As SAFTENG wraps up another successful year, I am reminded of its success. I got a thank you note from a facility manager who hired us to build an SMS/Safety Process to “bring some sense to safety.” He and his team were tired of the ups and downs and wanted consistency in their performance with continuous improvement. A member of the Corporate staff I have worked with for decades introduced us. I...

I have to chuckle when companies and experts tell me there is no such thing as a culture of safety. That there is only one culture (if even that). I call bullshit on that belief. One way to learn this is the hard way, such as what Boeing is going through.  And on an investor call yesterday, CEO Kelly Ortberg told investors: “he plans to prioritize a culture shift to reboot the company’s...

I will probably catch a lot of flack for repeating this (as I have this debate at least annually), as very few agree with me, but it needs to be repeated!  The use of a Lockout Hasp, the device shown to the left, is NOT associated with the phrase “group lockout.” And yes, I am well aware of how these devices are marketed and sold, and yes, when they are used, they allow multiple people...

Complex systems contain changing mixtures of failures latent within them The complexity of these systems makes it impossible for them to run without multiple flaws being present. Because these are individually insufficient to cause failure they are regarded as minor factors during operations. Eradication of all latent failures is limited primarily by economic cost but also because it is difficult...

If we spend enough time in chemical plants, we will encounter a widespread, albeit severe, human failure regarding a “safety-critical instrument.”  I am referring to the IMPROPER placement of personal gas monitors.  Nine times out of 10, where do we find these personal gas monitors on the worker’s body?  I am betting your experiences are similar to mine and you would...

The EPA’s revisions of its Risk Management Plan requirements regarding emergency drills have gotten much attention.  However, they were always a bit behind when it comes to the International Fire Code.  And need I remind those of you reading this that many states have adopted the IFC in some form. A Group H occupancy is defined as: Group H, High-hazard. High-hazard Group H occupancy...

In a 2024 LOI, OSHA reiterated its position that an Eyewash (EW) station must be capable of delivering 15 minutes of water flow. This means these EW bottles are NOT an “approved” EW station. Even the double barrel wall mount with two (2) squirt bottles does not meet the minimum flow rates. However, OSHA has stated that these squirt bottles CAN help flush a worker’s eyes; they...

OSHA will not issue citations to an employer that properly uses a non-metal guard so long as the guard is constructed of a substantial and suitable material. OSHA standard, 29 CFR § 1910.219(m)(1)(i) states: Standard conditions shall be secured by the use of the following materials. Expanded metal, perforated or solid sheet metal, wire mesh on a frame of angle iron, or iron pipe securely fastened...

The investigation found that they were processing hand sanitizer bottles by shredding them and separating the plastic from the hand sanitizer. During this process, a spark was created from the machine, which initiated a minor explosion and fire. The business has refuted the fire chief’s official account, saying, “There was no explosion at the site.“ “There was a loud noise,...

This can be related to process vessels, hoppers, pits, etc.- just about any “open-topped” space. Now, when it comes to hoppers, these will fall into the PRCS category based solely on their design with “inwardly converging walls or by a floor which slopes downward and tapers to a smaller cross-section.” But even then, a very shallow hopper does not pose the same hazards by...

OSHA found an animal food producer exposed employees to the risks of explosions, fires and long-term respiratory illnesses from excessive amounts of airborne dust, among two dozen safety and health violations they identified. The findings follow an inspection after the agency received complaints of unsafe working conditions. OSHA inspectors found the company’s poor housekeeping, its failure...

One of the acceptable “protection techniques” for electrical enclosures within a Hazardous Location is to “pressurize the enclosure.”  Here are the three (3) Types of Pressurized Enclosures and the HAZLOC they are permitted to be used, and their design basis: NFPA 70, 500.7, (D) Purged and Pressurized. This protection technique shall be permitted for equipment...