Amplify Your Process Safety: Recent Episodes
Amplify Process Safety, LLC
Join industry professionals as they share insight into the world of process safety, including news related to updated codes and standards, recent incidents and what you can learn from them, and their take on all elements of process safety. With decades of combined experience in real, practical implementation, they aren’t just advisors, they practice what they preach. Whether you’re new to process safety, in a role where you interact with aspects of process safety, or an experienced process safety professional, this is the podcast for you.
In this episode, Rob and Magi break down the CSB's incident report on the Honeywell Geismar facility, which includes three significant hydrofluoric acid releases that occurred between 2021 and 2024. They review the CSB's analysis of each incident, highlight safety issues and failures in process safety management, and review the CSB's recommendations for improving safety practices and preventing future incidents. Tune in to find out more and read the CSB's full report here.
For more CSB final report breakdowns, check out the episodes below:Episode 122 - Incident Breakdown: 2023 Fire Heater Fire at Marathon Martinez Renewables FacilityEpisode 105 - Incident Breakdown: 2022 Fatal Naphtha Release and Fire at BP-Husky Toledo Refinery in OhioEpisode 97 - Incident Breakdown: 2020 Fatal Oil and Gas Well Blowout in Burleson County, Texas
In this episode, Magi and Jackson discuss the importance of lockout/tagout procedures in process safety, analyzing several incidents that highlight failures in energy isolation and the consequences of neglecting safety protocols. They delve into the need for thorough procedures and best practices to prevent accidents in industrial settings.
For more about the CSB's ARRR, or AR3 as we like to call it, read volume one here and volume two here,k out the other episodes in the AR3 Miniseries: Episode 121 - ARRR Summaries & Trends and Episode 125 - AR3 Volume Two.
In this episode, Rob interviews Alex Pawlowski, Vice President of Design and Operations at SPEC Process Engineering and Construction. They discuss the critical role of process safety in engineering and construction, particularly in projects involving hazardous materials. Alex shares insights on how SPEC integrates safety into their design and construction processes, the challenges faced in maintaining safety standards, and the differences between capital and maintenance projects.
For more about SPEC, visit their website here, or find them on LinkedIn here. To connect with Alex, find him on LinkedIn here.
In this episode, Magi and Jackson discuss some of the incidents included in Volume 2 of the CSB's Accidental Release Reporting Rule, and some safeguards that can be put in place to prevent such incidents from happening.
For more about the 2023 Heater Fire at Marathon Martinez Renewables Facility, check out episode 122 here.
For more information about the ARRR, check out Volume 2 of the CSB's Accidental Release Reporting Rule here.
In this episode, Rob is joined by Tyson Alexander, head of sales at APSM. Tyson has been at APSM for over 18 years and he talks us through some of the history of APSM, including what the "A" stands for, the evolution of process safety management, and real-world application of APSM software.
For more information about APSM, visit their website at https://apsm.net/ and for the latest APSM news, follow them on LinkedIn here, or read their blog at https://apsm.net/blog/
To connect with Tyson, email him at tyson@apsm.net or connect with him on LinkedIn here.
In this episode, Rob and Magi discuss the recently released Safe Work Practice from the Center for Chemical Process Safety (CCPS) about Simultaneous Operations (SIMOPS) for offshore and operating plants. SIMOPS are defined as "two or more different activities occurring at the same time that are close enough to interfere with each other and transfer risk or performance implications." They discuss a few incidents where SIMOPS played a tragic part, as well as how CCPS recommends that facilities improve management of the inherent risk of SIMOPS.
For more information about the Wacker Polysilicon incident, check out the episode below:Episode 80 - Incident Breakdown: 2020 Fatal Chemical Release at Wacker Polysilicon Facility in Tennessee
For more about SIMOPS, visit the AIChE page below:
Simultaneous Operations (SIMOPS) - CCPS Safe Work Practice
In this episode, Magi and Jackson breakdown the most recent CSB final report. They cover the 2023 fire at the Marathon Martinez Renewables Facility that resulted in a significant injury for one employee and $350 million in property damage. This breakdown includes a review of the event, contributing factors and recommendations from the CSB. Tune in to find out more or read the report here.
For more CSB final report breakdowns, check out the episodes below:
Episode 105 - Incident Breakdown: 2022 Fatal Naphtha Release and Fire at BP-Husky Toledo Refinery in Ohio
Episode 97 - Incident Breakdown: 2020 Fatal Oil and Gas Well Blowout in Burleson County, Texas
Episode 95 - Incident Breakdown: 2019 Fatal Explosion and Fire at KMCO in Crosby, TX
In this episode Magi and Jackson break down the CSB's Accidental Release Reporting Rule (ARRR) - what it is and some of the incidents reported under this rule. The ARRR requires reporting certain incidents to the CSB and has led them to deploy to some incidents that they may not have otherwise investigated.
For more information about the Accidental Release Reporting Rule (ARRR), check out CSB Incident Reports Volume One
In this episode, Rob and Jackson lead listeners through NFPA 660; the new and improved combustible dust standard, which was released in late 2024. They discuss the reason for the new standard, other meaningful changes in the standard, general requirements of the standard, the titles of the industry specific chapters, which requirements are retroactive or not, and which annexes they found most valuable.
For further listening related to Combustible Dusts, be sure to check out these past episodes.
Episode 16 - Combustible Dusts & DHAs
Episode 46 - DHA Basics with Guest Mike Robertson
Episode 51 - Combustible Dust Testing with Guest Michelle Murphy
Episode 61 - Combustible Dust Management Systems
In this episode, Rob is joined by Casey Houston, principal engineer of Chemitics, a consulting firm that specializes in overpressure protection and effluent handling system designs. Casey has been a participant with the AIChE DIERS group since 2006 and has been a member with the API Subcommittee on Pressure Relief System designs since 2011. He is also the co-chair for the API Task Force on Technical Report 522. In this episode, they discuss updating pressure relief device standards and what goes into making API standards updates.
For more information about AIChE DIERS, visitwww.aiche.org/diers. To connect with Casey, email him atcasey@chemitics.com. For more on relief devices, check outEpisode 63 - Relief Devices Documentation with guest Chris Paskach andEpisode 72 - Incident Breakdown: 2018 Ethylene Release and Fire at Kuraray America, Inc. with Guest Christ Paskach.
In this episode, Rob and Magi discuss some of the natural disasters that have contributed to process safety incidents in recent years, including the impacts that Hurricanes Harvey, Laura, Ida, Ian, and Helene have had.
For related content, please check out our past episodes below.
Episode 26 - Natural Hazard Assessment and Planning
Episode 103 - Quantitative and Qualitative Natural Disaster Preparation with Guest Mike Washington
In this episode, Rob is joined by Jackson Colley, the newest member of the Amplify Process Safety team. Rob sits down with Jackson to talk about his background and what ultimately led him to joining Amplify. Welcome to the team, Jackson!
To connect with Jackson, find him on LinkedIn here or email him at jackson.colley@amplifyconsultants.com.
To learn more about the rest of our team, visit www.amplifyconsultants.com/about or check out our other intro episodes below:
Episode 0 - Amplify Your Process Safety Introduction
Episode 30 - The A-Team
Episode 98 - Introducing Magi
In this special episode, Rob and Magi present 2024 (Process Safety) Wrapped. They cover regulatory changes that took place this year, major incidents the CSB has deployed to, metrics on other minor process safety incidents they've tracked this year, CSB reports issued this year, and their hopes for a renewed focus on process safety in 2025.
Do you have a process safety related resolution for 2025? Or a topic you'd like us to delve deeper into in an episode next year? Reach out to us at podcast@amplifyconsultants.com.
For full length episodes on topics mentioned in today's episode, please check out the links below:
- Episode 108 - 2024 EPA RMP Updates
- Episode 105 - Incident Breakdown: 2022 Fatal Naphtha Release and Fire at BP-Husky Toledo Refinery in Ohio
In this episode, Rob welcomes back Mathew Todaro, a partner at Verrill Law who defends and negotiates on behalf of his clients under statutes such as the Clean Water Act, EPCRA, and FIFRA, with a particular focus on Section 112(r) of the Clean Air Act. Today, Rob and Mat give listeners a crash course on the EPA's Risk Management Plan (RMP) Rule. They cover applicability, the three program levels, the components and requirements of RMP, and touch on some recent RMP rule changes.
Be sure to check out Mat's previous appearances on our show at the links below:
- Episode 25 - After the EPA Inspector Leaves with Guest Mathew Todaro
- Episode 35 - Environmental Compliance Audits with Guest Mathew Todaro
- Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
- Episode 56 - Implementing EPA's General Duty Clause (GDC) (Does not feature Mat, but is a companion episode to #52)
- Episode 106 - EPA's National Enforcement and Compliance Initiatives with Guest Mathew Todaro
Connect with Mat on LinkedIn here.
In this episode, Rob welcomes back guest Neil Beekie, CEO and Co-Founder of OperAid. Listeners may remember him from Episode 79 (listen here) back in the summer of 2023, where he introduced us to OperAid, a software tool that assists operators with real-time verification of manual tasks. Today, Rob gets an update on present-day OperAid, including successes, the type of feedback that's been received since deployment, recent updates/improvements, how AI is and could be incorporated, and more.
To learn more about OperAid, visit https://operaid.ai. To connect with Neil, find him on LinkedIn or send an email to neil@operaid.ai.
In this episode, inspired by the CSB investigation update into the 2023 explosion and toxic chemical release at the Honeywell facility in Geismer, LA, Rob and Molly discuss the challenges of aging equipment and infrastructure at chemical plants and refineries. They discuss the aforementioned Honeywell incident, as well as three others where poorly maintained equipment was a key factor that ultimately led to an incident. Then they move on to discuss managing the asset life cycle, warning signs related to aging equipment, equipment deficiency management, and some considerations for aging support equipment and infrastructure.
Find the U.S. Chemical Safety Board Releases Investigation Update into 2023 Explosion and Toxic Chemical Release at Honeywell Facility in Geismer, LA here.
Here are the CCPS books we mentioned that are great resources to look into:
- Dealing with Aging Process Facilities and Infrastructures
- Recognizing Catastrophic Incident Warning Signs in the Process Industries
- Guidelines for Asset Integrity Management
And finally, here are a few related podcast episodes we recommend:
- Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP
- Episode 7 - API 510 with Guest William McBride
- Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride
- PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
In this episode, Rob and Magi discuss the CSB's new safety study titled "Remote Isolation of Process Equipment" that includes recommendations to regulators and emphasizes the need for greater adoption of remote isolation equipment at chemical facilities across the country. Rob and Magi run through the list of recent CSB investigations that are specifically highlighted in the safety study, where the CSB determined that lack of effective remote isolation equipment significantly contributed to incident consequences, discuss the recommendations the CSB made in their study to API, EPA, and OSHA, and talk about actionable next steps for listeners at applicable facilities.
Find the CSB's "Remote Isolation of Process Equipment" safety study here.
Check out our full episodes of some of the CSB investigations relating to lack of remote isolation equipment below.
- Episode 68 - Incident Breakdown: 2019 Refinery Fire and Explosions at Philadelphia Energy Solutions (PES) with Guest Tim Murphy
- Episode 73 - Incident Breakdown: 2019 Explosions and Fires at TPC Group (TPC) Port Neches Operations (PNO) Facility
- Episode 83 - Incident Breakdown: 2019 Tank Farm Fire at Intercontinental Terminals Company, LLC (ITC) in Deer Park, TX
- Episode 95 - Incident Breakdown: 2019 Fatal Explosion and Fire at KMCO in Crosby, TX
The final part of our mini deep dive into different aspects of Process Hazard Analyses (PHAs) is finally here. In today's episode, Molly and Magi talk PHA safeguards, including hierarchy of controls, common types of safeguards (including how and when operator response can be credited in a PHA), quantitative vs. qualitative risk assessment for safeguard effectiveness, independent protection layer (IPL) requirements, and their best tips for safeguard considerations based on their own PHA facilitation experience.
If you haven't already, be sure to check out our other PHA-related episodes mentioned in today's show:
- Episode 55 - Movie Breakdown: Control Room Concerns in The China Syndrome
- Episode 109 - PHA Principles Part 1 - Causes
- Episode 110 - PHA Principles Part 2 - Consequences
Thanks for listening, and please let us know what you think at podcast@amplifyconsultants.com.
