Services, Tools, & Resources for the Industrial EHS Journey!
It Just Happened - You Need Help Right Now!
A skilled experienced temporary extension of your management team
You can call companies like ServPro for disaster recovery after an incident to help with the physical cleanup and mess that's been made, but who can you call to step in as your in-house expert to work as an experienced extension of your management team for an limited duration assignment who has over 40 years experience been involved in dozens of similar incidents. I am that guy; I have been there to focus on getting things properly assessed and rebuilt, creating confidence in the operating staff in the solutions, and then helping to implement systems so that it never happens again.
It was a while ago - We Never Want It to Happen Again!
Please Assess What We've Done - Are We in Compliance - Risk Appetite?
PLEASE - WE NEVER WANT THIS TO HAPPEN AGAIN! I've heard this often, sitting face-to-face with the leadership and boards of public companies. The answer is to verify compliance with all applicable codes and standards and then assess the relative level of risk that has been knowingly or unknowingly accepted. We aim to make risks related to fuels and fired equipment systems tangible and well-understood so they can be managed in the same context as more easily understood operational risks. We can review the path you're on "post-incident" and provide guidance that can change cultures. Only culture change, accountability, and risk-based management secure the future against similar incidents.
CRISIS Management for Fuels & Fired Equipment Incidents
Our Mission
Our Experience
Our Experience
Case Study: Building a Legacy of Safety at Ford Motor Company
In 1999, a tragic explosion at Ford Motor Company’s Rouge Facility in Dearborn, Michigan, claimed six lives and highlighted critical gaps in fuels, fired equipment, and boiler safety management. In response, Ford retained John Puskar, P.E., and his team to develop and implement
Case Study: Building a Legacy of Safety at Ford Motor Company
In 1999, a tragic explosion at Ford Motor Company’s Rouge Facility in Dearborn, Michigan, claimed six lives and highlighted critical gaps in fuels, fired equipment, and boiler safety management. In response, Ford retained John Puskar, P.E., and his team to develop and implement a comprehensive safety program to address these risks across all their facilities.
Mr. Puskar’s approach combined technical expertise, rigorous process design, and hands-on training. He and his team created checklist-based systems to identify and screen for hazards associated with fuels and fired equipment, ensuring risks were identified and mitigated before incidents could occur. A cornerstone of this initiative was the extensive hands-on training program, which equipped thousands of team members and contractors with practical skills for operating and maintaining combustion equipment safely.
This work extended to every Ford facility in North America and many international sites, establishing a standardized and effective safety framework. Over the past 20 years, this program has evolved into a cornerstone of Ford’s risk management strategy for fired equipment systems.
Mr. Puskar’s ongoing efforts have not only improved safety but also embedded a culture of vigilance and best practices within Ford’s operations. This long-term partnership exemplifies how targeted, expert-driven programs can create enduring impacts on safety and operational excellence.
Our Experience
Our Experience
Our Experience
Case Study: Transforming Safety and Risk Management for a $9B Manufacturer
In December 2023, a $9B U.S. manufacturer faced a devastating explosion at its new $100MM manufacturing facility during commissioning. The gas-fired furnace explosion caused extensive damage to critical infrastructure, including electrical switchgear, halting operat
Case Study: Transforming Safety and Risk Management for a $9B Manufacturer
In December 2023, a $9B U.S. manufacturer faced a devastating explosion at its new $100MM manufacturing facility during commissioning. The gas-fired furnace explosion caused extensive damage to critical infrastructure, including electrical switchgear, halting operations at a plant that employed nearly 200 people. This facility was integral to the company’s vertically integrated operations, supplying essential materials to dozens of other plants. While no injuries occurred, the incident highlighted a serious risk: rebuilding without understanding the root cause could lead to a repeat event, potentially with catastrophic consequences.
Recognizing the gravity of the situation, the company flew John Puskar, P.E., via private jet from Cleveland, Ohio, within 24 hours. With decades of experience in industrial safety and risk management, Mr. Puskar knew that identifying the root cause was paramount before any reconstruction efforts could begin. Over several weeks, he led a structured root cause investigation using Kepner Tregoe and 5 Why’s methodologies. These efforts included intensive team meetings with groups of 20–30 individuals from various parts of the company, building consensus around root and contributing causes.
