Process Safety: Common Causes

“By becoming interested in the cause, we are less likely to dislike the effect.”  — Dale Carnegie I love the English language, even though I make a hash of it on occasions. I love its complexity and irregularity. I especially love the words. There are so many words that mean almost the same thing that [...]

By |2026-02-12T14:19:21-06:00February 12th, 2026|PHA, Process Safety|0 Comments

Incident Investigations: When Are They Needed?

“It seems to me that at this time we need education in the obvious more than investigation of the obscure.”  — Oliver Wendell Holmes, Jr. OSHA requires incident reports. For recordable injuries or illnesses, OSHA requires that a 301 Form, Injury and Illness Incident Report, be completed, per 29 CFR 1904.29(a). For workplaces with PSM-covered [...]

Process Safety: When “Normal” Isn’t Normal

“You keep using that word. I do not think it means what you think it means.” — Mandy Patinkin as Inigo Montoya from The Princess Bride (1987) I, like many older Americans, worry about my blood pressure enough to check it regularly. And like most people who check their blood pressure regularly, I know what [...]

By |2026-01-29T11:00:03-06:00January 29th, 2026|Procedures, Process Safety, Process Safety Management|Comments Off on Process Safety: When “Normal” Isn’t Normal

Process Safety: Pumping

“What a pure blessing it was to have a bath in a tub alone in a room where all you had to do was pump the water, not tote buckets.”  — Nancy E. Turner Somewhere in every process facility, liquids flow through pipes. Sometimes that flow is pulled by gravity. Some facilities push the liquid [...]

By |2026-01-22T13:48:47-06:00January 22nd, 2026|Chemicals, Process Safety, Workplace Safety|Comments Off on Process Safety: Pumping

Pressure Relief in Distilleries

“Pressure’s what you make of it.”  — Daniel Ricciardo Years ago, a colleague told me, “If the pressure is too high, it’s going to find a way to relieve. If you don’t plan for pressure relief, then you don’t get to pick how and where it relieves. And that can be disastrous.” For every piece [...]

By |2026-01-16T14:24:13-06:00January 16th, 2026|Craft Distillery Safety, Process Safety, Process Safety Management|Comments Off on Pressure Relief in Distilleries

Risk Management Plans: How Many?

“I have so much paperwork. I’m afraid my paperwork has paperwork.”  — Gabrielle Zevin One of the key differences between OSHA’s Process Safety Management (PSM) standard and the EPA’s Risk Management Planning (RMP) rule is the RMP rule’s requirement to submit documentation to the EPA. OSHA has no similar requirement for submission. If OSHA wants [...]

By |2026-01-08T12:37:41-06:00January 8th, 2026|Chemicals, Procedures, Process Safety|Comments Off on Risk Management Plans: How Many?

“OSHA Says”: Making a List, Checking It Twice

“You know what’s the greatest part of anything ever in the history of everything? Exaggeration. No wait; it’s correcting yourself. No, better yet, it’s making lists.” — Demetri Martin When Google offers an AI response, it includes a statement: “AI responses may include mistakes.” That was never so obvious to me as when I posed [...]

By |2026-01-14T18:26:57-06:00December 18th, 2025|Craft Distillery Safety, Procedures, Process Safety, Process Safety Management, Workplace Safety|Comments Off on “OSHA Says”: Making a List, Checking It Twice

Temperature Extremes: How Cold Is Too Cold to Touch?

“We sometimes freeze the specimen with liquid nitrogen, which is extremely cold, you know. This is another technique we use now – but the specimens are not alive.”  — Lennart Nilsson I recently facilitated a HazOp where the process required both very hot heat transfer media (steam and hot oil) and very cold heat transfer [...]

By |2025-12-11T12:40:53-06:00December 11th, 2025|Process Safety, Risk Assessment, Workplace Safety|Comments Off on Temperature Extremes: How Cold Is Too Cold to Touch?

SDSs: Can They Be Relied On?

“Don’t be misled by History, or any other unreliable source.” — Will Rogers I remember when I lost faith in safety data sheets – SDSs. Well, they were called Material Safety Data Sheets – MSDSs – then. I was a young engineer, and the only engineer, at a start-up. My boss, the owner, assigned me [...]

By |2025-11-20T09:39:27-06:00November 20th, 2025|Chemicals, Process Safety, Risk Assessment|Comments Off on SDSs: Can They Be Relied On?

The UPS Flight 2976 Crash: What Are the Chances?

“But you don’t ever think it would happen to you.” — Kyla Kennedy, server at Stooges Bar and Grill, near SDF (as quoted by CNN) The first time I ever gave any thought to the risk of a plane crashing into a chemical plant was when an acquaintance approached me at a conference with the [...]

By |2025-11-13T13:21:14-06:00November 13th, 2025|Current Events, Process Safety, Risk Assessment|Comments Off on The UPS Flight 2976 Crash: What Are the Chances?
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