This episode is the second of a three part series in which Molly and Magi take a deep dive into different aspects of Process Hazard Analyses (PHAs). In today's episode, they talk PHA consequences, including some common pitfalls to avoid when it comes to considering consequences in a PHA, general types of impacts used for PHA consequences, tools to use for defining impacts, and some consequence-related PHA best practices.
If you haven't already, be sure to check out our other PHA-related episodes mentioned in today's show:
- Episode 109 - PHA Principles Part 1 - Causes
- Episode 59 - Incident Breakdown: 2017 Pressure Vessel Explosion at Loy-Lange Box Company
- Episode 72 - Incident Breakdown: 2018 Ethylene Release and Fire at Kuraray America, Inc. with Guest Chris Paskach
And please follow our show so you can tune in to the final, third part of this mini-series when it becomes available in two weeks. Thanks for listening, and please let us know what you think at podcast@amplifyconsultants.com.
This episode is the first of a three part series in which Molly and Magi take a deep dive into different aspects of Process Hazard Analyses (PHAs). In today's episode, they talk PHA causes, including identifying causes of deviation in HAZOP, What-If, and Checklist methodologies, some common pitfalls they've observed regarding causes in PHAs, and what makes a cause not credible.
If you haven't already, be sure to check out our other PHA-related episodes:
- Episode 2 - Intro to PHAs
- Episode 17 - Tips for a Successful PHA
- Episode 19 - PHAs During the Project Life Cycle
- Episode 36 - Best Practices for Remote PHAs
- Episode 85 - Participating in Your First PHA
- PSM: Back to Basics, Part 3 - Process Hazard Analysis (PHA)
- Top 10 Talk: Amplify Your PHAs, Recording of live event (12/7/2021)
And please follow our show so you can tune in to the next two parts as they become available. Thanks for listening, and please let us know what you think at podcast@amplifyconsultants.com.
In this episode, Rob and Magi cover the recent changes made to the Environmental Protection Agency's (EPA's) Risk Management Program (RMP) Final Rule. The changes fall into four categories: the prevention program, emergency response, availability of information, and other areas of technical clarification. In this episode, they discuss each change, what each could mean for your facility going forward, and when each requirement must go into effect at your facility. If your site is subject to the RMP rule, you won't want to miss this episode.
Have a question about this week's episode, an idea for a future episode, or any process safety related question? Please drop us a line at podcast@amplifyconsultants.com.
In today's episode, Rob is joined by guest Shawn Marsh, Vice President of ESHQ Services North America at Evonik, a specialty chemicals manufacturer based in Germany, with production plants in 27 countries on six continents. Shawn explains how Evonik manages process safety and how he fits into that process, key metrics he uses to manage and measure process safety, the challenges of communicating process safety issues to individuals at different levels within his organization, his role in addressing process safety challenges at Evonik's North American sites, his advice for people in similar roles at other companies, and more.
For more on managing PSM from a corporate perspective, be sure to listen to Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy.
In this episode, Rob sits down with Mat Todaro of Verrill Law, who listeners may remember from his previous guest appearances on the show related to EPA's Risk Management Program and General Duty Clause. Today Rob and Mat discuss EPA's National Enforcement and Compliance Initiatives (NECI) for 2024, including what they are and which initiatives are new, modified, and continued, what is different about how NECI will be managed this time around, what this means for RMP facilities who have ammonia, HF, or are near an overburdened community, and Mat's thoughts on the Supreme Court's recent overturning of the Chevron doctrine. If you haven't listened to our previous episodes featuring Mat, be sure to check them out at the links below:
- Episode 25 - After the EPA Inspector Leaves with Guest Mathew Todaro
- Episode 35 - Environmental Compliance Audits with Guest Mathew Todaro
- Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
- Episode 56 - Implementing EPA's General Duty Clause (GDC) (Does not feature Mat, but is a companion episode to #52)
Connect with Mat on LinkedIn here.
In this episode Magi and Jo team up to cover a recent CSB final report. In this incident breakdown, they cover the 2022 accidental release of naphtha that resulted in a fire, two worker fatalities, and significant property damage at the BP-Husky refinery in Oregon, Ohio, including what happened leading up to the event, contributing factors, recommendations the CSB made in their final report, and what companies can learn from this incident. Find the CSB's final report for this incident here.
If you haven't listened to our episodes where we interviewed the CSB, please check out Episode 101 and Episode 102.
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In today's episode, Molly sits down with Stephen J. Wallace, the author of a newly released process safety thriller titled "Hazardous Lies". Although his book is a work of fiction, Stephen discusses how his book relates to real aspects of process safety and how it was informed by his real career experience in the process safety field, how he came up with the idea for the novel, his leap from technical writing in his career to creative writing, and how he made technical topics in the book accessible to non-technical readers. Stephen also shares his advice for those branching out from a technical field into a more creative role, and his advice for those who wish to steer their careers toward process safety.
You can purchase "Hazardous Lies" on Amazon here, or you can visit https://stephenjwallace.com/ to purchase the book or to learn more about Stephen.
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In this episode, Rob is joined again by guest Mike Washington, who is the Director of Industrial Safety at Arkema Inc., The Americas. Mike recently gave a talk at the AIChE Global Congress on Process Safety in New Orleans in March 2023 titled, “Quantitative Natural Disaster Assessment and Scorecard for Chemical Plants," and today discusses some of what he covered in that talk. Rob and Mike cover his motivation for presenting at the AIChE Global Congress on Process Safety, the basic approach of the assessment and scorecard, how Arkema is using the tool and how the plants have reacted to it, and advice he has for other companies struggling with planning for and reducing the risks of natural hazards.
If you haven't caught our previous episode with Mike, be sure to listen to Episode 96 - Educating the Next Generation of Process Safety Experts with Guest Mike Washington.
Mike invites you to connect with him on LinkedIn at https://www.linkedin.com/in/michael-washington-m-b-a-067b2520/
To hear more about this topic, be sure to listen to these episodes:
Episode 26 - Natural Hazard Assessment and Planning
Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning
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In this episode, we sit down for another conversation with the U.S. Chemical Safety and Hazard Investigation Board (CSB). This time, Molly and Jo talk with Supervisory Chemical Incident Investigator Lauren Johnson, Chemical Incident Investigator Melike Yersiz, P.E., and Video Producer and Public Affairs Specialist Shauna Lawhorne. We discuss how each CSB employee ended up at the agency, what a company can expect when the CSB comes to investigate an incident, some examples of how and when subject matter experts are used to assist with investigations, what has most surprised each of them during the course of their investigations, and how recommendations are tracked and managed. Then we get to ask everything we've been wondering about the CSB videos; how the CSB decides which investigations get a video, how they condense the investigation's material down, some details about the iconic narrator, and more.
A heartfelt thank you to all three CSB guests for their appearances on this episode, and to CSB Communications Manager, Hillary Cohen. To learn more about the CSB, please visit csb.gov, and if you haven't already be sure to check out our previous episode with the CSB: "Episode 101 - Conversations with the CSB - Part 1". To learn more about the CSB's accidental release reporting rule, and to access the published data, visit https://www.csb.gov/news/incident-report-rule-form-/.
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In this episode, Molly and Magi sit down with two U.S. Chemical Safety and Hazard Investigation Board (CSB) chemical incident investigators, Lauren Grim, P.E., CFEI and Drew Sahli. Lauren and Drew detail how each of their career paths led them to their current roles, what their jobs as chemical incident investigators are like, and, for those interested in also working at the CSB, the type of background and experience best suited for the job. Next, Molly and Magi ask about the size of the CSB agency, the challenges, surprises, and takeaways they've had during investigations, and their thoughts on how the CSB final investigation reports and videos should be utilized. Finally, Molly and Magi get to ask what all of us have been dying to know; now that the CSB has cleared their backlog of reports, what are they up to next? Be sure to tune in to this episode to find out, and subscribe to the show so you'll be the first to hear "Conversations with the CSB - Part 2" when it becomes available.
A huge thank you to Lauren Grim and Drew Sahil for their guest appearances on this episode, and to CSB Communications Manager, Hillary Cohen. To learn more about the CSB, please visit csb.gov.
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We've made it to episode 100, can you believe it? We invite you to celebrate this milestone with us in today's very special episode. Join the current Amplify team members as well as two former team members in reminiscing about the early days of the podcast, hear some fun facts about our audience, episodes, and past guests, learn which of our episodes made the top 10 most popular list, our goals for the future of the show, and more. Be sure to stick around to the end for some funny clips that have never before been aired. A special thank you to Wesley Carter and John Doan for joining us for the beginning of this episode. And thank you to you, our listeners, as we wouldn't be doing this without you. Thank you for sticking around for 100 episodes, and cheers to 100 more.
Time stamps:
Introduction: 00:00:36
Kick Off to Who is Who (Rob Bartlett, Molly Myers, Magi Riech, Jo Pastor, John Doan, Wesley Carter): 00:02:11
Fun Facts about Our Show (Listens, Guests, Listener Locations/Ages, Episodes): 00:33:17
Our Top 10 Episodes: 00:45:54
Feedback on the Show: 00:56:24
Closing & Where We're Headed: 00:57:12
Funny Clips: 1:03:10
We'd love to hear what you thought about this episode, which episode so far has been your favorite, or what you want to hear about next. Send the show an email at podcast@amplifyconsultants.com.
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In today's episode, Rob sits down with Blaine J. Hoffmann, from The SafetyPro Podcast, to discuss his new book, titled "Rethinking SAFETY Culture". Blaine details why he was motivated to write the book, how he defines safety culture, and discusses ways to implement the ideas he presents in "Rethinking SAFETY Culture". He also talks about his recommendations for digital safety management systems, how KPIs can be used to improve safety cultures, and more.
Find Blaine on LinkedIn here, find "Rethinking SAFETY Culture" on Amazon here, and be sure to check out Blaine's library of over 175 episodes at thesafetypropodcast.com or wherever you find your podcasts.
We also invite you to check out our previous episodes with Blaine, where we teamed up to discuss a variety of topics from both a process safety lens and an occupational safety lens.Episode 23 - Incident Investigation with The SafetyPro PodcastEpisode 24 - Emergency Planning & Response with The SafetyPro PodcastEpisode 27 - Contractor Management with The SafetyPro PodcastEpisode 28 - Hot Work with The SafetyPro Podcast
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In this episode, Rob is joined by the newest member of the Amplify Process Safety team, Magi Riech. Rob sits down with Magi to talk about her background and her journey into process safety throughout her career, and what fuels her passion for PSM/RMP. Welcome to the A Team, Magi!
To connect with Magi, find her on LinkedIn here or email her at magali.riech@amplifyconsultants.com.
To learn more about the rest of our team, visit www.amplifyconsultants.com/about or check out our other intro episodes below: Episode 0 - Amplify Your Process Safety IntroductionEpisode 30 - The A-TeamEpisode 43 - Introducing Molly
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In this episode, Molly is joined by the newest member of the A Team, Magi Riech, to discuss the CSB's final investigation report on the 2020 fatal oil and gas well blowout in Burleson County, Texas. The incident occurred on January 29, 2020, and the CSB released their final investigation report on this incident on December 26, 2023. On the day of the incident, oil and gas escaped the well during workover operations, and found an ignition source, ultimately leading to a flash fire that burned and killed three contract workers. Today, Molly and Magi discuss what exactly happened, delve into the contributing factors, cover the CSB's recommendations, and highlight the takeaways that any company could learn from this incident. Find the CSB's final report for the incident we discussed today here.Find the CSB's final report on the Pryor Trust Fatal Gas Well Blowout and Fire that we mentioned in this episode here. Stay tuned for Episode 98, in which we give Magi a proper introduction to our listeners. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message
In this very special episode, Rob and Molly sit down with Mike Washington, who is the Director of Industrial Safety at Arkema Inc,. The Americas, and also an adjunct lecturer at Prairie View A&M University and the University of Houston. They discuss the challenges of educating the next generation of engineers and managers on process safety, and touch on what current gaps they see, best practices to fill those gaps, and their hopes for the future, including how higher education can help to better better contribute to chemical engineers' knowledge of process safety.
