Our tendency to underestimate the likelihood of rare occurrences can lead us to dismiss the possibility of process safety incidents.

This In Case You Missed It episode brings the written word to life. Today, Trish Kerin, the director of IChemE Safety Centre and Stay Safe columnist for Chemical Processing, will read her column “It’s Not Impossible That It’s Possible”

Written By: Trish Kerin

Read By: Trish Kerin 

The standard's industry-agnostic approach, its potential to influence global PSM practices and its role in setting benchmarks for organizations not covered by traditional legislation will impact safety practices worldwide.

In this episode, Trish & Traci discuss the Canadian Process Safety Management (PSM) standard CSA Z767, the world's first national PSM standard. Adrian Pierorazio and Parnian Jadidian — part of the team that crafted the standard — explain its development, starting as a guideline and evolving into a national standard to provide a unified framework for PSM across various industries in Canada. The standard was updated in 2024 to incorporate industry feedback and expand key sections.

The incident at Formosa Plastics in 2004 highlighted critical lessons in process safety. Human factors, communication gaps and inadequate equipment played significant roles in the death of five workers.

This In Case You Missed It episode of Process Safety with Trish & Traci brings the written word to life. Today, I will be reading an excerpt from a column written a few years ago by John Bresland, president of Process Safety Risk Assessment LLC and former chair of the United States Chemical Safety Board. The column  “10 Rules To Succeed at Process Safety Management."

Written by: John Bresland

Read by: Traci Purdum

URL: https://www.chemicalprocessing.com/safety-security/fire-explosion-protection/article/11321430/10-rules-to-succeed-at-process-safety-management-chemical-processing

It's crucial to operate within our professional boundaries and effectively mitigate risks when operating beyond them. In this In Case You Missed It episode, Trish Kerin, director of the IChemE Safety Centre, reads her most recent column:

Embrace Challenges, Recognize Limits, Manage Risks

In this episode, we offer 7 steps for better cybersecurity.

If you are a process control engineer, an IT professional in a company with an automation division, or a business manager responsible for safety or security, you may be wondering how your organization can get moving on more robust cybersecurity practices.

View the transcript for links to all the materials mentioned in this podcast.

https://www.chemicalprocessing.com/process-safety-w-trish-traci/article/33038811/tipisodes-7-steps-to-better-cybersecurity

Boeing was known for its engineering excellence until a focus on profitability took over. Properly documenting management of change and recognizing weak signals could have prevented tragedy.

In this episode of Process Safety with Trish & Traci, we discuss the aviation industry's Boeing 737 MAX crisis and how it revealed critical management failures, emphasizing the importance of rigorous management of change, prioritizing safety over profitability and identifying weak signals. The mishaps stemmed from design flaws and inadequate pilot training, highlighting the need for systemic improvements to prevent similar tragedies. Lessons extend to other industries, emphasizing proactive risk mitigation and a culture of safety.

A hazard and operability study (HAZOP) mostly is a safety design check, not a design development review. Making and finalizing major design choices should occur long before a HAZOP.

In this In Case You Missed It Episode, Traci Purdum reads a column from Plant InSites columnist Andrew Sloley.

Written By: Andrew Sloley Read By: Traci Purdum  Read Article: https://www.chemicalprocessing.com/voices/plant-insites/article/21437737/use-hazops-properly

In today's episode, Trish and Traci discuss inherently safer design principles, emphasizing proactive safety measures. Trish shares examples, such as separating hazardous substances from work areas and minimizing potential risks through thoughtful design choices. They highlight challenges like maintaining design integrity throughout project phases and stress the importance of documenting safety rationale for future reference. The discussion extends to the intersection of inherently safer design with sustainability, emphasizing the need for ongoing vigilance and communication to ensure safer facilities and environments.

Daily experiences vary, but key events hold lessons. Reflection is vital for learning and shaping success.

Written By: Trish Kerin

Read By: Trish Kerin 

Read Article HERE https://www.chemicalprocessing.com/voices/stay-safe/article/33018718/the-difference-between-experiences-and-learning-in-process-safety

In their podcast, Trish and Traci discuss the importance of commemorating anniversaries of incidents, emphasizing the need to learn from the past. Trish highlights two reasons for reflection: learning from past events to prevent recurrence and honoring those who lost their lives. They delve into various historical incidents, such as the IChemE Safety Centre's 10th anniversary, the LNG explosion in Algeria, the Boston molasses spill, the flour dust explosion in Germany, the Valdez oil spill, Flixborough, the Phillips Petroleum incident in Texas, and the 40-year anniversary of the Bhopal disaster. The discussion underscores the ongoing relevance of these incidents and the importance of continuous learning in process safety.

Welcome to the crossover edition of Process Safety with Trish and Traci -- the podcast that aims to share insights from past incidents to help avoid future events. I’m Traci Purdum, EIC of Chemical Processing.

