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?

Process Safety in Distilleries: Electrical Classification

“To be beyond any existing classification has always pleased me.”  — Boyd Rice Every distiller understands that they are working with extremely explosive hazards. There is ethanol, a flammable liquid.  And there is milled grain, a source of combustible dust. Despite this, when I visit distilleries, I often see areas that should be electrically classified [...]

By |2025-11-06T11:07:10-06:00November 6th, 2025|Craft Distillery Safety, Process Safety, Risk Assessment, Workplace Safety|Comments Off on Process Safety in Distilleries: Electrical Classification

Combustible Dust: Probability of Ignition

“Before the first atomic bomb test, scientists took the time to calculate whether the blast would ignite the nitrogen in the Earth’s atmosphere and incinerate us all. The risk was low and the test went off, but Rees wonders what the odds would have had to be to discourage the bomb makers.”  — Dennis Overbye [...]

By |2025-10-30T10:55:47-05:00October 30th, 2025|Process Safety, Process Safety Management, Workplace Safety|Comments Off on Combustible Dust: Probability of Ignition

The PSM Standard: Are Craft Distilleries Covered?

“A rule without exceptions is an instrument capable of doing mischief to the innocent and bringing grief—as well as injustice—to those who should gain exemptions from the rule’s functioning.”  — Derrick Bell I don’t remember when I first realized that there is a difference between process safety management and Process Safety Management. Process safety—the aspect [...]

By |2025-11-06T11:11:04-06:00October 23rd, 2025|Chemicals, Craft Distillery Safety, Process Safety, Process Safety Management|Comments Off on The PSM Standard: Are Craft Distilleries Covered?
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