Mike invites you to connect with him on LinkedIn at https://www.linkedin.com/in/michael-washington-m-b-a-067b2520/.
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On April 2, 2019, the KMCO production facility in Crosby, TX, was producing sulfurized isobutylene as a lubrication additive, when they experienced a leak from a fracture in a segment of piping. The leaking material formed a vapor cloud and then found an ignition source, resulting in the death of one employee and serious injuries to two other employees. In this episode, Rob and Molly discuss what happened in detail, cover the contributing factors, and finally touch on the key learnings that other facilities can take away from this tragic event. Find the CSB's final report on this incident at https://www.csb.gov/csb-releases-final-report-into-fatal-2019-explosion-and-fire/.
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On January 28, 2021, the Foundation Food Group facility in Gainesville, Georgia, experienced a liquid nitrogen release that ultimately resulted in six employee fatalities. The U.S. Chemical Safety Board (CSB) released their final investigation report into this incident on December 11, 2023, and today Molly and Jo are here to cover all of the report's highlights. We'll walk you through details regarding the day of the incident, the hazards of liquid nitrogen, the root cause of the incident and other contributing factors, and close with what any company can learn from this incident. As always, we thank the CSB for their thorough reporting on this incident, and invite you to read their final investigation report at the link below.
https://www.csb.gov/csb-releases-final-report-into-2021-fatal-liquid-nitrogen-release-at-foundation-food-group-facility-in-georgia/
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On December 6, 2023, the US Chemical Safety Board (CSB) released its final report into the 2017 fatal dust explosion and fire at the Didion Milling Facility in Cambria, WI. In today's episode, Rob and Jo give you an overview of the CSB's findings, covering what happened, the causes, the recommendations CSB made, what types of companies could be at risk from incidents like this one, and key lessons for the industry.
Find the resources we mention in this week's episode at the links below:
CSB ReportEpisode 88 - Why Senior Management Should Care About Process Safety
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In this extra special episode, the whole Amplify crew is here to talk about how 2023 unfolded in terms of process safety. They cover an overview of CSB accidental release events as well as other process safety events they tracked across multiple countries and industries throughout the year, and what their big takeaways are from looking at all the data available for these incidents. In the second half of the episode, they share six process safety related New Years' resolutions you can adopt at your own facility in 2024 to help you have an incident-free year.
A huge thank you to all of our listeners for tuning in to our show this year. We wish you all the happiest of holidays and a safe 2024, and we look forward to bringing you more episodes in the new year.
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In this episode, Molly is joined by Brad Bazargani, who listeners may recognize as one of the process safety professionals who participated in Episode 84. Today, Molly and Brad discuss how to integrate process safety into large capital projects, including when PHAs should be conducted and which methodology should be used, managing changes, considerations for facility siting, development of operator training and procedures, establishment of MI programs, conducting PSSRs, and handling a large volume of process safety information. Listeners interested in connecting with Brad can find him on LinkedIn here.
Find another episode we mentioned today, Episode 74 - The Challenges of Engineering in a High Hazard Plant with Guest Doug McMahon, here.
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In this episode, Rob and Molly cover the latest CSB final report on the 2021 fatal vapor explosion and fire at the Yenkin-Majestic facility in Columbus, OH.
On April 8, 2021, a mixture of flammable naphtha solvent vapors and resin liquid escaped through the seal of a closed manway of an operating kettle and created a flammable vapor cloud, which quickly found an ignition source. The resulting explosion and fire led to the death of one employee, injuries to eight others, and over $90 million in property damage.
In this episode, Rob and Molly cover additional details related to the event, including contributing factors, share the CSB's recommendations, and then finally cover key lessons that any company can learn from this incident.
Find the CSB's final report for this incident here.
If you have a comment about this week's episode, an idea for a future episode, or any process safety related question, please drop us a line at amplifyconsultants.com.
Other episodes we mentioned today:
Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride
Episode 69 - Incident Breakdown: 2019 Explosion and Fire at AB Specialty Silicones
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In this episode, Rob and Jo talk about CMMS, or computerized maintenance managements systems. You'll learn how to make the best CMMS platform selection for your facility, important considerations you should make when it comes to the set up of your CMMS platform, and how to ensure your CMMS gets updated as changes are made in your facility. They'll also talk customization options, mobile apps, permissions, contractor involvement, recordkeeping, reporting/dashboards, and more. If you're considering making the move from a paper-based work order system to a CMMS platform, or looking to see how you can leverage the data currently captured within your CMMS platform, then this is the episode for you.
Some other episodes mentioned today that we recommend:
- Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP
- PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
- Episode 18 - PSM Management Systems
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In today's episode Rob and Molly answer two important questions when it comes to senior management and process safety: 1) Why is it important for senior management to understand process safety, and 2) how can senior management lead the company to ensure that process safety is a high priority?
They cover historic catastrophic impacts when process safety has not been prioritized, the Business Case for Process Safety (CCSP whitepaper), what "good" looks like when prioritizing process safety, the impacts of staffing and budget decisions on process safety, and more. No matter where your role falls within your organization's hierarchy, any employee who works at a facility handling highly hazardous substances is sure to find value in this episode.
Resources mentioned in today's episode:
- CSB Best Practice Guidance for Corporate Boards of Directors and Executives in the Offshore Oil and Gas Industry for Major Accident Prevention
- Center for Chemical Process Safety (CCPS) : Inspiring Process Safety Leadership – The Executive Role
- Center for Chemical Process Safety (CCPS): The Business Case for Process Safety
- Episode 40 - The Evolution of Process Safety Culture with Guest Trish Kerin
- Episode 47 - What New Plant Managers Should Know with Guest Nat Weiner
- Episode 48 - Management of Organizational Change (MOOC)
- Episode 60 - How Organizational Structure Impacts Process Safety with Gilsa Monteiro
- Episode 70 - Improving Process Safety Culture with Guest Peter Hereña
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In this episode, Molly is joined by guest Tom Kuechler. Tom (Ph.D., inorganic chemistry) has over 35 years of experience in the water treatment industry (pool/spas, drinking water, and cooling towers), chiefly with chlorinated isocyanurates, including 15 years at Occidental Chemical Corporation’s trichloroisocyanuric acid plant. His responsibilities have included product and application research, field trials, technical service, manufacturing support, and regulatory support.
Today, Molly and Tom discuss chemical reactivity issues in the hope that they will help to prevent other companies from suffering through catastrophic process safety incidents like those at Bio-Lab and Optima Belle, which were recently reported on by the CSB. They discuss safety data sheets and their importance, define what a water-reactive compound is, talk about the importance of preserving process safety knowledge at a facility over time, and address some process scale-up precautions that should be taken when handling reactive chemicals.
You can reach Tom Kuechler with any further questions at tomkuechler@gmail.com. To learn more about the CSB incident investigations mentioned in today's episode, go to csb.gov or listen to Episode 76 - Incident Breakdown: 2020 Toxic Gas Release and Chemical Fire at Bio-Lab Facility and Episode 82 - Incident Breakdown: 2020 Fatal Explosion at Optima Belle Facility.
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Molly and Rob are back with Part 2 of Operator Training in this companion episode to Episode 77 - Operator Training - Part 1: Initial Training.
Today they're talking operator refresher training; what's required by PSM & RMP, what's considered a best practice, and some training considerations for facilities with infrequent turnarounds.
If you haven't already, be sure to also check out Episode 31 -Effective Operator Training.
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So it's your first time on a Process Hazard Analysis (PHA) team, and you don't know what exactly to expect. Start with this episode! In this episode, Rob and Molly discuss everything you need to know as a first-time PHA team member. They cover the goals of a PHA, the basics of the most common PHA methodologies, PHA team members and requirements, ground rules for the study sessions, how the experience is valuable, what to expect after the study sessions end, and more. If you are an operator, I&E technician, or maintenance technician who has never participated in a PHA before, but you'd like to or you've been asked to be on the PHA team, this is the episode for you.
Find other related episodes that we mentioned in today's episode below. Episode 20 - Why "Boots on the Ground" are Vital to your Process Safety ProgramEpisode 53 - How Boots on the Ground Expertise Can Lead to PSM Success
Plus two episodes on Training, coming soon (we'll update these show notes then).
If you have a comment or question about today's episode, please drop us a line at podcast@amplifyconsultants.com.
If you're curious about what we do at Amplify Process Safety, or think we can help your facility, please send your inquiry to info@amplifyconsultants.com.
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Today's episode is an extra special one. We know we say that a lot, but we really mean it. In this episode, we bring you a collection of 11 stories from folks who share with us why process safety matters to them, and why you should care too. If you're new to the world of process safety, we hope this will inspire you, and if you're an experienced process safety professional, we think you'll enjoy these passionate stories that are sure to echo your own.
A huge thank you to everyone who participated in this episode.
If you have a comment or question about today's episode, please drop us a line at podcast@amplifyconsultants.com.
If you're curious about what we do at Amplify Process Safety, or think we can help your facility, please send your inquiry to info@amplifyconsultants.com.
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In this episode, Rob and Jo team up to cover another CSB final report. In this incident breakdown, they cover the 2019 tank farm fire at the Intercontinental Terminals Company, LLC (ITC) bulk liquid storage terminal in Deer Park, Texas. On March 17, 2019, a circulation pump failure led to the release of a butane-enriched naptha product from a large aboveground storage tank, and the flammable vapors eventually ignited. The resulting fire spread to the other 14 nearby tanks and then burned for three days before being extinguished. In this episode, Jo and Rob cover additional details regarding offsite consequences, discuss the five safety issues that the CSB highlighted in their report, share the CSB's recommendations, and then finally cover key lessons for industry.
Find the CSB's final report for this incident here. If you have a comment about this week's episode, an idea for a future episode, or any process-safety related question, please drop us a line at podcast@amplifyconsultants.com.
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In this episode, Molly and Jo are back with another incident breakdown, covering the CSB's final report on the 2020 fatal explosion at the Optima Belle Facility in Belle, WV. On December 8, 2020, workers were drying CDB-56 in a press-rated rotary double cone dryer, when the material began to decompose and generate significant amounts of toxic gases, leading to an overpressure of the dryer and subsequent rupture, fire, and toxic chlorine release. In this episode, Molly and Jo cover the materials involved in the incident, what exactly happened and why, contributing factors identified by the CSB, the CSB's recommendations, and what companies can learn from this incident to improve the safety of their own operations.
Find the CSB's final report for this incident here.
Episode 65 - Chemical Reactivity Testing with Guest Michelle Murphy here.
Find the Chemical Reactivity Hazards website we mentioned here.
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In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal explosion and fire at the Watson Grinding facility in Houston, Texas. On January 24, 2020, a propylene release in a coating booth at the facility resulted in a fire and explosion that killed two workers and one nearby resident, injured two workers, and damaged over 450 nearby structures. Today, Molly and Jo provide some background information on the facility, including previous incidents, precautions in place at the time of the incident, and contributing factors. Then they delve into how various elements of a process safety program could have helped to prevent this incident, discuss the CSB's recommendations, and end with three key learnings that facilities can learn from this incident.
Find the CSB's final report for this incident here.
Related episodes we mentioned: Your Process Safety Journey, Part 1 - The Foothills Your Process Safety Journey, Part 2 - Climbing The Mountain
Your Process Safety Journey, Part 3 - Nearing the Summit
Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
Episode 56 - Implementing EPA's General Duty Clause (GDC)
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In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal chemical release at Wacker Polysilicon facility in Charleston, Tennessee. On November 13, 2020, a contractor on the fifth level of an operating platform tightened the bolts on a graphite heat exchanger to an incorrect torque setting, cracking the exchanger, which released gaseous HCl and obscured two contractor groups' access down the 70-foot platform's only staircase. Three of the contractors attempted to climb down the outside of the structure, and all fell during their attempts; one fatally, while two others sustained serious injuries. Today, Molly and Jo provide some background information on the facility, its hazardous chemicals, and the events leading up to the loss of containment. Additionally, they discuss the safety issues identified by the CSB, including some interesting details regarding the PHA completed only three months prior that identified the need for a second means of egress in a release scenario identical to the incident. They point out other contributing factors, cover the CSB's various recommendations, and finally provide key learnings that any company can glean from this incident.
