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 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 Podcast Episode 24 - Emergency Planning & Response with The SafetyPro Podcast Episode 27 - Contractor Management with The SafetyPro Podcast Episode 28 - Hot Work with The SafetyPro Podcast

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. 

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

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

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. 

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.)

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/

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. 

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. 

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. 

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. 

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 Introduction Episode 30 - The A-Team Episode 43 - Introducing Molly

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/.

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.

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.

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. 

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. 

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. 

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

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, 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.

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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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/.

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/.

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/

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 Report Episode 88 - Why Senior Management Should Care About Process Safety

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.

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.

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

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 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

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
  

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.

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.

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 Program Episode 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.

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.

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.

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.

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)

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.