Serious safety incidents continue to occur at an alarming rate. Reviewing current and prior incidents is a key component of a successful Process Hazard Analysis (PHA). Safety incident investigations provide valuable lessons and recommendations for a more effective PHA. The U.S. Chemical Safety Board, CSB, safety message videos provide lessons learned, effective safety solutions, and important reminders from safety incident investigations. Safety incident awareness and compliance with your facility operating and maintenance procedures along with adherence to your safe work practices reduces the likelihood or consequences of similar incidents or hazards in the future. Shown below, are a few of the many CSB safety message videos applicable to PHA, risk analysis, and risk mitigation.
On August 6, 2012, the Chevron U.S.A. Inc. Refinery in Richmond, California experienced a catastrophic pipe rupture in the #4 Crude Unit. The ruptured pipe released flammable, high temperature light gas oil, which then partially vaporized into a large, opaque vapor cloud. Approximately two minutes following the release, the released process fluid ignited. 15,000 people from the surrounding communities sought medical treatment.
Preparations by companies, emergency responders, government authorities, and the public are critical to reducing injuries and saving lives during chemical emergencies. This U.S. Chemical Safety Board (CSB) video illustrates the findings from 10 years of CSB accident investigations on preparing for and responding to chemical disasters.
U.S. Chemical Safety Board Video on the 2009 massive explosion at the Caribbean Petroleum, or CAPECO, terminal facility near San Juan, Puerto Rico. The incident occurred when gasoline overflowed and sprayed out from a large aboveground storage tank, forming a 107-acre vapor cloud that ignited.
The US Chemical Safety Board on 7/11/2012 released a safety video that examines the concept of inherent safety and its application across industry; “Inherently Safer: The Future of Risk Reduction” stems from the August 28, 2008, explosion that killed two workers and injured eight others at the Bayer CropScience chemical plant in Institute, West Virginia. As a result of ongoing concern regarding the safety of the facility Congress directed the CSB to commission the National Academy of Sciences to study the feasibility of reducing or eliminating the inventory of methyl isocynanate stored at the Bayer plant.
On October 21, 2016, a chemical release occurred at the MGPI Processing plant in Atchison, Kansas. MGPI Processing produces distilled spirits and specialty wheat proteins and starches. The release occurred when a chemical delivery truck, owned and operated by Harcros Chemicals, was inadvertently connected to a tank containing incompatible material. The plume generated by the chemical reaction led to a shelter-in-place order for thousands of residents. At least 120 employees and members of the public sought medical attention.
Shock To The System - Chemical Safety Board video detailing key lessons for preventing hydraulic shock in ammonia refrigeration systems based on the CSB's investigation into the accident at Millard Refrigerated Services Inc. on August 23, 2010. 32,000 pounds of anhydrous ammonia were released to the atmosphere, resulting in over thirty off-site workers being hospitalized – four in an intensive care unit.
On the 30th anniversary of the fatal Union Carbide chemical release that killed thousands in Bhopal, India, U.S. Chemical Safety Board warns it could happen again.
At 1:33 pm on December 19, 2007, a powerful explosion and subsequent chemical fire killed four employees and destroyed T2 Laboratories, Inc. (T2), a chemical manufacturer in Jacksonville, Florida. It injured 32, including four employees and 28 members of the public who were working in surrounding businesses. On December 19, T2 was producing its 175th batch of methylcyclopentadienyl manganese tricarbonyl (MCMT). At 1:23 pm, the process operator had an outside operator call the owners to report a cooling problem and request they return to the site. Upon their return, one of the two owners went to the control room to assist. A few minutes later, at 1:33 pm, the reactor burst and its contents exploded, killing the owner and process operator who were in the control room and two outside operators who were exiting the reactor area.