Find the CSB's final report for this incident here.
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In this episode, Rob is joined by guest Neil Beekie, CEO and co-founder of OperAid. Neil discusses his background in plant operations, and details how a significant event he experienced as a lead operator led him to the eventual development of OperAid, a software tool that assists operators with real-time verification of manual tasks. Operators and non-operators alike will be sure to find value in this episode.
To learn more about OperAid, visit https://operaidsoft.com/. To connect with Neil, find him on LinkedIn or send an email to neil@operaidsoft.com.
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In this episode, Molly and Jo discuss the CSB's final investigation report on the 2021 fatal acid release at LyondellBasell La Port Complex in La Porte, Texas. On July 27, 2021, contractors inadvertently removed pressure retaining components of a valve, releasing 164,000 pounds of acetic acid mixture, which fatally injured two contract workers. Today, Molly and Jo provide some background information on LyondellBasell and the substances involved in the release, talk about what exactly happened at the time of the incident, and discuss what a valve actuator is and why contractors were trying to remove one that day. Then they discuss other incidents that the CSB identified where similar mistakes were made with plug valves and removal of pressure retaining components, touch on the contributing factors, and talk about what other companies can learn from this incident. Finally, they cover the CSB's recommendations, which include those addressed to LyondellBasell, the contract company, and to various RAGAGEP entities.
Find the CSB's final report for the incident we discussed today here.
Find the CSB's final report and video about the ExxonMobil Baton Rouge Refinery Chemical Release and Fire here.
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In this episode, Rob and Molly discuss the PSM requirements for initial operator training. They cover all of the requirements for content to cover in training, as well as their additional content suggestions, and talk about the different methodologies that can be used to perform verification and documentation of training.
Stay tuned for Part 2 in which Rob and Molly discuss refresher training for existing operators and other miscellaneous training topics.
If you haven't already, be sure to also check out Episode 31 -Effective Operator Training.
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In this episode, Rob and Jo discuss the CSB's investigation report on the 2020 toxic gas release and chemical fire at Bio-Lab Facility in Westlake, Louisiana. On August 27, 2020, strong winds from Hurricane Laura damaged buildings at the facility, causing rainwater to come into contact with the trichloroisocyanuric acid (TCCA) that was stored inside. A chemical reaction began, and the TCCA began to decompose, releasing heat that started a fire, while also releasing a large amount of hazardous gases that traveled offsite. Today, Rob and Jo provide some background about this Bio-Lab facility, discuss the events surrounding the incident, and cover the consequences of the incident. Then they discuss the CSB's five identified safety issues that contributed to the event, what types of companies might be at risk for similar events, and how any facility can prevent an incident like this one.
Find the CSB's final report here.
Listen to the other episodes we mentioned today at the links below:
Episode 26 - Natural Hazard Assessment and PlanningEpisode 52 - EPA's General Duty Clause with Guest Mathew TodaroEpisode 56 - Implementing EPA's General Duty Clause (GDC)Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning
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In this episode, Molly is joined by our show's very first podcast guest, William McBride, who first joined us all the way back in Episode 7. Today, Will and Molly discuss the types of inspections that are required for process vessels and tanks. They'll cover what's involved in inspecting ASME pressure vessels and atmospheric storage tanks, and how equipment that doesn't fit ASME VIII or API 2000 is handled when it comes to inspections, including open-top mixing vessels, "equipment" fabricated from piping components, and vessels fabricated to ASME code but not stamped. They also touch on best practices related to MI at sites that are non-PSM covered.
You can reach out to Will McBride directly at (903) 374-5806 or at wmcbride@xcelgrp.com.
Be sure to check out Will's first appearance on our show, and our other MI-related episodes at the links below.Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEPEpisode 7 - API 510 with Guest William McBridePSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
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In this episode, Rob is joined by guest Doug McMahon, who is a chemical engineer with 15 years of experience in the industry. Doug is currently the process technology manager at a site that produces organic peroxides, so he knows firsthand about the challenges of engineering in a high hazard plant. Today, Rob and Doug cover five of these challenges - which include choosing the right thing to do, making the right choices for how you will do it, managing details throughout the entire process, dealing with folks finding problems with your solution, and dealing with unintended consequences. Listeners from any type of site are sure to find value in this episode, so be sure to tune in.
We apologize in advance for a couple, brief, low-quality audio spots in this episode, but want you to know that this episode is full of content you don't want to miss!
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In this episode, Rob and Molly discuss the CSB's investigation report on the 2019 popcorn polymer accumulation, pipe rupture, explosions, and fires at the TPC Group (TPC) Port Neches Operations (PNO) facility in Port Neches, Texas. On November 27, 2019, a pump that had been taken out of service for 114 days created a deadleg where butadiene polymer developed. The polymer filled the pipe and developed enough pressure to rupture the piping, releasing flammable butadiene which then ignited, resulting in explosions and fires. The fires burned for over 1 month and 2 employees, 1 contractor, and 5 members of the public reported injuries. Additionally, a mandatory evacuation order was issued for a 4-mile radius, affecting people in 4 nearby towns. The incident resulted in significant property damage both on-site and off-site, and TPC filed for bankruptcy in 2022.
Today, Rob and Molly provide some background details about TPC, explain what a deadleg is and talk about how they should be managed in Butadiene facilities, discuss how TPC's PHA considered the potential for this hazard, touch on remotely operated isolation valves, and point to relevant RAGAGEP that provide guidance regarding this hazardous butadiene polymer formation. They also discuss contributing factors, what types of companies could be at risk from incidents like these, and what any type of facility could learn from this accident.
Find the CSB's final report here, and be sure to check out our other Incident Breakdown episodes where we cover additional CSB final reports.
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In this episode, Molly is joined a second time by guest Chris Paskach, who is currently the Flare Master at the Phillips 66 Wood River Refinery in Roxana, Illinois. Molly and Chris discuss the CSB's investigation report on the 2018 ethylene release and fire at the Kuraray America, Inc. EVAL facility in Pasadena, Texas. During the event on May 19, 2018, 2,347 pounds of ethylene were released in approximately three minutes, after high pressure conditions inside the reactor resulted in the use of the reactor's emergency pressure relief system. Unfortunately, the flammable ethylene vapor was released in an area where many contractors happened to be working, including those who were involved in welding activities, which most likely provided an ignition source for the vapor. While some workers were injured as they jumped and fled from the second or third story of the plant structure, others who wore fall protection equipment could not immediately escape the fire. As a result, two were life-flighted from the site, and a total of 23 workers were injured. CSB released an animated video detailing the events and its final report on the incident in December 2022. Today, Molly and Chris provide background into Kuraray, cover the details of what exactly happened leading up to the event, discuss contributing causes, and more. Finally, they'll wrap up by covering what they believe companies can learn from this accident.
Find the CSB's final report here.
Find the CSB's video on the incident here.
If you have further questions about today's episode, feel free to send us an email at podcast@amplifyconsultants.com or you can connect with Chris Paskach directly on LinkedIn here.
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In this episode, Jo and Molly discuss the CSB's final investigation report on the 2018 explosion and asphalt fire at the Husky Superior Refinery in Superior, Wisconsin. During a shutdown on April 26, 2018, flammable material got into a section of equipment which contained oxygen and ignited, causing two vessels to explode into fragments, one of which punctured a nearby asphalt storage tank. The resulting asphalt spill spread through several production units and then caught fire. Fortunately there were no casualties, but the incident did result in the injury of 36 refinery and contract workers, the evacuation of more than 2,500 residents, $550 million in property damage, and the release of 39,000 pounds of a flammable hydrocarbon vapor mixture. The CSB released an animated video detailing the events in December 2019, and then released its final report on the incident in December 2022. Today, we provide some background details, delve more into what happened, and cover how the refinery's shutdown, lack of knowledge, and inadequate PHA contributed to the event. Additionally, we'll cover all of the CSB's recommendations, which include recommendations addressed to the refinery, the Cenovus Corporation, OSHA, EPA, API, and Honeywell UOP. Finally, we'll cover five of our own big process safety takeaways from the incident, related to PSI, operating procedures and training, emergency response, learning from industry and the past, and the hazards of transient operations.
Find the CSB's final report here.
Find the CSB's video on the incident here.
Find additional information about the CSB's investigation here.
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In today's episode, Rob is joined by Peter Hereña, who currently serves as the process safety manager at CF Industries. Rob and Peter start their discussion by defining what process safety culture is, and what a good process safety culture looks like. Then Peter shares how his company organized a process safety week last October, and all of the components, planning, and branding that went into the event. Peter ends the episode by offering his advice to others who might also want to try a process safety week in an effort to reinforce a healthy process safety culture at their own companies.
For additional questions about his process safety week event, or to talk process safety culture further, please connect with Peter on LinkedIn here.
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In this episode, Rob and Jo discuss the CSB's investigation report on the 2019 explosion and fire at AB Specialty Silicones in Waukegan, Illinois. On May 3, 2019, operators were performing a batch operation when two incompatible chemicals were added to the same tank, which produced hydrogen gas, and eventually led to a massive explosion and fire that killed four employees. The CSB released its final report on the incident on 9/24/2021 and then an incompatible chemicals video about the incident on 4/28/2022. Today, we provide some background details, delve more into what happened, and cover what safety issues at the facility likely contributed to the event. We'll also cover the types of industries and facilities that could be at risk for incidents like this one, and share nine key learnings from this tragic event.
Find the CSB's final report here.
Find the CSB's video on the incident, Incompatible Chemicals: Explosion at AB Specialty Silicones, here.
And as always, please contact us with any questions or comments at podcast@amplifyconsultants.com.
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In this episode, Rob and Molly are joined by previous podcast guest, Tim Murphy, to discuss the 2019 fire and explosions at Philadelphia Energy Solutions (PES). In a previous role many years ago, Tim served as a process safety coordinator for the refinery, and although he was not employed there later when the incident occurred, he is able to provide additional context surrounding the incident due to this former role. In this episode, you'll learn a brief history of the facility, hear what happened on June 21, 2019 and why, and learn about the hazards associated with the refinery. You'll also hear the group's thoughts on a few of the US Chemical Safety board's findings, and the key lessons that other facilities in the process industry can take away from this incident.
Find the CSB's final investigation report and video here.
Listen to Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy here.
Find other episodes where we delve into CSB investigation reports by typing "incident breakdown" into the search bar on our website at www.amplifyconsultants.com/podcast.
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On September 28, 2022, the US Chemical Safety Board (CSB) released its final report on the 2016 flash fire incident that injured 7 workers at Sunoco Logistics Partners in Nederland, TX. In today's episode, Rob and John provide context related to the hot work activities that were taking place at the time of the incident, go through the CSB's findings and recommendations, and then provide their thoughts on the hazards related to hot work and the use of contractors.
Find the resources we mention in this week's episode at the links below:
CSB Report
CSB Hot Work Safety Bulletin
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In this episode, our midwestern colleagues take the podcast by storm (pun intended). John and Molly talk about how tornadoes and other natural hazards can be accounted for in both emergency planning and as part of a robust Process Hazard Analysis (PHA). They'll cover routine drills, evacuation, and shelter in place practices, muster points and emergency response, and their opinions on complacency towards repeated drills. Whether you too, find yourself in Tornado Alley, or if you're located elsewhere, you'll want to stick around for this episode.
Also be sure to check out Episode 26 - Natural Hazard Assessment and Planning.
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On Monday, November 21, 2022, hot work activities at an industrial trading company in China led to a fatal fire when cotton cloth located near the welding activities went up in flames. The fire killed 38, injured 2, and took over 4 hours to extinguish. In this episode, Rob and Molly bring you the latest information about the incident, and offer a reminder about the role that a robust hot work program plays in preventing loss of life.
Read more about the incident here and here.
View the CSB's Dangers of Hot Work video here.
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In Episode 65, guest Michelle Murphy is back again with Molly - this time to talk about chemical reactivity testing. Molly and Michelle cover the basics of chemical reactivity testing, including who should consider this type of testing, where to start, what can be learned from testing, information about the samples needed, and much, much, more.
Listen to our previous episode with Michelle Murphy, Episode 51 - Combustible Dust Testing with Guest Michelle Murphy, here. To contact Michelle, send an email to her at mmurphy@sigma-hse.com, or reach her by phone at 978-880-2915 (office) or 603-303-7863 (cell).
