In theory, everything will work as planned. It's not until a system is tested that manufacturers can be certain their processes are sound. Even better, an unexpected "test" to the system will expose all chinks in the process chain.

Enter Rocky Raccoon. According to Industry Safety And Security Source, a raccoon found its way into electrical equipment at the Delaware City, Del., refinery knocking a number of units offline, causing a large flaring incident in early December.

Searching for information on electrical risks, I came across a funny sign. It reads: Caution -- If you think OSHA is a small town in Wisconsin you're in trouble.

Worker safety should be the No. 1 concern for any chemical manufacturer. Sure, a robust bottom line is nice – but if companies put employees at risk to achieve financial results they're going to spiral down fast. And even if manufacturers are following protocol to keep the workforce safe, sometimes it's not enough.

A Chemical Processing reader brought to my attention a safety concern he had with a recent column I wrote, Sit back and Listen. In this column I highlight our podcast series and encourage readers to download podcasts and listen to them during their downtime, which in my opinion includes driving.

The U.S. Chemical Safety Board recently released the paper "Seven Key Lessons to Prevent Worker Deaths During Hot Work In and Around Tanks -- Effective Hazard Assessment and Use of Combustible Gas Monitoring Will Save Lives"

Dear Sir:
 
You picked a great topic and started out - I am sure - with a good intention.  But somehow you managed to overlook a most inconvenient truth. 

Dear Mr. Rosenzweig,

I have read your editorial on Bhopal, as well as Professor Kletz's article, in the recent edition of Chemical Processing.

I recently traveled to Blue Springs, Mo., to visit with the folks at Fike Corp., supplier of products and services that protect people and critical assets from dangers such as fire, explosion and over-pressurization.

Specifically, I went there to interview experts about the importance of assessing the risk of dust explosions.

I regularly monitor chemical accidents in the news. It's a way to help me understand the dangers that Chemical Processing readers face on a daily basis. Manufacturing can be a dangerous profession. Add chemicals to the mix and the potential hazards grow exponentially. The best defense is being prepared for the worst.

Indeed, just last week a chemical leak at the Bayer CropScience plant in Kansas City, Mo., was quickly contained by Kansas City hazmat crews and Bayer emergency crews.

If you've never been to the U.S. Chemical Safety Board's Web site, it's time you remedy that. The site is full of useful videos, news and articles all aimed at helping you make your site a safer place to work.