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On January 24, 2020, a catastrophic explosion occurred at Watson Grinding and Manufacturing, a precision machining and coatings facility in Houston, Texas. The explosion was triggered by an undetected propylene gas leak, resulting in the deaths of two employees, severe damage to nearby businesses and homes, and multiple injuries. The U.S. Chemical Safety Board (CSB) conducted an in-depth investigation to identify the causes of the explosion and propose safety improvements.

Battery manufacturing presents complex safety challenges involving flammable solvents, reactive materials, combustible dust, and high stored electrical energy. While not all facilities fall under formal Process Safety Management (PSM) regulations, the hazards present mirror those found in traditional high-risk chemical processing environments. From slurry preparation and drying operations to formation and testing of high-energy cells, abnormal but foreseeable conditions can e

When deficiencies in safeguards against hazardous scenarios are discovered as part of a Process Hazard Analysis (PHA) study, it is required that a recommendation is made in order to mitigate the concern identified.