Forensic Engineers and Consultants

Archive: Industrial Process Equipment

The Paths of Chemical Exposure

The Safety Hierarchy states that hazards should be mitigated first by engineering controls, secondly by guarding, and lastly by warning/training.  When the first two, engineering controls and guards, fail in a manufacturing setting, a chemical release could occur. A forensic chemical engineer can help determine the root cause of that failure. Read More

Ammonia – The Good, The Bad, The Smelly… Part Two

Now that you know what ammonia is (see Part One here), how it behaves, and how to safely store it and work with it, let’s look at some areas in industry where it is used.

Anhydrous ammonia has a use in pollution control.  Industrial boilers and power plants burn coal or natural gas to make steam and/or electricity. When the fuel is burned using air as the oxygen source nitrogen gets exposed to the heat as well because air is 79% nitrogen.  The nitrogen gets oxidized and forms several compounds referred to as NOx (NO, NO2, NO3).  NOx compounds are harmful to Read More

Waste Gas Treatment Equipment Failure: Design & Installation Defects Cause Fire

The thirty-thousand-foot view of manufacturing is raw material in, alter in an appropriate fashion, finished product out, by-product out.  Since the finished product keeps a business in business, it gets the most attention.  What about by-products or waste streams?  Read More

Machine Guarding and Risk Assessment

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The Occupational Health and Safety Administration (OSHA) “Top 10 for 2018” violations once again have Machine Safeguarding earning a position on the list. Machine safeguarding was the 9th most cited standard as noted in the list below:

  1. Fall protection, construction (29 CFR 1926.501)
  2. Hazard communication standard, general industry (29 CFR 1910.1200)
  3. Scaffolding, general requirements, construction (29 CFR 1926.451)
  4. Respiratory protection, general industry (29 CFR 1910.134)
  5. Control of hazardous energy (lockout/tagout), general industry (29 CFR 1910.147)
  6. Ladders, construction (29 CFR 1926.1053)]
  7. Powered industrial trucks, general industry (29 CFR 1910.178)
  8. Fall Protection–Training Requirements (29 CFR 1926.503
  9. Machinery and Machine Guarding, general requirements (29 CFR 1910.212)
  10. Eye and Face Protection (29 CFR 1926.102)

(Source: www.osha.gov/Top_Ten_Standards.html)

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Unguarded Shear Point on Force Tester Amputates Worker’s Finger

A worker was injured while testing gas springs similar to the type that hold the hatchback of an SUV open. The hazard that injured the worker was an unguarded shear point. The tester contained a mounting plate that was raised and lowered by a pneumatic cylinder.

The pneumatic cylinder lowered the mounting plate while the worker’s fingers were in the hazardous, unguarded shear point. Read More

Testing As Part of Gas Appliance Incident Investigation

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Equipment and appliances supplied with fuel gases like natural gas, propane and butane are a common and convenient part of most of our lives.  Such devices as gas grills and ranges, ovens, furnaces, space heaters and water heaters usually perform without incident.  However, when they malfunction the potential for incidents such as fires and explosions, carbon monoxide (CO) poisoning and burn injuries may occur. These incidents may be due to design and manufacturing defects in the product, or improper installation or operation of the device.

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Defective Vertical Baler Causes Serious Crush Injury to Operator’s Arm

I recently worked on an interesting case involving a box baler. An employee of a butcher shop put some empty cardboard boxes in a vertical box baler and pushed the control switch to compact the boxes. After the 30 by 60 inch platen weighing 851 pounds returned to its raised position, the employee reached into the open space above the bottom door on the baler and began to clear cardboard from the bale tie slots in the bottom of the raised platen. Suddenly, and without warning, the steel pin attaching the platen to the raised hydraulic cylinder rod failed. The heavy steel platen fell and crushed his arm which was outstretched over the baler door into the compaction space.

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Permit-Required Confined Spaces – What You Need to Know to Safely Enter (and Exit!)

According to the OSHA regulations, a confined space is anyplace that meets the following criteria:

(1)   Is large enough and so configured that an employee can bodily enter and perform assigned work; and
(2)  Has limited or restricted means for entry or exit; and
(3)  Is not designed for continuous employee occupancy. Read More

Chemical Engineers: More than Glorified Plumbers – Really!

As a senior at Virginia Tech, I was told that ChemE’s were little more than glorified plumbers.  Looking back, I’m pretty sure it was to keep our geek-egos in check. It was an effective tool! However, as I grew and traveled as a professional, it became an effective descriptor; applying to a larger scale and using a modifier or two for specific applications.  So, if you have a loss that falls into one of the categories below, a ChemE could be the expert you need. Read More

Graphitic Corrosion – Difficult to determine before a failure!

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Graphitic corrosion is a process that may happen in equipment made of iron, particularly grey cast iron, but also ductile cast iron. Graphitic corrosion can lead to unexpected catastrophic failure of the affected part because the cast iron can lose its strength without a visible warning such as a change in size, shape, or appearance. Read More

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