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I am proud to announce that SAFTENG and The Chlorine Institute have renewed our partnership for another year (through 2026).  Members of The Chlorine Institute receive a FREE SAFTENG membership.  If you qualify, please contact me

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Why does OSHA use 10% LEL to define a HAZ ATM within a PRCS?
One of the top questions I get via SAFTENG and in my PRCS or Hazardous Atmospheres training courses is… Why did OSHA use 10% LEL to define a hazardous atmosphere? There is an official and logical reason, both of which should be understood. First, the “official” reason: … HomeRead More »
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"Banner Safety," it can work, but often does more harm than good
We have all seen them; most of us have used them to deliver a safety message.  Let me say this up-front: it is never the banner’s fault! A SAFTENG member was reading my posts about “safety banners” and contacted me to discuss their use.  They were convinced I was 100% against using “safety banners” after reading my rants against their use.  I had to point...
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PRCS incident kills 7, injures 3 @ Cement Plant (LOTO Failure - 2 Videos)
   Source: VnExpress/Anh Phu   Seven (7) workers were killed, and three (3) others were injured while conducting periodic maintenance on one of the plant’s kilns when the incident occurred.  When the workers entered the rotary kiln to start the repair work, the kiln unexpectedly restarted. Replacing the eroded kiln plates is done every 5-7 months and “Things usually...
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Figures 1 and 2 Gas cylinders with inappropriate use of Teflon tape
H2 and O2 explosion learnings (UH explosion resultings in amputation)
Since gas use was integral to the UH accident and since compressed gas cylinders present serious safety issues, several specific examples of improper gas and gas cylinder usage are detailed here. 1. Cylinders in the laboratories adjacent to POST 30 as well as in several laboratories located in different buildings, contained Teflon tape on the CGA connection threads to the cylinder valveoutlet (Figures...
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Employee injured in Wisconsin stadium explosion settles suit for $22M
He was working for a subcontractor on April 13, 2022, when a GC foreman used a flame torch to dry an area of the floor of an enclosed mechanical room beneath the football stadium as he and another worker were applying a flammable material to the floor. The torch sparked an explosion, and he was burned over 70% of his body when he tried to run from the room but stumbled, spilling primer on himself,...
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Utilizing an SMS needs to be a CORE VALUE, not a government mandate
Image Souce:  Flight Guardian
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20 container
Combustible Dust and entry into Permit-Required Confined Spaces (PRCS)
Both OSHA PRCS standards define and quantify a Hazardous Atmosphere in terms of combustible dust using the distance one can see through the dust cloud… Hazardous atmosphere means an atmosphere that may expose employees to the risk of death, incapacitation, impairment of ability to self-rescue (that is, escape unaided from a permit space), injury, or acute illness from one or more of the following...
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VW Plant votes 73% to 27% for a union - Is this a measure of "culture"?
VW chose Tennessee for its new assembly plant because it is a “right to work” state. The union campaigns lost in 2014 and 2019, but last week, it won big (2,628 for and 985 opposed), at least based on the NLRB count so far. A few votes are being challenged, but nothing near the number needed to change the overall outcome.   Could this be viewed as a cultural indicator?  We are...
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Safety Thought of the Week... Operating situations are richly varied
Some raw materials are sensitive to humidity; this valve sticks and is more demanding than its supposedly similar neighbor; that pump has broken down; this operation sometimes occurs at night and sometimes during the day, sometimes when it’s hot, other times when it’s cold, sometimes our co-worker is tall, sometimes he is short, we may be under pressure time-wise, etc. Thanks to their experience and...
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TV Remotes HFE A. Dalton Credit
Making Human Factors matter by REDUCING the opportunity for error
The story behind this picture is said to be a 19-year-old granddaughter’s attempt at designing for her grandfather’s dementia. Human Factors Engineering (HFE)!!! Making human factors matter by REDUCING the opportunity for error. It really can be this simple! Pic Credit: Amy Dalton
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Ford Quaility is 1
Safety Management System (SMS) was stolen from the QMS/ISO era of Quality
If you have ever attended one of my SMS presentations or training courses, you know I am a huge Edward Demming fan. I started my career during the ISO 9001 era, which many call the “Quality Era.”  Do you remember Ford’s slogan in the 1990s?  “Quality is #1,” and the ISO quality movement was considerably driven by automobile manufacturers such as Ford, GM, etc.  But...
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Line Break gone bad (Hydrate)
The following incident is a precautionary example of the potential hazards of improperly depressurizing piping to remove a hydrate.  During production operations, a control room operator observed a decrease in gas lift pressure supplied through a pipeline to a remote well location. The control room operator notified the onboard platform operators of the pressure drop and the possibility of a hydrate...
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