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In Episode 62, we covered PSM practices that we considered to be red flags indicating the potential for a weak process safety program. In today's episode, we tackle just the opposite - the PSM All-Stars. What can we learn from the best of the best, and what exactly are these All-Stars doing that makes their process safety programs so great? John and Molly break it down for you in today's episode, and cover the top 10 best practices they've seen from the most impressive PSM champions across industry.
Check out our other Top 10 Talks on your favorite podcast platform, or by using the search bar on our website's podcast page at www.amplifyconsultants.com/podcast.
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In this episode, Molly is joined by Chris Paskach, who is currently the Flare Master at the Phillips 66 Wood River Refinery in Roxana, Illinois. Although there are only a few short references to relief devices in the PSM standard, the amount of documentation that is required is quite expansive, so Molly and Chris break down the basics for you in this episode. They'll cover the relief system design and design basis information required for PSI, reference information needed to support a process hazard analysis (PHA), relief, vent systems, and device information needed for your mechanical integrity (MI) program, and more. If you have further questions about today's episode, feel free to send us an email at podcast@amplifyconsultants.com or you can connect with Chris Paskach directly on LinkedIn here.
Also be sure to check out Episode 54 - Pressure Relief Device Concepts with Guest Eric Hirsch and Episode 45 - Piping Requirements for Pressure Relief Devices if you're interested in taking a deeper dive into pressure relief topics.
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In today's episode, we bring you another Top 10 Talk, this time on practices we deem to be "process safety red flags". In this episode, John and Rob cover what they consider to be red flags pointing to the potential for systemic issues in a facility's process safety program. They'll cover management's attitude, prioritization, and resource allocation, approaches to documentation, including reliance on paper-based systems, lack of attention to detail and poor operational discipline, lack of urgency in maintaining safety critical assets, lack of understanding when it comes to hazards and how to properly manage them, change management processes, attitudes toward action item closures, contractor involvement, and more.
We want to know what you think; did we miss any process safety red flags, or have you experienced any of these at your facility? Leave us a voice message at the link below or send a note to podcast@amplifyconsultants.com.
And if you haven't already, check out our previous Top 10 Talks here (PHAs), here (Compliance Audits), and here (P&IDs).
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On Tuesday, September 20, 2022, an accidental release event occurred at the BP-Husky Toledo refinery in Oregon, OH, which ultimately resulted in two employee fatalities, the release of sulfur dioxide and hydrogen sulfide, and significant property damage. In this episode, John and Rob bring you the latest information about the incident, and offer a reminder about the role that PHAs, operating procedures, MOCs, and PSSRs play when it comes to shutdown/turnaround operations and safety.
CSB Deploys Team to Fatal Refinery Incident in Ohio
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In this episode, Rob and Molly compare the requirements of combustible dust management systems with the requirements of the PSM standard. They walk through each similar element and then point out the three largest differences between the PSM standard and the NFPA combustible dust standard. Whether your facility is already PSM-covered, or isn't, you'll want to catch this episode if you handle combustible dusts. We also recommend that you check out Episode 16 - Combustible Dusts & DHAs and Episode 51 - Combustible Dust Testing with Guest Michelle Murphy too to learn more.
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In this episode, Rob and Molly compare the requirements of combustible dust management systems with the requirements of the PSM standard. They walk through each similar element and then point out the three largest differences between the PSM standard and the NFPA combustible dust standard. Whether your facility is already PSM-covered, or isn't, you'll want to catch this episode if you handle combustible dusts. We also recommend that you check out Episode 16 - Combustible Dusts & DHAs and Episode 51 - Combustible Dust Testing with Guest Michelle Murphy too to learn more.
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In this very special episode, Rob is joined by guest Gilsa Monteiro, a process safety expert with nearly nineteen years of experience in the Oil & Gas industry, to discuss how an organization's decentralized structure may undermine process safety. In this episode, you'll learn the defining features of both a centralized and decentralized organizational structure, the process safety dangers of a decentralized structure and how to avoid those dangers, and other factors to consider when it comes to process safety, like how bonus structures can impact risk and process safety.
Useful links from today's episode:
Read Gilsa's paper (part 1) How do organizational structures impact operational safety? Part 1 – Understanding the dangers of decentralization
Request a copy of Gilsa's paper (part 2) How do organizational structures impact operational safety? Part 2 - Designing structures that strengthen safety
Check out Organising for Safety: How structure creates culture by Andrew Hopkins
Connect with Gilsa Monteiro on LinkedIn.
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On August 19, 2022, an explosion at a sugar refinery in Andhra Pradesh's Kakinada district took the lives of two workers and injured nine others. In this episode, Rob and Molly bring you the latest information about the incident, and offer a reminder about the role good housekeeping plays in keeping the people who work in facilities that handle combustible dusts safe. For additional information, check out the resources we've gathered below.
News Releases:
2 dead, 6 hurt after explosion rocks sugar refinery in Andhra Pradesh’s Kakinada
Andhra Pradesh: Two dead, 9 injured in sugar factory explosion in Kakinada
In this episode we also referred to the CSB's video for the Imperial Sugar Company Dust Explosion and Fire, which you can view here.
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On August 2, 2022, the US Chemical Safety Board (CSB) released its final report into the 2017 pressure vessel explosion at Loy-Lange Box Company in St. Louis, MO. In today's episode, Molly and Jo take a deep dive into that report and break it down for you. So what can you expect in this breakdown? We'll cover some background information about the facility and its process, give you details about the day of the incident, and then break down the factors that ultimately led to the vessel's failure on April 3, 2017. Finally, we'll discuss how certain elements of a robust process safety program could have helped to prevent this tragedy, and provide you with three big takeaways that we think you'll find valuable, regardless of the industry or materials you work with.
Find the resources we mention in this week's episode at the links below:
- CSB Report
- Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP
- PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
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We're back with another Top 10 Talk, this time to discuss how to Amplify Your P&IDs. In this episode, Rob and Molly cover their top ten tips for how to improve your P&IDs, and touch on consistent standards, drawing details, managing revisions, reference flags, tag numbers, line numbering, instrumentation, equipment information, relief devices, referencing P&IDs across your PSM program, and more. Then they break the rules and throw in two more bonus tips at the end (so I guess this is a Top 12 Talk). If you're looking to improve your process safety information (PSI) documentation, or improve the quality of your PHAs, then this is the episode for you.
We want to know what you think; did we miss any P&ID best practices, or do you have any questions about what we covered? Leave us a voice message at the link below or send a note to podcast@amplifyconsultants.com.
If you haven't already, check out our previous Top 10 Talks here (PHAs) and here (Compliance Audits).
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In this episode, Molly and John discuss the subtleties of Management of Change (MOC). If you're familiar with MOC, then you already know that in order to comply with the PSM standard, you need to "establish and implement written procedures to manage changes (except for 'replacements in kind') to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process". But what if the line between a real change and a replacement in kind isn't totally clear? For example, what if you replace a pressure relief device with another of the same size, but the replacement is from a different manufacturer than the original device? Tune in to this episode to learn more about this specific situation and other similar cases, where you might find yourself on the fence about whether an MOC is truly required.
Have a specific scenario that we didn't discuss? Send an email to podcast@amplifyconsultants.com and our consultants will respond with their expert advice.
For those not familiar with MOCs, we suggest checking out these previous episodes of our show:
Episode 5 - MOC & PSSR
PSM: Back to Basics, Part 4 - Management of Change (MOC)
Episode 48 - Management of Organizational Change (MOOC)
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In a previous episode (#52), Mat Todaro, an attorney who specializes in enforcement defense, talked with us about EPA's General Duty Clause (GDC) at a high level. In this companion episode, Molly and Rob dive into the specific requirements of EPA's GDC, and point out its similarities and differences to OSHA's Process Safety Management (PSM) regulation and EPA's Risk Management Plan (RMP) regulation.
Be sure to check out the resources we've gathered below regarding EPA's GDC, or reach out to us with any questions you might have related to your facility and EPA's GDC by sending us an email at info@amplifyconsultants.com.
Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
The General Duty Clause Fact Sheet (pdf) (April 2020)
Guidance for Implementation of the General Duty Clause: Clean Air Act Section 112(r)(1), May 2000 (pdf)
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This week we're excited to bring you a new type of episode, a movie breakdown. In this episode, John and Molly give their take on what's happening in a clip featuring a nuclear power plant control room in the 1979 thriller/drama film, The China Syndrome. We invite you to watch the clip at the provided link below before you tune into this episode. In this episode, we cover our concerns related to the events transpiring in the control room, and offer useful reminders about relief mitigation, process deviations, operating procedures, PHA considerations, evacuation plans, maintenance outages, and more.
The China Syndrome clip: https://youtu.be/nemYBeT4aQY
Let us know what you thought about this episode, or send us an idea for a future movie breakdown episode, where we explore a clip through the lens of process safety by sending an email to podcast@amplifyconsultants.com.
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In Episode 45, we covered the basics of piping requirements for pressure relief devices. In this episode, Rob is joined by Eric Hirsch, to take a deeper dive into pressure relief device concepts. Eric, a principal process engineer at Nexus Engineering Group, works in process design with a focus on pressure relief devices. In this episode, Eric and Rob cover basic requirements for pressure relief devices and the calculations that go with them. You'll learn about back pressures, considerations for common subheaders and global relief scenarios, impacts to the relief capacity of a system, identifying fire zones/circles, design issues with flare knock out pots, Eric's thoughts on the use of rupture disks for overpressure protection, SIS instrumentation, designing for 2-phase relief, and more. Then Eric gives his expert advice regarding a frequently asked question: Do I have to have overpressure protection on every pressure vessel and/or piping system and do I need calculations for all of those? He'll touch on what could get you in trouble with OSHA during an enforcement audit when it comes to your pressure relief scenarios, how often you should revalidate them, and more. Don't miss this content-packed episode from an expert on pressure relief devices.
To contact Eric Hirsch directly, send an email to eric.hirsch@nexusegroup.com or give him a call at 216-456-8564.
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Operators, maintenance technicians, and I&E technicians - those we deem "boots on the ground" - are a vital and often untapped resource when it comes to a successful Process Safety Management (PSM) program. In this episode, John and Molly discuss how to set yourself up for successful buy-in and a positive PSM culture with boots on the ground personnel and talk about how experienced operators can be utilized to build, review, and optimize Standard Operating Procedures (SOPs). John and Molly also touch on how operators can assist with field labeling and P&ID updates, delivering relevant and engaging refresher training, and how experienced operators can be involved in the Management of Change (MOC) process, Process Hazard Analyses (PHAs), and in Incident Investigations. Whether you manage "boots on the ground" personnel, or you are one yourself, you'll want to catch this episode to learn more about how this important resource can contribute to overall PSM program success.
To learn more, be sure to check out a previous episode we have on this topic, Episode 20 - Why "Boots on the Ground" are Vital to your Process Safety Program.
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Join us for a recording of another Top 10 Talk event. During this event, Rob Bartlett and John Doan, presented their top ten tips for successful Compliance Audits. A list of the tips that Rob and John elaborate on is presented below.
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Know the Basics
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Choose Your Auditor Wisely
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Understand Compliance Criteria
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Preparation is Key
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Prepare Personnel
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Have an Agenda
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Documentation is Critical
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Focus on Improvement
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Understand the Findings
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The Final Report is not the Finish Line
If you would prefer to watch the talk instead, view a video recording of the event here.
We want to know what you think - we welcome any feedback that you have about this event, and invite you to share your thoughts, including suggestions for future Top 10 Talk topics, in this short survey.
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Mathew Todaro of Verrill Law joins us for a third time in this episode - this time to talk about EPA's General Duty Clause (GDC). In this episode, Mat, an attorney that specializes in enforcement defense, provides an overview of the objectives of EPA's GDC. But with such broad language and no specific list of covered substances, what are the real requirements for facilities when it comes to this GDC? And with so many similarities between the requirements of PSM/RMP and the GDC, are there even advantages for a facility to keep less than the threshold quantity of a hazardous substance that would require a PSM/RMP program? Mat and Rob cover the answers to these important questions and more in this episode.
