Safety Column
Catastrophic Dangers of Welding on Volumetric Devices
John Satterlee - Chief Metrologist Illinois Department of Agriculture | Bureau of Weights & Measures
Gasoline vapors are widely recognized as extremely dangerous and volatile, presenting both acute and long-term health risks. While most people understand the hazards associated with gasoline in open environments, far fewer recognize how these vapors can persist in poorly ventilated spaces. This lack of awareness can have life-threatening consequences. In particular, poorly ventilated equipment such as volumetric provers can trap gasoline vapors long after liquid fuel is no longer present. Gasoline vapors are difficult to remove for several reasons. They are three to four times heavier than air, causing the vapors to settle in low-lying or enclosed areas where ventilation is inadequate. Without proper cleaning and airflow, these vapors can accumulate unnoticed. Compounding the danger is gasoline’s extremely low flash point, approximately −40 °F, which allows it to generate flammable vapors even at very cold temperatures. This discussion was prompted by information provided by Robert M. Murnane Jr., President of Pemberton Fabricators, Inc., regarding two separate but strikingly similar incidents. In both cases, catastrophic explosions occurred when welders were working on stainless-steel volumetric devices that had not been properly cleaned or ventilated. While welders were attaching brackets to the devices, residual gasoline vapors inside were ignited by the welding process, resulting in violent explosions. The force of the explosions was severe enough to blow out the sides of the volumetric devices. In one instance, a section of steel was ejected with such intensity that it struck and left a significant dent on a neighboring prover. Notably, the damaged volumetric devices belonged to two different state agencies. Although no injuries occurred, both incidents had the potential for serious injury or loss of life.
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