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

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

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?

Bad Chemistry: Mixing Cleaning Products

“Ignorance is not too dangerous. If you combine it with power, then this is a toxic mix.”  — Yuvai Noah Harari Not surprisingly, eighteen of the thirty incidents in Volume 3 of the Chemical Safety Board’s series on incident reports addressed incidents at refineries and large chemical complexes. One incident in Volume 3, though, was [...]

By |2025-11-06T11:13:32-06:00August 14th, 2025|Chemicals, Craft Distillery Safety, Process Safety, Workplace Safety|Comments Off on Bad Chemistry: Mixing Cleaning Products

A+: What Is A Perfect PHA?

“Perfection is not attainable, but if we chase perfection, we can catch excellence.”  — Vince Lombardi I don’t believe that I have ever facilitated a perfect PHA. The question is, how would I recognize it if it was perfect? And would others agree? What exactly is a perfect PHA? A PHA Identifies Hazards The primary [...]

By |2025-05-08T16:39:47-05:00May 8th, 2025|PHA, Process Safety, Process Safety Management, Recommendations|Comments Off on A+: What Is A Perfect PHA?

“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 |2025-05-23T13:13:02-05:00April 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?

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
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