Mr. Puskar dedicated himself to the project long-term, spending over 100 hotel nights onsite and working weekly for months to provide consistent support. He collaborated closely with key management team leaders, acting as an extension of the management team to facilitate the redesign and reconstruction efforts. Additionally, he brought in a team of experts in critical areas such as process safety, electrical systems, and operational training to ensure a comprehensive recovery.
Once the root cause was established, Mr. Puskar supported the team in conducting Process Hazard Analyses (PHA) and Layer of Protection Analysis (LOPA) to validate system improvements and ensure safety enhancements. He also played a key role in developing tailored training programs and fostering a sustainable safety culture, focusing on managing risks associated with fuels and fired equipment.
The recovery and improvement process took nearly a year. Today, the facility operates at record production levels, with robust safety systems and a workforce empowered by enhanced risk management practices. This case demonstrates Mr. Puskar’s ability to integrate seamlessly with management teams to drive transformative change, combining technical expertise with a collaborative and strategic approach.
Our Approach
Our Experience
Our Approach
Case Study: Enhancing Safety and Rebuilding After the 2009 ConAgra Foods Plant Explosion
In 2009, a devastating explosion at ConAgra Foods’ Garner, NC plant shook the company and the surrounding community. The incident tragically claimed four lives, injured many others, and caused extensive damage to the facility. The explosion was tied to
Case Study: Enhancing Safety and Rebuilding After the 2009 ConAgra Foods Plant Explosion
In 2009, a devastating explosion at ConAgra Foods’ Garner, NC plant shook the company and the surrounding community. The incident tragically claimed four lives, injured many others, and caused extensive damage to the facility. The explosion was tied to issues involving fuels and combustion equipment, creating an urgent need for expertise to address the root causes and guide the recovery process.
John Puskar, P.E., and his team were called to the site shortly after the incident to lead efforts related to fuels and combustion safety. Recognizing the gravity of the situation, Mr. Puskar and his team worked on-site for months, coordinating root cause analysis and supporting the design and reconstruction of affected areas. Their efforts were instrumental in restoring suitable parts of the facility to operational condition.
With a focus on addressing the root causes of the tragedy, Mr. Puskar and his team provided targeted design and reconstruction advice, ensuring that safety enhancements were embedded into the rebuilt systems. Their involvement extended beyond Garner, as they conducted safety training and implemented comprehensive combustion safety inspection programs at other ConAgra facilities nationwide. These initiatives aimed to institutionalize safety practices and prevent similar incidents across the company.
Through their sustained efforts, Mr. Puskar and his team not only helped ConAgra recover from a catastrophic event but also strengthened its overall approach to fuels and combustion safety. This case underscores the importance of expertise, collaboration, and a commitment to safety in the aftermath of industrial tragedies.
CEOs & Boards have relied on the PTS Team worldwide for over
Fuels & Fired Equipment Compliance Programs
Fuels and Fired Equipment Compliance Program:
- Reactive: Post-incident compliance audits to address regulatory gaps.
- Proactive: Systematic implementation of our 10-checklist system to prevent future failures.
Risk Appetite & Assessment - Fuels & Fired Equipment
- Reactive: Facilitation of PHA and LOPA sessions post-incident to address immediate risks.
- Proactive: Identification of vulnerabilities in facilities just outside the traditional process safety world, mitigating risks before incidents occur.
Alarms Rationalization & Management
- Reactive: Post-incident workshops to refine alarm systems contributing to failures.
- Proactive: Development of alarm systems and response sheets to enhance safety and operational awareness, ensuring critical warnings are actionable.
Emergency services - 24/7 support - fires & explosions
Insurer or Law Firm Seeking Support
On-site within 24 hours, finding the root cause
On-site within 24 hours, finding the root cause
Need representation at a fire or explosion site, cause and origin support, evidence collection, discuss merits of a case or claim.
On-site within 24 hours, finding the root cause
On-site within 24 hours, finding the root cause
On-site within 24 hours, finding the root cause
Major equipment outage, boilers, gas lines, process ovens, fire or explosion, need immediate advice and project management.
More About Prescient Technical Services
About PTS & John Puskar, P.E.
