!  Lastly... of course their NOT wearing their seatbelts... yeah that is the only thing unsafe in this video!  Just sad that they were so proud of themselves they posted this on YOUTUBE for the world to view.


Last Updated on Sunday, 21 September 2014 17:15
2014 Photo of the Week #38 (Ladders)
Safety Info Posts - Photo of the Week
Written by Bryan Haywood   
Sunday, 21 September 2014 09:50


Last Updated on Sunday, 21 September 2014 09:57
Ammonia Explosion 30 years ago this week
Safety Info Posts - Hazardous Materials
Written by Bryan Haywood   
Friday, 19 September 2014 18:55

For many HAZMAT students, learning that a HAZMAT shipped as a Non-Flammable Class 2 HAZMAT can actually ignite is a sobering fact of emergency response. But when they find out this HAZMAT is anhydrous ammonia (NH3) there is a level of disbelief. But it was this week 30 years ago (9/17/84) at approximately 4:00 p.m., when an explosion occurred in a cold storage warehouse building near Shreveport, Louisiana. The explosion occurred while two members of the Shreveport Fire Department's Hazardous Material Unit were attempting to isolate an anhydrous ammonia leak in a section of the building's refrigeration system.

Last Updated on Friday, 19 September 2014 19:40
Safety Info Posts - Safety Alerts
Written by Bryan Haywood   
Friday, 19 September 2014 15:42

This Notice concerns the DBI-SALA Lad-Saf™ Flexible Cable Ladder Safety System, also known as a “Safety Climb System.” Capital Safety has received a limited number of reports of 7x19 strand carrier cable slippage from the carrier clamp in the top bracket of these ladder safety systems. Although this top bracket design has been used in the market for more than 40 years without incident, the reported slippage raises the potential for injury to users of affected systems. Based on our analysis of component manufacture dates, the affected systems are:  CLICK HERE for the official alert

Last Updated on Friday, 19 September 2014 15:45
EPA RMP Citations @ a dairy processing plant (NH3; $7,500)
Safety Info Posts - PSM and RMP Citations/Analysis
Written by Bryan Haywood   
Friday, 19 September 2014 13:22

On December 3, 2013, EPA conducted a compliance inspection of Respondent's facility to determine compliance with the Risk Management Plan (RMP) regulations promulgated at 40 C.F.R. part 68 under section 112(r)(7) of the Act. The EPA found that the Respondent had violated regulations implementing section 112(r)(7) of the Act by failing to comply with the specific requirements outlined in the attached RMP Program Level 3 Process Checklist-Alleged Violations & Penalty Assessment (Checklist and Penalty Assessment). The Checklist and Penalty Assessment is incorporated into this ESA.

Last Updated on Friday, 19 September 2014 13:32
Conveyors, Duct Work, and your Hot Work Permitting Process
Safety Info Posts - OSHA Compliance Posts
Written by Bryan Haywood   
Thursday, 18 September 2014 09:04

In "general industry" workplaces OSHA has a “General Requirements” standard for conducting Welding, Cutting, and Brazing activities (1910.252). For those working within the battery limits of a PSM/RMP covered process, both OSHA (1910.119(k)(2) and EPA (68.85(b) reference 1910.252(a) as the basics of safely conducting these HW activities. But there is one (1) requirement that we almost always see missing from every aspect of a facilities HW program, permitting, and even training, and that is…

Last Updated on Thursday, 18 September 2014 09:37
OSHA’s revised Injury and Illness Reporting may call for an MOC at PSM/RMP facilities
Safety Info Posts - Chemical Process Safety (PSM/RMP)
Written by Bryan Haywood   
Wednesday, 17 September 2014 14:49

Yes, as many of you have figured out I am a big fan of using the Management of Change process to actually manage changes that may officially be outside the PSM/RMP requirements. But how would OSHA changing their injury/illness reporting requirements impact my Process Safety Management System? Here’s how…

Last Updated on Wednesday, 17 September 2014 14:54
Testimonial for Safety Glasses
Safety Info Posts - General Safety Topics
Written by Bryan Haywood   
Wednesday, 17 September 2014 13:24


The incident just occurred yesterday (8/21/14).  A miner operator (underground coal) was cutting rock bottoms in a mine construction area, when he either hit a rib bolt with the cutter head, or a miner bit sheared in two. In either case, the steel fragment became a high speed projectile and struck the employee in the eye. As you can see in the photos, had the employee NOT been wearing safety glasses, his injuries would have been severe and in all likelihood, he would have lost his eye.  Following the incident, the employee stated, “I saw it coming at me but it was flying so fast that I had no time to react.”  The employee did sustain minor superficial cuts above and below his eye as a result of the impact of the steel piece against the safety glasses, but he returned to work on the very next shift with no residual effects and as though no incident had even occurred.

CLICK on READ MORE below to see the full size photos (2)

MANY THANKS to Bob Cornett and his Mine Safety Group for sharing this with us. 

Last Updated on Wednesday, 17 September 2014 13:34

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