Find the GUIDANCE FOR IMPLEMENTATION OF THE GENERAL DUTY CLAUSE CLEAN AIR ACT SECTION 112(r)(1) here: https://www.epa.gov/sites/default/files/documents/gendutyclause-rpt.pdf
Be sure to check out Mat's previous appearances on our podcast by listening to episodes 25 and 35. Connect with Mat on LinkedIn here.
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In this episode, Molly is joined by guest Michelle Murphy, a chemical engineer who has worked in process safety for 25 years. Earlier in her career, Michelle designed, built, and managed a combustible dust testing laboratory, and now she is the newly appointed president of Sigma-HSE INC., the North American division of Sigma-HSE. Molly and Michelle cover the basics when it comes to combustible dust testing, including defining combustible dusts, discussing why dust testing is needed, and reviewing what types of tests are available. You'll learn how to select a combustible dust test, what commonly used tests tell you about your dust, how testing samples should be prepared and collected, tips for making the most of your testing budget, and how testing relates to your MOC and PHA processes.
If you have additional questions about combustible dusts or combustible dust testing, Michelle invites you to visit Sigma-HSE.com, send an email to her at mmurphy@sigma-hse.com, or reach her by phone at 603-303-7863.
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In this episode, Rob and John talk about remote facilities - how a remote facility is defined, how risk is managed differently versus at a large, regularly populated plant, how operator response times differ, precautions taken for operators performing lone work, how incidents might be handled, security, and more.
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You may remember our guest David Hatch, from Episode 39, when he spoke to our listeners about using bow ties to manage risk. Today, David, a process safety expert and entrepreneur, is back to talk with Rob about the Integrity Cards that he has developed. In his process safety career, David had not seen a reduction in accidents and wondered to himself if maybe those in hazardous industries weren't focusing on the right things. He saw an opportunity to condense process safety knowledge into an accessible and familiar version - a pack of cards, where each card represented a different loss of containment, and thus the Integrity Cards were born. These Integrity Cards are meant to be used in a structured way to inform those on the front line of legitimate hazards that they face, and can be used in PHAs, toolbox talks, management meetings, and more. In this episode, David covers his inspiration for creating the cards, shares suggestions for using the cards, talks about how QR codes are expanding the knowledge each card can convey, shares how his cards can be used electronically, and touches on other opportunities outside the world of process safety in which customized decks can be utilized.
To learn more, visit https://integrity.cards/ or find David Hatch on LinkedIn at https://www.linkedin.com/in/dh04tch/.
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In our first episode to kick off 2022, Rob and Molly talk Management of Organization Change (MOOC). Management of Organizational Change is a systematic way to ensure that adherence to process safety policies doesn't suffer when any sort of organizational change takes place that could potentially affect process safety, including but not limited to pandemic effects on staffing and remote work, other personnel changes due to resignations, new hires, or promotions, work stoppage due to union strikes, and more. In this episode you'll learn what MOOCs are, when they should be used, differences and similarities between MOOCs and other Management of Change (MOC) used for process safety compliance, and how organizational changes can act as enabling events for PSM incidents.
To learn more, check out the CCPS book mentioned in this episode, Guidelines for Managing Process Safety Risks During Organizational Change.
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In the final installment of their three-part series, the A-Team shares advice for mature process safety programs. When your program reaches this phase, likely around the 10-year mark, it's important to continue maintenance of ongoing compliance and strive for continuous improvement. In this episode, Rob, Molly, John, and Jo cover best-in class practices for a mature PSM program, and touch on the unique challenges that you'll face in this phase of your journey.
Don't forget to listen to the first two parts of this series, Part 1 - The Foothills and Part 2 - Climbing the Mountain to learn more about our tips for newer PSM programs.
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In the second part of our three-episode series covering facilities' process safety journeys, the team is back to share information pertinent to programs that are still "climbing the process safety mountain" - more specifically, those who are about 3-10 years into the development and deployment of their PSM program. In this episode, Rob, Molly, John, and Jo cover the main goals during this phase, including improving compliance and refining your existing programs, and then go on to discuss process safety culture, PSI, operator participation, policy updates, electronic systems, pressure relief audits, emergency response plans, MOC expansion, facility siting, mechanical integrity programs, and much, much more. Don't forget to join us for the last episode in the series, in which we touch on continuous improvement for mature PSM programs.
To listen to the previously released Mechanical Integrity (MI) episodes that Rob references, visit here and here.
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Join us for a recording of Amplify's first Top 10 Talk. During this event, Rob Bartlett and Molly Myers, P.E., presented their top ten tips for successful Process Hazard Analyses (PHAs). A list of the tips that Rob and Molly elaborate on is presented below.
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Choose your facilitator wisely
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Documentation in key
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The method matters
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Create nodes like Goldilocks
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Valuable members make a valuable team
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What risk are you willing to accept?
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Ask, "what's the worst that could happen?"
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Approach operator response realistically
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The final report is not the finish line
10.Don't procrastinate
A Q&A session follows the presentation.
If you would prefer to watch the talk instead, view a video recording of the event here.
We want to know what you think - we welcome any feedback that you have about this event, and invite you to share your thoughts, including suggestions for future Top 10 Talk topics, in this short survey.
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In this very special episode, the first of a three-part series, the whole A-Team comes together to share their expert advice for facilities that are just beginning their process safety journey. In this episode, Rob, Molly, John, and Jo cover the main goals that you'll want to keep in mind when you begin establishing your process safety program, including the unique challenges that you may face during this part of your journey.
Be sure to join us again in the next two parts when we cover our tips for PSM programs in the 3-10 year range, and then our final episode in the series covering continuous improvement for mature PSM programs.
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In this episode, Rob welcomes Nat Weiner to the podcast. Nat, who has extensive experience both as a plant manager and in a role managing plant managers tells us what advice he would give to someone who has recently taken on the "Plant Manager" title. Tune in to this episode to learn Nat's best tips for new plant managers, including how to best leverage the information contained in the last PHA, what you should focus on once basic PSM compliance is met, and what might keep a plant manager up at night. If you're in Ops, you won't want to miss this episode.
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In this episode, Rob welcomes process safety consultant Mike Robertson to the podcast. With over 30 years of experience in the chemical industry, Mike provides a thorough overview of what a Dust Hazard Analysis (DHA) is, why and when they are required, required versus preferred documentation to gather for DHA prep, and provides listeners with both similarities and differences between a DHA and a PHA (Process Hazard Analysis). Mike wraps up the episode by covering some typical DHA recommendations he often comes across and tells listeners two things he wishes everyone knew about Dust Hazard Analyses. We apologize in advance for a couple, brief, low-quality audio spots in this episode, but want you to know that this episode is full of content you don't want to miss!
To view the Imperial Sugar incident video from the CSB that is mentioned in this episode, visit https://www.csb.gov/imperial-sugar-company-dust-explosion-and-fire/.
Get in touch with Mike Robertson at 678-815-7678 or at processesmatter@gmail.com.
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In this episode, Rob and Molly talk piping requirements for pressure relief devices, including which Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) apply. With an extensive background as a pressure relief specialist, Molly walks through the basic requirements outlined in ASME Section VIII and API 520, Part II, tips for layouts, including safe discharging locations, and addresses some frequently asked questions regarding requirements for relief device calculations.
Want to talk pressure relief devices further? Let us know what you'd like us to address in a future episode, or reach out to Molly directly at molly.myers@amplifyconsultants.com.
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In this episode, Rob welcomes Nicholas Krump, an expert in changing safety cultures. Nicholas shares the challenges he sees companies face again and again when it comes to implementing a positive safety culture, actionable tips for walking into a new safety culture, and elaborates on the value of buy-in/participation from hourly employees. To learn more about Nicholas and to connect with him, find him on LinkedIn here.
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In this episode, Rob is proud to introduce the newest member of the Amplify Team, Molly Myers. Along with a diverse background across multiple industries, Molly has sat on both sides of the table when it comes to supporting a facility's PSM compliance, sometimes with an internal role supporting process safety and other times as an outside consultant. Molly shares what drew her to process safety and why she thinks it matters, the best and hardest parts of being a process safety consultant, the challenges she sees facilities struggle with when it comes to compliance, and the changes she's witnessed in PSM practices since the early days of the regulation.
Learn more about Molly and the rest of the team on our website at www.amplifyconsultants.com/about.
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On July 28, 2021, the CSB deployed to a fatal incident that took place at the LyondellBasell chemical plant in La Porte, TX. The release took the lives of two contractors and hospitalized thirty employees. In this episode, Rob brings you the latest information about the incident, and offers a reminder about the role process safety plays in keeping the people who work in and around facilities that handle hazardous materials safe. For additional information, check out the resources we've gathered below.
CSB News Release, 7/28/2021
News Releases:
Acetic acid explained: What it is and how it's used
2 dead, 30 hospitalized in chemical leak at LyondellBasell chemical plant in La Porte
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In this episode, Rob is joined by Human Factors Engineer, Monica Philippart. Monica and Rob explore the definition and importance of human factors, how human factors should be integrated into both process design and incident investigation, and how organizations might improve their consideration of human factors beyond just a simple checklist.
To learn more, find Monica on LinkedIn here.
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In this episode, Rob sits down with Tim Murphy, the Process Safety Manager of Arkema Inc., responsible for providing PSM and RMP support for more than 25 facilities. With such a large number of sites to support, how does Tim ensure that each site values PSM and understands its importance? And what advice does Tim have for new engineers who might be considering a career in process safety? Tune in to this episode to find out.
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In this episode, Elena is joined by guest Trish Kerin, Director of the Institution of Chemical Engineers (IChemE), a multi-national institution tasked with advancing chemical engineering's contribution for the benefit of society. Elena and Trish discuss the specific incidents across the globe that highlighted the need for process safety in the past, touch on the importance of considering human factors, and caution against claiming "double jeopardy" when talking about adequate process safety safeguards. Elena and Trish then delve into the challenges of improving process safety culture, and Trish explains iChemE's role and involvement. Elena and Trish also cover the importance of good leadership, their hopes for the future of process safety and collaboration within industries, then leave those new to process safety with a few words of helpful career advice.
Learn more about IChemE at https://www.icheme.org/
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In this episode, Rob is joined by guest David Hatch, a professional Process Safety Engineer with over 30 years of experience in Major Accident Hazard facilities and Design, Operating & Consulting roles in highly regulated industries including Oil & Gas, Pharmaceuticals, and Energy & Chemicals. In this episode you'll learn what a Bow Tie diagram is, its relationship to PHAs, how Bow Ties are currently being used, and where David sees the future of Bow Ties headed in the next five to ten years.
Find the CCPSC Book mentioned in the episode, Bow Ties in Risk Management: A Concept Book for Process Safety.
Connect with David on LinkedIn or learn more about him through the Process Safety Integrity website.
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On April 8, 2021, the CSB deployed to a fatal paint plant incident that took place at the Yenkin-Majestic Paints and OPC Polymers manufacturing site in Columbus, Ohio. The fire and explosion killed one employee and injured eight others. In this episode, Rob and Elena bring you the latest information about the incident, and offer a reminder about the role process safety plays in keeping the people who work in and around facilities that handle hazardous materials safe. For additional information, check out the resources we've gathered below.
OSHA Inspection: 282228.015 - Yenkin-Majestic Paint Corporation
CSB News Release, 4/8/2021
CSB First Update, 4/9/2021
News Releases:
https://www.dispatch.com/story/news/2021/04/08/columbus-ohio-paint-manufacturing-plant-explosion/7137210002/
https://www.10tv.com/article/news/local/cameras-capture-deadly-explosion-at-columbus-paint-plant/530-93c1b939-c5ba-48a7-bc54-020da0bc46b8
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In this episode, Rob, John, and Elena talk PSM compliance audits in the age of COVID-19. They'll talk you through how remote compliance audits work from start to finish, pros and cons about the remote audit format, and how remote audits compare to in-person compliance audits. Whether you participate in audits as part of a company team, or perform audits yourself, this is the episode for you.
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In this episode, Rob sits down with experienced EH&S Director, Mike Burson, to talk safety culture. Rob and Mike cover the challenges when it comes to developing a safety culture at different levels of an organization, talk strategies to improve an organization's safety culture, share stories about their experiences and struggles, and more.
