Articles

Industrial Process Safety a Critical Consideration When Scaling Up Production: T2 Laboratories

Success in business often starts out with a well-intended idea. In the case of T2 Laboratories, a growing market for the gasoline additive methylcyclopentadienyl manganese tricarbonyl (MCMT), inspired the company owners to leverage their chemical industry expe…

How a Past Chemical Plant Disaster Offers a Vision for an Altered Industrial Safety Future: T2 Laboratories

When most process safety incidents occur, it is never just one miscue that brings about the disaster, but, rather, a series of mistakes or shortcuts either introduced or built in that build up as a cumulative effect over time.

Why Hazard Education is an Important Plant Safety Critical Success Factor: T2 Laboratories

Learning from previous plant safety incidents large and small is critical to deploying successful process safety practices. From extreme situations where both lives and physical plant assets are lost (consider the 2007 T2 Laboratories chemical plant incident w…

Why Hazard Recognition is Step 1 in Bolstering Plant Safety: T2 Laboratories

On December 19, 2007. an exothermic reaction at T2 Laboratories, a Jacksonville, Florida-based chemical manufacturer, led to a runaway condition resulting in a massive explosion that killed four workers, injured 32 others and destroyed neighboring businesses.

When Running People Past Their Breaking Point Effects Safety: The Bayer Crop Science Incident

One element that figured prominently in the 2008 explosion at the Bayer Crop Science facility in Institute, West Virginia, was a lack of operator training for the new DCS that had just been installed at the methomyl production unit. While this was undoubtedly …

When Operators Run without Training: The Bayer Crop Science Incident

Prior to the 2008 incident, the methomyl unit at the Institute facility had been shut down for two major equipment upgrades: the DCS had been replaced and the old carbon steel residue treater vessel had been replaced with a new stainless steel pressure vessel.…

When Equipment Problems Share the Blame: The Bayer Crop Science Incident

Equipment Problems Share the Blame Bayer Crop Sciences Poses Equipment Problems Share the Blameacceptable levels. When the two operators who were killed went to the vessel, the expected to find this vent was simply blocked and were going to clear it. These …

Under Pressure to Start Production: The Bayer Crop Science Incident

Bayer Crop Science company procedures called for a PSSR (pre-startup safety review) to be run for the methomyl unit before it was restarted. This was a complex process that was supposed to prove that all the equipment and safety devices were in order, allowing…

Pushing Process Beyond Personnel: The Bayer Crop Science Incident

History has shown that industrial disasters are rarely the result of some single failure in a plant environment that is otherwise carefully operated and scrupulously maintained. In most situations, an incident, large or small, is the logical and inevitable res…

The Inevitable Cost of an Incident: BP Texas City Refinery

On March 23, 2005 at the Texas City refinery, a geyser of flammable hydrocarbon liquid and vapor erupted from a blowdown stack, which ignited creating a huge fire. The result: 15 fatalities and 180 injuries. All the individuals who died were in or around a gro…
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