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 [...]

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 [...]

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?

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

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?

CSB Incident Reports: Volume 3

“We must be part of the general staff at the inception, rather than the ambulance drivers at the bitter end.”  — Lane Kirkland Despite being established under the authority of the Clean Air Act Amendments of 1990, which has not been repealed, the Trump administration intends to discontinue funding the Chemical Safety Board as of [...]

By |2025-08-07T11:01:32-05:00August 7th, 2025|Current Events, Process Safety, Process Safety Management, Workplace Safety|Comments Off on CSB Incident Reports: Volume 3

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?

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?

Incident Safety Investigations: Who Should Lead Them?

“Every man is guilty of all the good he did not do.”  — Voltaire Early in my career, our boss assigned a colleague and me to investigate an incident that was still having a significant impact on the plant. Being an arrogant know-it-all, I mean, an engineer, I was confident that I already knew what [...]

By |2025-03-20T09:21:45-05:00March 20th, 2025|Process Safety Management, Workplace Safety|Comments Off on Incident Safety Investigations: Who Should Lead Them?
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