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|0 Comments

“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?

Codes and Regulations: The Hong Kong High-Rise Fire

“It is your concern when your neighbor’s wall is on fire.”  — Horace On November 26, 2025, a fire enveloped a high-rise apartment in the Wang Fuk Court complex that was undergoing significant renovation. The fire killed at least 159 people and took the Hong Kong fire department almost two full days to extinguish. Hong [...]

By |2025-12-04T12:30:33-06:00December 4th, 2025|Current Events, Workplace Safety|Comments Off on Codes and Regulations: The Hong Kong High-Rise Fire

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

Missing in Tennessee: Victims of the AES Munitions Plant Explosion

“At this time, we have not located any survivors.”  — Chris Davis, Humphreys County Sheriff Not long ago, I was at a plant to facilitate a HazOp and LOPA for one of their processes. As is usually the case, my visit included going out to the process, accompanied by my host—an engineer from one of [...]

By |2025-10-16T13:35:07-05:00October 16th, 2025|Current Events, Workplace Safety|Comments Off on Missing in Tennessee: Victims of the AES Munitions Plant Explosion

Carbon Dioxide: Silent but Deadly

“I had thought fermentation was controlled death.”  — Michelle Zauner I enjoy touring distilleries. I love seeing the process of making whiskey, but I’m usually taken aback when we get to the fermentation step. Occasionally, the fermenters are enclosed and vent to the roof. Most fermenters that I see, however, are open top vats. This [...]

By |2025-11-06T11:11:31-06:00October 2nd, 2025|Chemicals, Craft Distillery Safety, Gas, Process Safety, Workplace Safety|Comments Off on Carbon Dioxide: Silent but Deadly

Hot Potato

“More often than not, to blame someone else is to play ‘hot potato’ with something that’s neither hot nor a potato.”  — Craig D. Lounsbrough Imagine you work at a plant that makes a polymer. One of the raw materials is the monomer and it is toxic, reactive, and flammable. It contains an inhibitor to [...]

By |2025-09-18T09:55:07-05:00September 18th, 2025|Procedures, Process Safety, Workplace Safety|Comments Off on Hot Potato

Confined Spaces: Even in Craft Distilleries and Microbreweries

“I have a horror of being in confined spaces.”  — Hayley Mills At a craft distillery that is not too far from Bluefield’s offices, the owner spoke about his need to climb into the pot still to clean out the stillage, especially the spent grains. He saw me wince and said, “Yeah, I know. It’s [...]

By |2025-11-06T11:12:04-06:00September 11th, 2025|Craft Distillery Safety, Procedures, Process Safety, Workplace Safety|Comments Off on Confined Spaces: Even in Craft Distilleries and Microbreweries
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