Forensic Engineers and Consultants

Tag Archive: Jennifer Morningstar

  1. Steam Explosions…Spectacular Expansions, Spectacular Losses

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    I’ve heard some people say that the term steam explosion is a malaprop because explosions involve combustion.  However, if you look up the definition of explosion, you get this: “a large-scale, rapid, or spectacular expansion or bursting out or forth.” (Thanks, Meriam-Webster!!)  If you’ve ever witnessed a steam explosion, you’ll agree that it is a MOST appropriate term!

    Steam explosions occur when water or other liquid undergoes a sudden phase change (more…)

  2. One of the Most Amazing Compounds Around – Water?!?!

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    Around Christmas day of 2022, a mass of very cold air settled in the deep south/southeastern United States (where I live).  It remained below freezing for over 24 hours.  That is very unusual down here.  There was a spate of burst pipes all over the area.  Why?  Water is one of a very few compounds that expands when it freezes…by approximately 9%!!  If a volume of water is sealed off in a section of piping, and that water freezes, it is likely the pipe will rupture. Then, when it warms up again and thaws, liquid water will leave the pipe for an adventure!! (more…)

  3. Everybody Has A Part to Play – What’s Your Role?

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    Across industry and construction sites, there are times when employees of different employers are working side by side, or at least on the same site at the same time.  Some industry examples are when chemical plants have contractors on-site for routine maintenance or during process shutdowns for major overhauls or repairs. OSHA refers to these as multi-employer worksites.  In December of 1999, they revised their citation policy which allows for more than one employer at a worksite to be cited for conditions that violate OSHA standards. (more…)

  4. What Does a Recovery Boiler Recover? – Quite a bit, actually!

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    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…)

  5. OSHA’s Process Safety Management – Is This Process Covered?

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    In February of 1992, the OSHA Process Safety Management (PSM) standard was issued. The official title is: ‘Process Safety Management of Highly Hazardous Chemicals.’ As its title implies, not every facility is covered by this rigorous standard. A process must contain highly hazardous, as defined by OSHA, chemicals above a certain weight threshold, again defined by OSHA. Notice that this is a process by process determination, so there could be certain processes at a manufacturing facility that are not covered by this standard situated beside other processes that are.
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  6. Boiler Blowdown – It’s Not a Dance Move

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    When thinking about the safe operation of boilers (and don’t we all?), several systems can readily be named; flame control, fuel/air ratio; steam pressure control, levels in the vessel, etc. What about the water? It seems so passive, as long as there is enough for level control, what’s the big deal? Well, it turns out, that as the steam produced by a boiler is used in the process, the condensate from that steam is returned to the boiler as feedwater. However, since 100% of the condensate is not returned, whatever solids had been in that water before it evaporated to form steam are left in the remaining water.  Fresh feedwater is added to maintain levels, but even fresh water contains some dissolved solids. So over time, the water in the boiler system gets saturated with all sorts of dissolved minerals.
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  7. How a Central Indian Town Changed the United States Code of Federal Regulations

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    On December 3, 1984, at a pesticide ingredient manufacturing facility owned by Union Carbide, a leak occurred in the Methyl Isocyanate (MIC) plant. Due to the toxic nature of the gases released and the plant’s proximity to local residences, the death toll was in the thousands; both plant workers and nearby residents.  The first recorded public meeting in response to this incident was on December 9th, in Institute, WV, the site of Union Carbide’s only US MIC production unit.  Full disclosure: my father was a research & development chemist for Union Carbide and Institute is about 10 miles down the Kanawha River from my hometown of Charleston, WV. (more…)

  9. Commercial Gas-Fired Cookers Can Do More Than Burn

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    The first hazard that comes to mind when thinking about large scale ovens and steam kettles is burning or scalding injury. Carbon monoxide poisoning is just as dangerous but less understood, so oftentimes proper prevention methods are not followed. In the United States, this results in over 20,000 emergency room visits and over 400 deaths a year. Before we get to the case study and poisoning prevention methods, we need to know what CO is, where it comes from, and why it is poisonous. (more…)

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