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In the age of COVID-19, many services moved online to be held remotely, and Process Hazard Analyses (PHAs) were no exception. In this episode, consultants Rob and Elena talk about what they've learned over the past year when it comes to remote PHAs, including what works best and what unique challenges you might be faced with. You'll learn how remote PHA prep looks different, our thoughts on using cameras, how best to virtually "manage" the room, tips for dealing with P&IDs and other needed documentation, how we handle breaks, field verification, and "zoom fatigue", and our thoughts on efficiency and scheduling when it comes to longer PHAs. Whether you participate in PHA studies as a facilitator or just a member of the team, you're sure to find value in this episode.
To hear more from us on the topic of PHAs, check out Episode 2 (Intro to PHAs), Episode 12 (Risk Matrices), Episode 17 (Tips for a Successful PHA), Episode 19 (PHAs during the Project Life Cycle), or PSM: Back to Basics, Part 3 (Process Hazard Analysis).
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Mathew Todaro of Verrill joins us again in this episode - this time to talk about environmental compliance audits. Mat, an attorney that specializes in enforcement defense, explains how EPA enforcement and emphasis of the RMP regulation has changed in recent years, and how you can best prepare your facility should you become the next site of an EPA investigation. Rob and Mat talk about how performing internal compliance audits more often than the 3-year frequency required by PSM and RMP can be a valuable tool, but also cover how to protect that information and how a lawyer might be used to assist in these endeavors. If you're interested in learning more about protecting your facility while also ensuring compliance and the safety of employees, the surrounding community, and the environment, then this is the episode for you.
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In this episode, Rob sits down with John, the newest member of the Amplify team. John talks about his career experience, what led him to his current role, successes and difficulties he's witnessed with PSM implementation, and why he feels so passionate about process safety.
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In our very first Process Safety Incident Alert, Rob and John bring you the latest information about the fatal chemical release that occurred on January 28, 2021, at a food producer in Gainesville, Georgia. They also discuss another recent event involving liquid nitrogen in John's neck of the woods, talk about the industries and locations where liquid nitrogen incidents typically occur, and then provide listeners with a call to action: what can you do if you work at a facility that handles liquid nitrogen to prevent future incidents?
Read more from the CSB regarding this incident here, here, and here.
Read more about the incident in Kansas that John mentions here and here.
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We're back with another episode of our PSM: Back to Basics miniseries, where we cover a PSM topic in a beginner-friendly manner for those newest to the process safety world. In this episode, Rob and Jo talk about what the PSM standard requires when it comes to Mechanical Integrity, the parallels between MI for a plant and maintenance on your car, how you might get started building your facility's MI program, and where you can go to learn more.
Check out the CCPS book on Guidelines for Asset Integrity Management.
Ready to learn more? Take a deeper dive and listen to Episode 1 - Intro to Mechanical Integrity (MI) and RAGAGEP.
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The world of process safety is STILL chock-full of acronyms. In part 1 of our beginner-friendly miniseries, PSM: Back to Basics, we tackled the essential acronyms that PSM newbies need to know, providing an explanation and context for each term. In this episode, Rob and Jo are back to cover even more acronyms: ALARP/ALARA, BPCS, BRM, CSO/CSC, DHA, EAP/ERP, ESD, FSS, IEL/IEF, IPL, ITPM, LEL, LOPC, MCE, NFPA, OEM, PFD, PRD, and PSV.
Ready to learn more? Be sure to check out the previous four parts of the PSM: Back to Basics miniseries.
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In our last episode of 2020 Rob and Wesley talk quality assurance and quality control. Listen to learn what QA/QC means, what the PSM standard says, the importance of independent verification, and how things can go right (or very wrong) when it comes to QA/QC.
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In this episode, Wesley and Rob cover process safety leading and lagging indicators. They cover what these metrics are, why they're important for your organization, and some key resources you can turn to in order to learn more.
API Recommended Practice 754 - Process Safety Performance Indicators For The Refining And Petrochemical Industries
IOGP Report 456 – Process safety – recommended practice on key performance indicators
CCPS Process Safety Leading and Lagging Metrics
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In this episode, Rob, Wesley, and Elena team up to talk about operator training. You'll learn what the PSM standard requires, how your operating procedures affect the quality of your training program, and some tips to improve your training program and its effectiveness, including the use of a competency matrix (not to be confused with The Matrix, though we do give a shout out to Keanu Reeves). Join us for a fun, informative episode covering all the dos and don'ts you need to know when it comes to operator training.
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Who are these people and why do they have a podcast? In a much needed follow-up to episode 0, you'll meet all the members of the Amplify team, hear about the very different journeys that led them to Amplify, and learn what makes them passionate about process safety. Tune in as our normally virtual team sits down together for the first time for an episode jam-packed with jabs, sarcasm, and laughs. We look forward to meeting you! Learn more about our team on our website at https://www.amplifyconsultants.com/about.
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In today’s episode, Wesley welcomes Bob Wasileski to the show, an Energy risk engineer from Allianz Global Corporate & Specialty (AGCS), who has sat on both sides of the table when it comes to insurance surveys. In this episode, you’ll learn what an insurance survey is and how it explores both sides of the bow tie diagram, the top 10 things risk engineers look for when they survey your facility, and how you can use insurance risk engineeringreports to make a positive impact on your PSM program and to your insurance premium. If you would like to get more involved with insurance surveys at your site and create value from the process then this is the episode for you.
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We're back with Blaine Hoffmann from The SafetyPro Podcast, for part four of our collaborative series comparing and contrasting the PSM standard with OSHA general industry regulations. In this episode we cover the requirements surrounding Hot Work, any work that involves burning, welding, cutting, brazing, soldering, grinding, using fire- or spark-producing tools, or other work that produces a source of ignition. You'll learn what the PSM standard requires for hot work, its relationship with standard 1910.252 (for general industry), and even about what the OSHA construction standard says about hot work activities. You'll also hear an up close and personal story about hot work and associated hazards, and then we'll walk you through 7 key lessons from the CSB to prevent worker deaths during hot work in and around tanks.
Listen to the Contractor Management episode we referenced a few times here: https://www.amplifyconsultants.com/podcast/episode/2ea6f639/episode-27-contractor-management-with-the-safetypro-podcast
CSB Fact Sheet: Safe Hot Work Practices (Summary of 7 Key Lessons to Prevent Worker Deaths during Hot Work in and around Tanks)
Full CSB Safety Bulletin: Seven Key Lessons to Prevent Worker Deaths During Hot Work In and Around Tanks
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In this episode we welcome back Blaine Hoffmann from The SafetyPro Podcast for another collaboration where we talk both occupational safety and process safety, and this time we cover contractor management. We'll talk about what OSHA says about contractor management for general industry, and what's required for PSM-covered facilities, how contractor management relates to both occupational and process safety, and why you should care.
Find OSHA's Recommended Practices for Safety and Health Programs, Communication and Coordination for Host Employers, Contractors, and Staffing Agencies, here.
Also, a special note about today's episode: While we regularly recommend videos from the U.S. Chemical Safety Board (CSB) and think they make excellent training material, in this episode we mistakenly said that there was a CSB animation video for the Phillips disaster of 1989 in Pasadena, TX. No such video exists, but you may learn more about the incident on its Wikipedia page, on Youtube, or from ABC13 Houston.
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Flooding, hurricanes, tornadoes - oh my! In this episode we welcome one of our consultants, Elena Prats, CCPSC, to the podcast for the very first time. In an episode full of personal anecdotes and useful tips, Elena and Wesley cover how to assess and plan for natural hazards at your facility, when industry has been prepared and when it hasn't, and some thoughts about future natural hazard trends. Whether you think your facility is prepared or you know it isn't, this is the episode for you.
Article about Hurricane Harvey
Article about Hurricane Trends
CCPS Monograph: Assessment of and planning for natural hazards
CSB Safety Message and Safety Alert
Six questions to learn from the Fukushima disaster through Human and Organizational Factors
CSB animation for Arkema Crosby
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An EPA inspector has just been at your site, now what? Time to sigh in relief or time to panic? In this episode we pick up where we left off after Episode 4 - Government Inspections, and we cover what to expect once the EPA inspector is gone. Special guest Mathew Todaro of Verill Law joins us in this episode, using his years of experience handling complex regulatory matters to clue you into what your next steps should be and what routes the EPA could choose to take. We'll cover the two things the inspector could reach out for after they leave, what the EPA takes into consideration when making their enforcement decisions, the difference between informal and formal enforcement routes, when you should seek counsel, how fines are calculated, and more. If you've always wondered what's involved in EPA inspection and enforcement or want to know what happens when we put an engineer and a lawyer in a (virtual) room together, then this is the episode for you.
Learn more about Mathew Todaro here: https://www.verrill-law.com/mathew-j-todaro/
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We've teamed up with The SafetyPro Podcast again to bring you an episode on emergency planning and response. We'll cover general industry's requirements, what PSM says, and a bit about RMP's requirements. You'll also get to hear from Blaine, a former first responder, regarding his experience with emergency response and we'll cover two incidents that truly highlight the importance of emergency action plans. If you work at a PSM-covered facility, or in any industry where safety is essential, you don't want to miss this episode.
CCPS Process Safety Beacon - Emergency Preparation - The Titanic Disaster (July 2012)
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In this very special episode, process safety and occupational safety worlds collide as Wesley teams up with Blaine Hoffmann from The SafetyPro Podcast to discuss incident investigation. You'll learn what OSHA's PSM standard says about incident investigation, as well as OSHA's requirements for general industry, why incident investigation is important, why root cause analysis matters, and more.
OSHA Recordkeeping Policies and Procedure Manual
OSHA/EPA Root Cause Analysis Fact Sheet
The SafetyPro Podcast, 082: SMS Pt 3 - What is Root Cause Analysis (RCA)
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In part four of our Back to Basics miniseries, we're talking MOC basics. You'll learn what MOC, or management of change, is, what the process is like, and who is typically involved in each step. We'll also cover two incidents that highlight the importance of MOC.
Find the two incidents we discussed and many others in Incidents that Define Process Safety.
Learn more about MOC in Episode 5 - MOC & PSSR.
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Wesley and Jo are back with part 3 of PSM: Back to Basics, with more content for those newest to PSM. In this episode, you'll learn what a Process Hazard Analysis, or PHA, is and what methodologies exist for conducting a PHA study. You'll also learn the basics of nodes and HAZOP studies, and then we'll discuss a gas plant incident at a facility where no HAZOP study was found to have been conducted.
Ready to learn more about PHAs after this episode? Check out the episodes below for a deeper dive into Process Hazard Analyses.
Episode 2 - Intro to PHAs
Episode 17 - Tips for a Successful PHA
Episode 19 - PHAs During the Project Life Cycle
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New to process safety and not sure where to start? In part 2 of our new miniseries, PSM: Back to Basics, Wesley and Jo cover a plethora of process safety resources, including websites, books, conferences, apps, and more.
OSHA Letters of Interpretation
OSHA Compliance Directive
AIChE Academy e-Learning
SAChE
Mary Kay O'Connor Process Safety Center at Texas A&M
Process Safety International Symposium
Instrumentation and Automation Symposium
CCPS Conferences
GPA Midstream Convention
U.S. Chemical Safety Board (CSB)
CCPS Process Safety Beacon
Our Podcast, Amplify Your Process Safety
Guidelines for Evaluating Process Plant Buildings for External Explosions, Fires, and Toxic Releases, 2nd Edition
Guidelines for Risk Based Process Safety
Guidelines for Asset Integrity Management
CCPS Glossary (& App)
CCPS Process Safety Incident Evaluation App
Incidents That Define Process Safety
Process Safety: Key Concepts and Practical Approaches
Failure to Learn: The BP Texas City Refinery Disaster
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The world of process safety is chock-full of acronyms. In part 1 of our new miniseries, PSM: Back to Basics, Wesley and Jo tackle the essential acronyms that PSM newbies need to know, providing an explanation and context for each term. In this episode, you'll learn about AIChE, API, ASME, CCPS, CCPSC, C&Es, CFR, CSB, CSP, EPA, ERP, II, MI, (e)MOC, NURF, PFDs, PHA, P&IDs, PSI, PSM, PSSR, RAGAGEP, and RMP.
