Case Studies

Combustible Dust Emergency Relief System Evaluation

A global manufacturer of specialty minerals and fertilizers was evaluating starch, a new product to their facility, which contained combustible dust. The client wanted to ensure full protection for their equipment while processing this new material. In accordance with the prescriptive measures of NFPA 654, all equipment handling combustible dusts should be provided with explosion protection. Because their facility already had existing equipment, there were no practical means for reducing oxidant concentrations, and diluting the combustible dust product was not an option. Deflagration venting per NFPA 68 was the best option for explosion protection.

Process Hazard Analysis Revalidation of Chemical Laboratories

A leading chemical supplier relocated their microbiology and environmental labs from one location to another one in 2008. A Process Hazard Analysis (PHA) was conducted when the labs were initially set up. The client wanted to have a revalidation of that PHA by conducting a new PHA to review the basic design and practices. Specifically, this new PHA study focused on conceptually identifying any hazards associated with the labs from the point of view of general housekeeping, emergency equipment, piping, electrical, and ergonomics which could have direct impacts on the people, environment, property, and/ or public relations. Read more

Chemical Delivered into Wrong Tank

A supplier was being sued because when delivered, his product went into the wrong storage tank. This lead to a chemical reaction and release of chlorine to which the plaintiffs claimed they were exposed. Read more

Fire Exposure and Relief Protection for Vessels Containing Reactive Chemicals

The client was storing reactive materials in vessels that could be subject to fire exposure. They wanted to ensure that the relief protection on these vessels was correctly sized and well documented, and if not, what changes were required to ensure an effective relief system.

Risk Assessments of Refinery Units

A large Canadian Refinery is performing risk assessments to identify personnel, environmental, and operational hazards. This work is being done on a planned schedule with a different unit being reviewed annually. The challenge was to use Process Hazard Analysis (PHA) methodologies that provide an effective analysis appropriate to the unit to be studied and the potential hazards. Read more

Process Safety Management Quality Audits

Companies have implemented their process safety management programs to comply with OSHA and EPA requirements, but they continue to have accidents. Process safety management programs can meet the letter of the law, but may not be effective in preventing accidents. Traditional audit programs look at documentation and procedures, but do little to evaluate the program quality or effectiveness. Read more