About Mike Schmidt

With a career in the CPI that began in 1977 with Union Carbide, Mike was profoundly impacted by the 1984 tragedy in Bhopal and has been working on process safety ever since.

Beyond the Limits: Extreme Oxygen

“Oxygen is the vital ingredient for the survival of every cell in our bodies. Too little—or too much—can spell disaster.”  — Venki Ramakrishnan A reader recently complained about OSHA’s insistence on defining the safe limits of oxygen in terms of volume percent: 19.5% by volume to 23.5% by volume. “The fact that OSHA does not [...]

By |2025-05-01T09:33:23-05:00May 1st, 2025|Procedures, Workplace Safety|0 Comments

Pressure Relief: Low Pressure Vessels

“Pressure comes from within and so must be mastered from within.”  — Ed Jacoby Ten years ago, on Friday morning, April 24, 2015, a catastrophic still failure at the Silver Trail Distillery in Hardin, Kentucky seriously injured two workers, one who died 17 days later from his injuries. They were about four gallons into a [...]

Process Hazards: Using Compressed Gas to Transfer Liquids

“Science explorers are like an ideal gas. They can expand to fill any volume, but they can only do work under pressure…and the pressure’s on.”  — Robert Ballard Every time that someone at a process facility tells me that they use compressed gas to transfer liquids from one tank to another, I wince. It’s not [...]

By |2025-04-17T10:00:59-05:00April 17th, 2025|Chemicals, Gas, Procedures, Process Safety, Workplace Safety|Comments Off on Process Hazards: Using Compressed Gas to Transfer Liquids

“OSHA Says”: Thermal Exposure

“If you can’t take the heat, get out of the kitchen.”  — Harry S. Truman For decades, I’ve told people that OSHA requires thermal protection on surfaces over 140°F (60 C) up to a height of 7 feet. People just accepted that because a) I was the expert and b) it made sense. Recently, though, [...]

By |2025-04-10T09:46:58-05:00April 10th, 2025|PHA, Process Safety, Risk Assessment, Workplace Safety|Comments Off on “OSHA Says”: Thermal Exposure

Process Safety: On the Bourbon Trail

“Devils drinking devils and the flames are getting higher. All of Bardstown’s crying tonight, Heaven Hill’s on fire.”  — Shannon Lawson, The Galoots Chris Schmidt and I recently returned from a week-long trip to Kentucky to enjoy the countryside and to sample bourbons from some of the 46 distilleries on the Kentucky Bourbon Trail. As [...]

“It’s Probably Water”: Is That Good Enough?

“You can’t trust water. Even a straight stick turns crooked in it.”  — W. C. Fields ChrisSchmidt and I recently visited several distilleries on Kentucky’s Bourbon Trail. After tasting one particularly strong whiskey, she reached for a tall glass of clear liquid to chase it down. “Yeah, that’s probably water,” said our tasting guide, hinting [...]

By |2025-03-27T08:31:27-05:00March 27th, 2025|Chemicals, Process Safety, Process Safety Management, Workplace Safety|Comments Off on “It’s Probably Water”: Is That Good Enough?

Incident Safety Investigations: Who Should Lead Them?

“Every man is guilty of all the good he did not do.”  — Voltaire Early in my career, our boss assigned a colleague and me to investigate an incident that was still having a significant impact on the plant. Being an arrogant know-it-all, I mean, an engineer, I was confident that I already knew what [...]

By |2025-03-20T09:21:45-05:00March 20th, 2025|Process Safety Management, Workplace Safety|Comments Off on Incident Safety Investigations: Who Should Lead Them?

Breaking Safe: Delta Flight 4819

“No Watson, this was not done by accident, but by design.”  — Sherlock Holmes On Monday, February 17, 2025, after being cleared for landing at the Toronto Pearson International Airport, Delta Flight 4819, a Bombardier CRJ-900, crashed. Buffeted by wind gusts up to 37 mph, the plane hit the runway hard, lost its right wing, [...]

By |2025-03-13T13:30:57-05:00March 13th, 2025|Current Events, Process Safety, Workplace Safety|Comments Off on Breaking Safe: Delta Flight 4819

Gambling With Safety: Acceptable Risk vs. Tolerable Risk

“How often misused words generate misleading thoughts.”  ‑ Herbert Spencer I once worked for an organization where senior managers freely expressed their differences of opinion. Often, they would dismiss a colleague’s position, saying, “That’s just semantics.” It became easy for me to conclude that semantics, the meaning of words and statements, were trivial. I know better [...]

By |2025-03-06T10:09:11-06:00March 6th, 2025|PHA, Process Safety, Process Safety Management, Risk Assessment|Comments Off on Gambling With Safety: Acceptable Risk vs. Tolerable Risk

Bad Chemistry: Safe Ice-Melt

“Emotions can certainly be misleading: they can fool you into believing stuff that is definitely, demonstrably untrue.”  — Francis Spufford Places that rarely experience snow and are ill-prepared to deal with it have seen debilitating snow storms this year. In response, broadcast meteorologists and local news anchors offered advice on choosing ice melt that was [...]

By |2025-02-27T08:33:58-06:00February 27th, 2025|Chemicals|Comments Off on Bad Chemistry: Safe Ice-Melt
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