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

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

OSHA Says: Promptly, Timely, and As Soon As Possible

“We cannot do everything at once, but we can do something at once.”  — Calvin Coolidge I love a good play on words. “At once” can mean either “simultaneously” or it can mean “immediately”, and Calvin Coolidge managed to pack both meanings into a single sentence. “We cannot do everything simultaneously, but we can do [...]

By |2025-09-29T11:52:57-05:00September 26th, 2025|PHA, Process Safety, Process Safety Management|Comments Off on OSHA Says: Promptly, Timely, and As Soon As Possible

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

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?

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

Process and Product Safety: Contaminants

“All happy families are alike; each unhappy family is unhappy in its own way.”  — Leo Tolstoy, in Anna Karenina I once worked with a facility that discharged process equipment cleaning water to the city sewer. They had a tough time staying below the discharge limits for copper. In turned out that the city water [...]

By |2025-11-06T11:14:13-06:00July 31st, 2025|Chemicals, Craft Distillery Safety, PHA, Process Safety|Comments Off on Process and Product Safety: Contaminants

Recordkeeping for Process Safety: Permit Retention

“A memorandum is not to inform the reader but to protect the writer.”  — Dean Acheson A reader asked me “How long do I need to keep confined space entry permits for a covered process?” He knew my thoughts on retaining hot work permits and wondered if the same approach applied to other permits in [...]

By |2025-07-10T09:32:30-05:00July 10th, 2025|Procedures, Process Safety, Process Safety Management|Comments Off on Recordkeeping for Process Safety: Permit Retention

Run To Failure: That’s a Maintenance Strategy?

“What’s wrong with the car? What do you think’s wrong with the car? Damn thing’s broke.”  — Richard Pryor When I was a poor college student, I wasn’t too poor to have an old beater of a car. It was paid for, but I could barely afford gas, much less proper maintenance. So, I tended [...]

By |2025-06-12T13:21:45-05:00June 12th, 2025|Procedures, Process Safety, Workplace Safety|Comments Off on Run To Failure: That’s a Maintenance Strategy?
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