Case Studies

Process Hazard Analysis for a Food Packaging Manufacturer

During a Verified Pharmacy Program (VPP) inspection, a potential combustible dust hazard was found at a food packaging manufacturer. When the facility was given a quote for millions of dollars in expensive explosion protection equipment, they realized a more accurately defined risk analysis of their operations was needed. Read more

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 led 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. Read more

Risk Assessments of Refinery Units

A large Canadian refinery was performing risk assessments to identify personnel, environmental, and operational hazards. This work was being completed according to a schedule, and each year a new unit was to be evaluated. The challenge for them was how to use Process Hazard Analysis (PHA) methodologies for an effective analysis appropriate to the unit to be studied. Read more