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Interpreting Industrial Incident Data – Lesson Learned
June 17, 2021 12:46 pm Leave a Comment
This is a case study about an incident I investigated involving a major upset in a distillation column. This blog builds on the previous blogs about the Distributed Control System, DCS – Data is the Key.

Distillation is a method of separating mixtures of compounds with differing boiling points. Uncle Bill with his still on the hill separates ethanol, that boils at 173°F, from water that boils at 212°F. If the mixture is heated to above 173°F, but below 212°F, the ethanol will boil, the vapor will travel up out of the unit and then can be condensed and served over ice with an olive… Any mixture of two or more chemicals with different boiling points can be separated in this way. The distillation (more…)
The Condensate System – An Important Item in Routine HVAC Maintenance
May 20, 2021 11:09 am Leave a Comment
HVAC systems are almost everywhere in the United States now. As a life-long resident of the humid south that grew up in a home without central air conditioning; I definitely appreciate the ability of a well-designed and maintained HVAC system to remove the oppressive summer humidity.

The very humidity that makes your clothes damp with sweat and hastened the invention of cooled leather seats in automobiles also has another route to create havoc…condensate.

In order for an HVAC or “air-conditioning system” to reduce the humidity in the air of your home or office it must first cool the air down to a point where the air can no longer keep the moisture in suspension as water vapor. The moisture must condense… creating condensate. This is what is happening when your cool beverage of choice “sweats” on the exterior of the container in the humid summer. Now that you have liquid water, as opposed to water vapor, this condensate must be directed out of your conditioned space to prevent water damage due to backed up or leaking condensate. (more…)
What Does a Recovery Boiler Recover? – Quite a bit, actually!
May 19, 2021 3:39 pm Leave a Comment
The Kraft paper process was invented in 1879 and produces a stronger finished product that other paper manufacturing methods. One of the waste streams is known as black liquor and is a mixture of solids and water. It contains lignin, hemicelluloses and chemicals used in the pulping process. The original process had no use for this harmful waste stream and it was dumped into nearby waterways, to their detriment!!! Mr. G.H. Tomlinson invented the recovery boiler in the early 1930’s. This development made the Kraft process the manufacturing method of choice, as explained below. (more…)
Improper Hearth Extension Leads to Structure Fire
March 25, 2021 3:54 pm Leave a Comment
The fire service affords you the opportunity to witness and observe things that a lot of engineers and even most people do not get the chance to see. An example of this is the situation where extended elevated temperatures combined with poor construction techniques to result in a structure fire.

I have personally observed several occasions where a structure fire was initiated due to improper construction of the fireplace hearth extension. The most recent one followed a multi-day cold snap, at least by South Carolina standards. The thermometer read 17 degrees F as I drove to the call of smoke in a residence (more…)
Heat Exchanger Failures Will Shut Your Process Down
February 26, 2021 11:11 am Leave a Comment
Heat exchangers, as the name implies, are used to bring a process stream to a desired temperature. They can heat or cool either gases or liquids. They are fairly intricate in their construction, therefore not the cheapest piece of equipment to purchase. For that reason, facilities don’t keep “spare” exchangers lying around, so when they fail catastrophically, the entire manufacturing process goes down with them… and stays down until they are fixed or replaced. Ow!

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Proper Construction and Maintenance Can Prevent Deadly Chimney Fires
February 16, 2021 1:52 pm Leave a Comment

There are few things as comforting to me during the winter months as a warm fire burning in the fireplace. And in this case, I am talking the real deal, the kind that warms you multiple times; from cutting, splitting and stacking the firewood until finally lighting a fire in the fireplace. However, just like your parents taught you, fire can be dangerous. And having an actual fire in your home fireplace comes with some required maintenance to ensure you can safely control the fire and keep it where it belongs. (more…)
Major Causes of Wood Truss Failures
February 10, 2021 8:45 am Leave a Comment
Wood truss failures can vary and identifying the cause requires visual inspection as well as a working knowledge of the structural loads and building codes. These truss systems must transfer the gravity and lateral loads to the foundations. Consequently, the framing system and the foundation provide strength and stability for a structure. The most common type of wood-framed construction uses roof trusses, exterior and interior load-bearing walls, beams, girders, posts, and floor framing to resist the gravity and vertical loads. This type of wood-framed construction engages a system of horizontal diaphragms (roof and floors) and shear walls (vertical exterior sheathed walls) to resist the lateral loads. (more…)
Stress Corrosion Cracking of Stainless Steel in Marine Environments
January 29, 2021 3:37 pm Leave a Comment
Stress corrosion cracking involves the slow growth of small, often microscopic, cracks through a metal part in a corrosive environment. The cracking can continue to the point that the part fails suddenly and unexpectedly even though it still appears new and in good condition.

My first experience with stress corrosion cracking happened in the Charleston harbor when the stainless steel rudder suddenly separated from a sailboat during moderate winds. What had been a pleasant evening sail turned instantly into being in a difficult to control boat in the middle of the busy shipping channel. The rudder remained attached only (more…)
Residential Structure Fires
January 25, 2021 2:05 pm Leave a Comment
The winter season is well underway in the United States, with the Christmas and New Years holidays behind us and the depths of cold weather here for the duration. With winter, many people spend more hours indoors as compared to the summer when outdoor activities ramp up. With more time spent indoors, it is somewhat intuitive that the use of electricity would increase as well.

Electricity is one of the most influential utilities in our daily life. Much of what modern societies rely on to get through a normal day requires electricity. Have you ever been in a slight panic looking for an electric outlet when your cell phone is below 10% charge? Or how many times do we all attempt to turn on a light switch when we enter a room during a known power outage from sheer habit? Even our personal transportation which has relied on gasoline for roughly 100 years is shifting toward electric automobiles. (more…)
Heating System Losses, Part One
January 18, 2021 9:36 am Leave a Comment
When fall and winter arrive and temperatures drop, it is a great comfort to have a heating system to warm your home or office. Several categories of heating equipment exist to provide both primary and secondary heating. Primary heating systems include fuel gas/fuel oil/electric forced air furnaces, heat pumps, hydronic heating/steam systems and even wood-fired heating systems. Secondary heating equipment includes electric, gas and kerosene space heaters of both fixed and portable design, and fireplaces. Each of the different types of heating systems have unique hazards that, uncontrolled, can result in fires, explosions, burn injuries, and carbon monoxide poisoning. (more…)

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