Accountability Checklist Systems
Fired Equipment Safety Training
Mr. Puskar holds a Bachelor's degree in Mechanical Engineering from Youngstown State University and MBA from Case Western Reserve University in Cleveland, Ohio. Mr. Puskar is an ASME (American Society of Mechanical Engineers) Fellow, this is an exclusive grade of membership which only approximately 3,000 members of the 75,000 member group have attained. Mr. Puskar is also a Fellow of the Association of Energy Engineers. Mr. Puskar is a licensed professional engineer in 6 states and holds 8 different contractors licenses. Mr. Puskar won the 2015 Ugiris-Barnett Safety Award which is a unique national award bestowed by the American Society of Mechanical Engineers to someone who has demonstrated unique contributions to the field of safety. Mr. Puskar has traveled over 4 million miles to visit more than 400 industrial plants in 14 countries in the cause of fuels and fired equipment safety. Mr. Puskar's full CV is available upon request.
Fired Equipment Safety Training
Accountability Checklist Systems
Fired Equipment Safety Training
Mr. Puskar has trained thousands in fuels and combustion systems safety. He has published more than 100 papers and journal articles and spoken at more than 100 workshops and conferences. He has developed an online school and a YouTube Channel where more than 50 instructional videos are available. Mr. Puskar has developed hands on combustion safety courses and ongoing programs related to Isolation, Purging, and Gas Reintroduction and Combustion Safety for fortune 500 public companies with global operations.
Accountability Checklist Systems
Accountability Checklist Systems
Accountability Checklist Systems
Mr. Puskar pioneered the development of corporate checklist safety programs to inspect and test fuel fired equipment for major fortune 500 companies like Ford, GM, Alcoa, National Grid, and many more. These systems use proprietary techniques to screen for code compliance, best practices, recalled or obsolete components, new technologies, and maintenance practices that can enhance safety and reduce risks.
Legal Support-Fires & Explosions
Safety, Risk, Code Compliance Audits - Capital Projects Support
Accountability Checklist Systems
Available 24//7365 to evaluate a site or to consult about what just happened. Mr. Puskar has been involved in the largest industrial fuels and combustion systems disasters in history in the United States. His experience with code committees, understanding the aftermath of an incident, and relating cause and origin in simple terms are invaluable for legal cases.
PHA Support Steam, Boilers, Fired Equipment
Safety, Risk, Code Compliance Audits - Capital Projects Support
Safety, Risk, Code Compliance Audits - Capital Projects Support
The quality of a PHA is often all about who's at the table. Good PHA's require knowledgeable subject matter experts. Mr. Puskar has been involved in many PHA's and risk analysis related to fired equipment including boilers, steam systems, fired heaters, natural gas and LNG systems. His personal involvement in dozens of fires and explosions give him an insight that is not available anywhere else.
Safety, Risk, Code Compliance Audits - Capital Projects Support
Safety, Risk, Code Compliance Audits - Capital Projects Support
Safety, Risk, Code Compliance Audits - Capital Projects Support
Does the current project meet code requirements? Are there issues that were missed? If you don't do a lot of fuel fired equipment or boiler projects your staff may not understand all the requirements for a compliant facility. Mr. Puskar can review project plans, provide advice about options to consider, and provide on-site installation review for capital projects related to fuels and combustion systems.
Services to MInimize Fire & Explosion Risks
Training - Knowledge, Skills, & Validation
Forensic Consulting (Cause & Origin - Professional Opinions)
Training - Knowledge, Skills, & Validation
Mr. Puskar has trained thousands in over a dozen countries over the past 30 years. Mr. Puskar has a standard curriculum that can be tailored to meet your organization's needs. DOWNLOAD THE PTS STANDARD COURSE OFFERINGS BELOW.
Piping & Equipment Safety Audits
Forensic Consulting (Cause & Origin - Professional Opinions)
Training - Knowledge, Skills, & Validation
Mr. Puskar was the first to standardize codes and best practices into comprehensive checklists and apply them to hundreds of facilities on a systematic basis. These checklists systems have been applied to audit more than 50,000 pieces of equipment all over the world.
