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|0 Comments

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 [...]

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

Ethanol: What Are the Limits?

“Ventilation is the profound secret of existence.”  — Peter Sloterdijk Most people, when hearing about the legal limits of ethanol, will think of Blood Alcohol Concentration (BAC). Except for Utah, where the BAC limit for driving is 0.05%, the BAC limit in the United States is 0.08%. That applies to drivers that are 21 years [...]

By |2025-11-06T11:12:56-06:00August 28th, 2025|Chemicals, Craft Distillery Safety, Process Safety|Comments Off on Ethanol: What Are the Limits?

Clairton Coke Works: Time to Close?

“Obsolescence is a factor which says that the new thing I bring you is worth more than the unused value of the old thing.” – Charles Kettering I am the blacksmith at a historic village. I burn coke, coke I make right there on the forge. I start by laying bituminous coal around the coke [...]

By |2025-08-21T15:09:20-05:00August 21st, 2025|Current Events, Workplace Safety|Comments Off on Clairton Coke Works: Time to Close?

Hot Work: Explosion and Fire in Tequila, Mexico

“Tastes like heaven, burns like hell.” — Fireball slogan Tequila is a far cry from the cloying cinnamon-flavored spirit called Fireball. But they both have one thing in common: they burn like hell. Literally. As do all spirits. For reference, the flash point of 80 proof (40% ABV) spirits, is 26 C (79°F), meaning [...]

By |2025-07-24T09:20:38-05:00July 24th, 2025|Chemicals, Process Safety, Workplace Safety|Comments Off on Hot Work: Explosion and Fire in Tequila, Mexico

Unusual Process Hazards: Manhole Covers

“If I had a nickel for every time this happened, I’d have two nickels. Which isn’t a lot, but it’s weird that it happened twice. Right?”  — Dr. Heinz Doofenshmirz Friends and acquaintances recently flooded my inbox with stories about a series of sewer explosions near the north riverfront of St. Louis. It launched several [...]

By |2025-01-14T13:58:57-06:00September 5th, 2024|Chemicals, Current Events, Process Safety|1 Comment

Close to the Edge: Banking, Railroads, and…the Chemical Industry?

“Banking should be boring.”  — Senator Elizabeth Warren We tend to celebrate those adventurers who take big risks for the chance at big rewards, at least when it pays off. On the other hand, we tend to condemn those that take big risks but don’t suffer the consequences when their risk-taking doesn’t pay off. Especially [...]

By |2025-01-16T13:27:35-06:00March 23rd, 2023|Chemicals, Current Events, Process Safety|Comments Off on Close to the Edge: Banking, Railroads, and…the Chemical Industry?

Just Right: Hazardous (Classified) Locations

“My life experience confirms that the U.S. government frequently overclassifies data.”  — Michael Hayden When it comes to hazardous (classified) locations—electrical classification—even seemingly sophisticated technical facilities often get it wrong. The issue isn’t with the class, or the group, but with the division. Getting the division wrong, though, can render a facility more hazardous than it [...]

By |2025-08-07T15:03:33-05:00January 26th, 2023|Chemicals, Combustible Dust, Process Safety|Comments Off on Just Right: Hazardous (Classified) Locations

Not a Dust Explosion: Fatalities at a Polish Granary

“The essential act of war is destruction, not necessarily of human lives, but of the products of human labor.”  — George Orwell Yesterday afternoon, I was asked what I knew about the granary explosion that happened in Poland, killing two workers. I hadn’t heard of it, but my thoughts immediately went to NFPA 652, the [...]

By |2025-01-16T13:48:57-06:00November 17th, 2022|Combustible Dust, Current Events|1 Comment
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