Encountered an acronym in the PSM world that we didn't cover? Send an email to podcast@amplifyconsultants.com and we'll give you a shout out in our follow-up to this episode, when we cover even more process safety acronyms.
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What do toothpaste, coffee, Superbowl Sunday, and Spock have to do with alarms? You'll find out in this episode, where we welcome back guest Curt Snyder, a certified functional safety expert, as we discuss building an alarm management program in your facility. We'll cover what goes into creating your alarm management program, why these programs matter, and more, along with plenty of anecdotes that will be sure to make you chuckle. If you're looking for some tips from a seasoned alarm management professional and want to know how operators can become "alarm champions" then this is the episode for you.
Looking for more resources regarding alarm management programs? Curt recommends the following:
- Book: The Alarm Management Handbook - Second Edition: A Comprehensive Guide (buy it here on Amazon: https://www.amazon.com/Alarm-Management-Handbook-Second-Comprehensive-ebook/dp/B00GR8HBS8)
- Book: EEMUA Publication 191 Alarm systems - A guide to design, management and procurement (buy a digital/PDF version here: https://www.eemua.org/Products/Publications/Digital/EEMUA-Publication-191.aspx)
- Book: Effective Alarm Management Practices (ASM Consortium Guidelines) (buy it here on Amazon: https://www.amazon.com/Effective-Management-Practices-Consortium-Guidelines/dp/1442184256)
- Standard: ANSI/ISA-18.2-2016, Management of Alarm Systems for the Process Industries
- Standard: 49 CFR 195.446, Pipeline and Hazardous Materials Safety Administration (PHMSA), Control Room Management for Hazardous Liquids (See paragraph e for alarm management)
- Standard: 49 CFR 192.631, PHMSA Control Room Management for Gas (See paragraph e for alarm management)
- Standard: API RP 1167, Pipeline SCADA Alarm Management, API's version of alarm management written to support the PHMSA regulation
- Article: Understanding and Applying the ANSI/ ISA 18.2 Alarm Management Standard from ISA's InTech magazine (download as PDF here: https://www.isa.org/standards-and-publications/isa-publications/intech-magazine/white-papers/pas-understanding-and-applying-ansi-isa-18-2-alarm-management-standard/)
(Note: No links above are affiliate links, and we do not receive commission for any purchases made.)
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In this episode, we welcome guest Curt Snyder, a certified functional safety expert. Wesley and Curt discuss ISA 84, RAGAGEP prescribed by CCPS for the mechanical integrity element of SIS, while also referring to IEC 61511-1, which is a nearly identical standard. In this jam-packed, highly technical episode, you'll learn why these standards exist, their objectives, and then we'll provide a high-level walk-through of the SIS life cycle for a greenfield capital project.
Find the article Curt recommends in this episode here: https://www.isa.org/standards-and-publications/isa-publications/intech-magazine/2012/june/cover-story-understanding-isa-84/
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Operators, maintenance technicians, and I&E technicians - those we deem "boots on the ground" - are vital to the success of your process safety program. In this episode, Wesley and Rob discuss the key roles these individuals play when it comes to Process Hazard Analyses (PHAs), operating procedures, operator training, incident investigation, near miss reporting, compliance audits, Management of Change (MOC), and more. Whether you're at the corporate or management level looking to add value to your process safety program, or a "boots on the ground" individual who wants to get more involved and become a champion of process safety, this is the episode for you.
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Construction projects big and small are bound to happen at your facility. What if you have a long construction phase after your initial PHA? What if you don't have your arms around all the modifications that have been made during the project? How can you and your PHA team prep before a big project starts? What can go wrong if you wait until the end of a project to do a PHA? In this episode, Wesley and Rob discuss these topics and more to ensure you're adequately prepared to handle PHAs during the project life cycle.
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In this episode, Wesley and Rob talk about PSM management systems. They'll compare paper and electronic systems, and cover what factors you should consider when choosing a management system for your MOCs, action item tracking, and more. If you're starting a PSM program from scratch or you're looking to overhaul your current program, this is the episode for you.
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In this episode, Wesley and Rob present some guidelines for a successful Process Hazard Analysis (PHA) based on their years of experience as PHA participants and facilitators. They'll cover tips related to prep, study sessions, and more, ensuring you're ready for your next PHA.
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In this episode, Wesley and Rob talk combustible dusts - what they are, why they're hazardous, and which NFPA standards apply to them. They'll also talk about a major event related to combustible dusts, and about upcoming requirements involving Dust Hazard Analyses (DHAs).
To view the CSB video mentioned in today's episode, please visit https://www.csb.gov/imperial-sugar-company-dust-explosion-and-fire/.
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In this episode, Wesley and Rob cover a few major events that happened in industry in 2019, and update you on the latest ruling regarding RMP regulation changes.
To learn more about these major events and others currently under investigation, visit the U.S. Chemical Safety Board's website at csb.gov.
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In this episode, Wesley and Rob talk about how the people who know the process best, such as operators, maintenance technicians, and I&E technicians, can use weak signals, or leading indicators, to help prevent process safety events. They'll define what weak signals are, share some personal experiences, and shed light on what you can do when you discover something that doesn't seem right at your facility.
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In this episode, Wesley and Rob discuss the basic elements of an incident investigation, while also addressing how blame and investigation findings should be handled.
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In this episode, Wesley and Rob present a crash course on risk matrices. They'll cover what a risk matrix is, its role in Process Hazard Analyses (PHAs), limitations to consider regarding matrix size, and more. If you're new to PSM, this is the episode for you.
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In this very special episode, Wesley returns to his alma mater to sit down with Dr. Jim Holste, interim director of the Mary Kay O'Connor Process Safety Center at Texas A&M University in College Station, Texas, during this year's International Symposium. Dr. Holste talks about the center's formation and mission, its satellite campuses and ties to industry, and the various degrees and certificates offered through the center.
If you'd like to learn more about the Mary Kay O'Connor Process Safety Center, please visit http://psc.tamu.edu or contact the center at mkopsc@tamu.edu.
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In part 1 we covered some background and consensus standards regarding facility siting. In this episode, part 2, Wesley and Rob will break down the whole facility siting process from start to finish. First, they'll cover two different approaches to a facility siting study and they'll compare a consequence based approach with a quantitative risk assessment (QRA) approach. Then they'll discuss what other information is important for your study, including what release scenarios to incorporate, defining your maximum credible events (MCEs), and identifying the scope of the study. Finally, you'll learn about what to expect in your report, the importance of requesting a closing meeting, and how the study can inform various aspects of your PSM program in addition to its primary goal of saving lives.
To learn more, check out this book from CCPS: https://www.aiche.org/ccps/resources/publications/books/guidelines-evaluating-process-plant-buildings-external-explosions-fires-and-toxic-releases-2nd
API 752: https://www.api.org/oil-and-natural-gas/health-and-safety/refinery-and-plant-safety/process-safety/process-safety-standards/rp-752
API 753: https://www.api.org/oil-and-natural-gas/health-and-safety/refinery-and-plant-safety/process-safety/process-safety-standards/rp-753
API 756: https://www.api.org/~/media/files/publications/whats%20new/756_e1%20pa.pdf
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Facility siting. These two words appear in OSHA's PSM standard in the midst of other requirements that your PHA study must address, but no other details are provided. In part 1 of this facility siting episode, Wesley and Rob dive into a catastrophic event that highlighted the importance of facility siting, and then give a brief overview of what a facility siting study focuses on and how the it can ultimately inform your PHA study. Join your hosts again in two weeks for part 2 of this episode, where they'll discuss facility siting more in-depth, including study approaches, and both short and long term solutions you can explore after receiving your facility siting report.
Check out the CCPS book mentioned by Wesley here: https://www.aiche.org/ccps/resources/publications/books/guidelines-evaluating-process-plant-buildings-external-explosions-fires-and-toxic-releases-2nd
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In this episode, Wesley and Rob discuss the newest changes and revisions to the EPA's Risk Management Plan rule. You'll learn about new requirements involving emergency response plans, hazard reviews, training, compliance audits, incident investigations, and more. Wesley and Rob will also cover which changes have a future compliance obligation of March 15, 2021 and which changes your facility must be in compliance with now.
For additional information regarding the regulations discussed in this episode, please visit the EPA's website here: https://www.epa.gov/rmp/final-amendments-risk-management-program-rmp-rule
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In this special episode, Wesley welcomes our very first guest, William McBride, from CrossBridge Compliance. Will and Wesley discuss API 510, the recommended practice or inspection guideline for pressure vessels and talk about the importance of a vessel's U-1A. Will also explores the five important variables that go into calculating a vessel's remaining life from a mechanical integrity inspection standpoint: Maximum Allowable Working Pressure (MAWP), Stress Value for Materials of Construction, Joint Efficiency (JE), Corrosion Allowance (CA), and Corrosion Rate (CR).
For additional information and guidance regarding asset integrity programs, please visit www.crossbridgecompliance.com or contact Will directly at wmcbride@crossbridgecompliance.com
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In this episode, Wesley and Rob get back to basics. How do you know if the PSM and RMP regulations apply to your facility? What is a process? What exemptions exist? Where can you find information about the threshold quantities that qualify you for certain programs?
After listening, check out additional guidance from the EPA regarding RMP requirements here: https://www.epa.gov/rmp/guidance-facilities-risk-management-programs-rmp
Read the PSM regulation here: https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.119
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In this episode, Wesley and Rob talk about Management of Change (MOC), including which types of changes require MOCs, the steps that should be included as part of the MOC workflow, and how operators can take ownership and become champions of the MOC process. You'll also learn about the Pre-Startup Safety Review element of MOCs, and why this is a vital step of the MOC process.
Interested in learning more? Check out this book from the Center for Chemical Process Safety (CCPS): https://www.aiche.org/ccps/publications/books/guidelines-management-change-process-safety
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In this episode, Wesley and Rob talk about government inspections. What can you expect when an inspector shows up at your door? What are you allowed to ask for? What's the ideal "audit attitude" to have? Hear the answers to these questions and more in today's episode, and feel more confident during your next inspection.
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In this episode, Wesley and Rob talk about several major industrial incidents that not only highlighted the need for better regulation of highly hazardous materials, but eventually led to the creation of both OSHA's Process Safety Management (PSM) standard and EPA's Risk Management Plan (RMP) rule. But these regulations are over 25 years old - do we still need them? Are they going away anytime soon? Listen as our hosts discuss why these regulations are not only necessary, but here to stay.
Looking for a great read about one of the incidents that was mentioned in today's episode? Check out Failure to Learn by Andrew Hopkins. Buy it on Amazon here: https://www.amazon.com/Failure-Learn-Texas-Refinery-Disaster/dp/1921322446/ref=sr_1_2?dchild=1&keywords=failure+to+learn&qid=1588018647&s=books&sr=1-2 (Note: This is not an affiliate link and we do not receive commission for any purchases made.)
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In this episode, Wesley and Rob talk through the PHA, or Process Hazard Analysis, element of OSHA's Process Safety Management (PSM) standard, especially as it applies to "boots on the ground" - the operators, maintenance personnel, I&E technicians, and other individuals who perform the physical work around a process. You'll learn about choosing a methodology, PHA team composition requirements, checklists included in a PHA, and other requirements, and then gain insight into how the information contained in the final report can be useful to you, and which pieces are most valuable.
Interested in the API standard Wesley mentioned regarding tents? Check it out here: https://www.api.org/~/media/files/publications/whats%20new/756_e1%20pa.pdf
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In this episode, Wesley and Rob give an overview of the Mechanical Integrity (MI) element of OSHA’s Process Safety Management (PSM) standard. And, what in the world is RAGAGEP? You’ll learn some background for the term with references to OSHA’s 2016 interpretation letter, and then they’ll sling some more acronyms at you as they explain a few examples of widely adopted codes, consensus documents, and non-consensus documents.
Interested in the OSHA interpretation letter Rob mentioned? Check it out here: https://www.osha.gov/laws-regs/standardinterpretations/2016-05-11-0
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Who are these guys and why do they have a podcast?
In this episode you'll learn all about your hosts, Wesley Carter and Rob Bartlett, why they're putting process safety knowledge out into the world, and what you can expect in a typical episode.
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