Reports indicated that a cooling system failure allowed the tank's contents to overheat, creating dangerous pressure conditions that threatened an explosion. Fortunately, emergency responders were able to stabilize the situation before disaster struck. While the official investigation continues, the event serves as a powerful reminder of the importance of process safety, system design, maintenance, and redundancy in facilities that handle hazardous materials.
To better understand how similar situations can be prevented in the future, we spoke with three Bürkert USA experts: Taylor McKusick, Systems Business Development Manager; Derek Kellam, Engineering - Team Lead, and Jason Scharf, System Design Engineer.
Drawing on decades of combined experience in process automation, instrumentation, and fluid control, they shared their perspectives on the importance of integrated monitoring systems, redundant safety mechanisms, preventative maintenance, fail-safe operation, and modern automation technologies that can help facilities identify problems earlier.
TAYLOR MCKUSICK
When Bürkert works with customers on critical applications, one of the first questions we ask is: What happens if this system fails? When hazardous chemicals are involved, cooling systems, pressure management, and temperature control are often mission critical. If those systems stop working, the consequences can extend far beyond lost production time. It can affect the safety of employees and even the surrounding community.
Of course, even the best-designed system is only as reliable as the maintenance behind it. That's why monitoring and preventative care are so important. The Bürkert Efficient Device Integration Platform (EDIP) was created with this in mind. It allows operators to automate maintenance reminders, calibration schedules, inspections, and even accommodate alarm notifications. When these tasks are directly built into the control system, facilities can reduce the chances of critical upkeep activities being overlooked.
Turnover is another consideration. As more engineers retire, new professionals come in and are often asking different questions. "Why are we still doing things this way? Why are we accepting compressed air leaks, excessive water consumption, or energy losses that cost thousands of dollars every year?" Sometimes, legacy systems remain in place simply because they're familiar to the old guard, not because they're the most efficient solution available today.
Modern automation makes it possible to operate differently. Think about new data centers as an example. Some are hours away from major population centers. But with remote monitoring, data logging, and automated diagnostics, a smaller team can often oversee multiple facilities while maintaining a high level of reliability. Instead of assigning teams to each facility, a smaller team of more skilled experts can monitor multiple facilities.
We're also seeing advances in instrumentation. Multifunction sensors can now measure flow, temperature, velocity, and other process variables from a single device. That means fewer installation points, fewer potential leak paths, a smaller system footprint, and more useful process data. The result is efficient, reliable, and better prepared to identify problems before they become emergencies.
DEREK KELLAM
For applications involving potentially hazardous or reactive fluids, it is critical to conduct a comprehensive system design review, including HAZOP and FMEA analyses. These methods help identify potential hazards and operational risks by analyzing each part of the process. Their use is critical for preventing incidents, ensuring safety, and improving overall system efficiency.
A material compatibility review is also critical. Every valve, sensor, seal, and wetted component has to be suitable for the process media. If the wrong materials are used, they can deteriorate over time, creating reliability and safety issues that may go unnoticed until a problem occurs.
But it's not just about selecting the right components. You need to evaluate the entire process system. For example, are there adequate pressure-relief mechanisms? Is the tank being monitored for temperature and pressure changes?
You also make sure there are backup sensors or redundant systems in place if a primary device fails. Remember that when hazardous fluids are involved, redundancy is often one of the most important safeguards. If one layer of protection fails, another should be ready to respond.
We also place a strong emphasis on fail-safe design. Engineers need to consider what happens if power is lost, a signal fails, or a critical piece of equipment stops working. In those situations, should a valve automatically open, close, or relieve pressure? Those decisions can have a significant impact on how safely a system responds during an unexpected event.
There are a lot of factors to consider. Bürkert's integrated instrumentation and control solutions are designed to help operators track critical process conditions such as temperature, pressure, flow, and fluid quality. By allowing sensors, valves, and control devices to communicate with one another, operators gain a clearer picture of what is happening throughout the process and can often identify developing issues before they become serious problems.
While every application is different, incidents like this serve as a reminder that safety doesn't come from a single device or technology. It comes from thoughtful system design, multiple layers of protection, regular inspection and testing, and continuous monitoring. The goal is to identify small issues early, before they have the opportunity to become costly shutdowns, environmental incidents, or threats to public safety.
JASON SCHARF
No one is sure what happened, exactly, but based on the information that has been reported so far, it appears that multiple systems may have failed at the same time, or in quick succession. It may be that the tank became overheated, pressure increased, and critical safety mechanisms were either unable to respond or did not function as intended. While the investigation will ultimately determine the exact causes, incidents like this highlight the importance of building multiple layers of protection into any process involving hazardous materials.
From a Bürkert perspective, there are several ways that layers of automation and instrumentation can contribute to safer operations. As an example, Bürkert temperature, pressure and flow sensors can monitor changing process conditions initiating corrective actions before a situation becomes dangerous.
Of course, the key to safety is to ensure they work together as part of an integrated system. That's where redundancy becomes critical. In a hazardous process, it's just too risky to rely on a single sensor, a single valve, or a single layer of protection. Multiple temperature sensors, pressure sensors, flow sensors, and automated valves need to be configured to verify one another and provide backup protection if one component fails. For example, if the pressure in a tank starts to rise, a pressure sensor can be used to trigger a vent valve to open. The pressure sensor can then be used to confirm that pressure is being relieved and the vent valve can then be closed. If that doesn't happen, a secondary system can be triggered automatically.
One of Bürkert's strengths is the ability to integrate these components into a coordinated control system. Sensors, valves, and monitoring devices can communicate with one another, providing operators with real-time information and helping them identify problems before they escalate. When you have a system in place, instead of reacting to a full-blown emergency, it's possible to detect abnormal conditions early enough to prevent a crisis.
However, even the best-designed system is only as reliable as its maintenance program. Safety devices, sensors, and valves must be inspected, tested, and maintained on a regular schedule. There's a long history of industrial incidents happening because safety systems were neglected, improperly tested, or allowed to fall into disrepair. Redundancy only works when every layer of protection remains operational.
That's why maintenance should be viewed as part of the safety system itself. At Bürkert, our service team can support customers by helping establish maintenance schedules, perform inspections, and verify that critical components continue to operate as designed. Whether maintenance is performed by the facility's own personnel or with outside support, consistent testing and verification are essential.
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As of this writing, the official investigation into the GKN Aerospace incident remains ongoing, and Bürkert is not involved in that investigation. As a result, it would be inappropriate to speculate on the specific causes of the event or the effectiveness of the systems that were in place.
However, incidents involving hazardous materials serve as important reminders of the value of comprehensive process safety planning. Industrial facilities can reduce risk through a combination of properly engineered systems, appropriate instrumentation, multiple layers of protection, preventative maintenance programs, operator training, and regular inspection of critical equipment. The specific requirements for any application depend on numerous factors, including the process, media, operating conditions, regulatory requirements, and facility design.
At Bürkert, we work with customers to develop fluid control and automation solutions that support safe, reliable, and efficient operations. While no single product or technology can eliminate all risk, a systematic approach to process design, monitoring, maintenance, and continuous improvement can help facilities identify potential issues earlier and improve their ability to respond to changing operating conditions.
Every application presents unique challenges, and system design decisions should always be made in consultation with qualified engineering, safety, and regulatory professionals who are familiar with the specific process and operating environment. Contact Bürkert today to learn more.