Forensic Consulting (Cause & Origin - Professional Opinions)
Forensic Consulting (Cause & Origin - Professional Opinions)
Forensic Consulting (Cause & Origin - Professional Opinions)
Mr. Puskar has supported litigation for natural gas, boiler and oven explosions, Carbon Monoxide deaths, gas release explosions, pressure vessel steam explosions and more. MR. PUSKAR CAN PROVIDE A SCHEDULED "NO FEE" INITIAL CONSULT TO LEGAL TEAMS.
Capital Project Support
Purging plans, operating and maintenance procedures.
Forensic Consulting (Cause & Origin - Professional Opinions)
Mr. Puskar supports owners and insurers for capital projects where expertise is lacking or staff is over assigned. These services can include verifying construction progress, conformance with design documents, participating in HAZOP sessions, and or supporting commissioning and procedure writing.
Keynote Speaker
Purging plans, operating and maintenance procedures.
Purging plans, operating and maintenance procedures.
Mr. Puskar has interesting and meaningful messages that shape hearts and minds and change cultures. One example is:
What it's like immediately after a tragedy, and how to recover:
How do you pick up the pieces immediately after a tragedy? What are the sites and sounds after a horrible explosion and fire, what are the feelings of the staff?, How do you get back on track? How do you change the culture moving forward?
Purging plans, operating and maintenance procedures.
Purging plans, operating and maintenance procedures.
Purging plans, operating and maintenance procedures.
Mr. Puskar can provide procedure development services for operating and maintaining new or existing equipment to include: start-up shut down, lock-out tag-out, emergency, and abnormal operations.
Mr Puskar has extensive experience with purging and flammable gas handling. He has developed corporate gas hazards safety programs including detailed purge plans for NFPA 56 compliance.
Example solutions to client needs
Major Gas/Electric Utility Fuels and Combustion Equipment Audit Program
Major Gas/Electric Utility Fuels and Combustion Equipment Audit Program
Major Gas/Electric Utility Fuels and Combustion Equipment Audit Program
Mr. Puskar helped to develop a corporate-wide combustion equipment safety device inspection and testing program for more than 300 pieces of equipment that support this major electric and gas utility in the US. This top 5 utility has engaged Mr. Puskar for ongoing training and program expansion over the past several years.
Boiler Burner Retrofit-Design, Equipment Selection, Commisioning
Major Gas/Electric Utility Fuels and Combustion Equipment Audit Program
Major Gas/Electric Utility Fuels and Combustion Equipment Audit Program
Mr. Puskar recently supported the retrofit of a 60 year old multiple burner boiler, (900 psig/850F), 300,000 pph. This included scoping fuels trains, specialty valves, and control systems. The support included managing stakeholder meetings and providing site support over the course of about 12 months and then participating in commissioning.
Major Paper Mill Safety Training
Major Gas/Electric Utility Fuels and Combustion Equipment Audit Program
Supporting Litigation for Major Cases Involving Fatailities
Mr. Puskar has served a major paper mill for a number of years providing annual training focused on fuels, combustion, and steam systems safety. In January of 2018 Mr. Puskar provided an intense session discussing 25 top hazards in the facility and delivered it to every employee in the plant over a week as part of their OSHA Training days (over 400 persons).
Supporting Litigation for Major Cases Involving Fatailities
Post Incident-Primary Metals Producer Corporate Gas Hazards Program
Supporting Litigation for Major Cases Involving Fatailities
Mr. Puskar recently supported a major insurer on a boiler explosion case that resulted in a dismissal. Mr. Puskar is currently consulting for a plaintiff's attorney on a large multiple fatality nationally televised and known case.
New Billion Dollar Pipe Mill Code Review
Post Incident-Primary Metals Producer Corporate Gas Hazards Program
Post Incident-Primary Metals Producer Corporate Gas Hazards Program
A global German manufacturers new billion dollar pipe mill in the US had Italian furnaces and ovens. The client needed to understand for insurers and others the level of compliance with applicable US codes.
Post Incident-Primary Metals Producer Corporate Gas Hazards Program
Post Incident-Primary Metals Producer Corporate Gas Hazards Program
Post Incident-Primary Metals Producer Corporate Gas Hazards Program
Mr. Puskar developed a gas hazards safety program for a major primary metals producer after a major incident. This program is still in place 10 years later and this client has not experienced any additional incidents.