Today’s crossover is from our Chemical Processing Distilled podcast series. I recently spoke with Dave Strobhar, founder and principal human factors engineer for Beville Engineering. We discussed

Unlocking Efficiency By Reducing Emergency Procedures. This conversation struck me as a perfect addition to the Trish & Traci series, so without further adieu, let’s listen in.

The plant floor at the West Pharmaceuticals facility in Kingston, N.C., was kept spotless to meet hygiene requirements. However, combustible polyethylene dust accumulated in the suspended ceiling. This led to a dust explosion on January 29, 2003, that killed six workers, injured 38, and destroyed the plant. The U.S. Chemical Safety and Hazard Investigation Board (CSB) couldn’t identify the ignition source.

As I noted in a previous column, the CSB blames dust explosions for numerous fatalities at many plants. Let’s get into how to identify the risks of dust fires and explosions.

Written By: Dirk Willard

Read By: Traci Purdum 

Read Article HERE 

In this episode, Trish and Traci, along with guest Melissa Humphries, discuss the challenges of intuitively understanding uncertainty and likelihoods in risk assessments. They highlight the common pitfalls of dismissing low-likelihood events and the impact of human nature on risk perception. Melissa explains statistical concepts like risk and uncertainty, emphasizing the importance of communicating findings effectively. They delve into the role of statistical methods in identifying influential factors affecting risk and stress the need for storytelling and stakeholder engagement in conveying complex statistical results.

This In Case You Missed It episode brings the written word to life. Today, Trish Kerin, the director of IChemE Safety Centre, and Stay Safe columnist for Chemical Processing, will read her column “Reflecting On Tragedy Can Improve Process Safety,” which appeared in the December 2023 edition of our magazine. Written By: Trish Kerin Read By: Trish Kerin  Read Article HERE 

In the podcast episode, Traci and Trish discuss the 31st anniversary of the La Mède Refinery explosion in France, detailing the events and the consequences, including six fatalities and significant financial loss. Trish emphasizes the importance of rigorous corrosion inspection programs and the need for comprehensive risk assessments in facility design. They explore legal implications, questioning the attribution of blame to specific individuals. The conversation shifts to the need for explosion-proof control rooms and considerations for retrofitting existing facilities. Traci raises the importance of space between units to prevent a domino effect during explosions, and Trish highlights various mitigation measures, including advanced firefighting techniques and vapor barriers. The episode underscores the continual evolution of safety technologies and emphasizes the importance of embracing new developments to enhance facility safety.

This episode discusses the 1989 Pasadena chemical plant explosion that claimed 23 lives. The incident led to the modernization of process safety measures in the U.S. Trish and Traci emphasize the importance of dedicated firewater systems, meticulous maintenance procedures, and strategies to combat complacency. They also explore the use of case studies and emphasize the positive legacy of Mary Kay O'Connor in promoting process safety. Subscribe to stay informed and visit chemicalprocessing.com for additional resources.

A deep understanding of risks empowers us to make informed decisions

Plants with good safety performance can become complacent over time, and lessons learned from incidents are often forgotten. It's crucial to instill and maintain a culture of constant unease to ensure ongoing safety.

According to the article, Former chair of the UK’s Health and Safety Executive Judith Hackitt bluntly warns: “Be clear that your role is to create unease, not to provide false (re)assurance.”

In any facility, we always need to consider the risks and ensure we are managing them with appropriate controls to ensure process safety. Especially when we make changes, we need to ensure that different circumstances are considered.

In this episode, we discuss risk assessment. The chemical industry is a high-hazard industry. That does not mean it has to be high-risk. We have to effectively manage risk to prevent an incident, and then if prevention fails, mitigate the consequences. If we get this wrong, people die. 

In our latest episode, we sit down with Dr. Cheryl Bodnar, one of the brilliant minds behind "Contents Under Pressure," an immersive game designed to teach process safety. Discover the story behind the game and its impact on education and industry.

https://contentsunderpressure.engineering.uconn.edu/

Transcript: https://chemicalprocessing.com/33010965

By following these tips, chemical facilities can enhance the effectiveness of their process-hazard reviews in the Management of Change (MoC) process, minimizing the risk of missing critical safety considerations and ensuring a robust safety management system.

Control system failures, alarm floods, maintenance issues and emergency response factored into this non-deadly incident.

In Case You Missed It edition of Process Safety with Trish and Traci. In Case You Missed It brings the written word to life. In today’s episode, Trish Kerin, the director of IChemE Safety Centre, and Stay Safe columnist for Chemical Processing, will read her column “Prepare For The Worst”, which appeared in the August 2023 edition of Chemical Processing magazine. She explains how safety training saved her from dying during a scuba diving mishap

The tragedy exposed various deficiencies in safety management and emergency response. It remains a stark reminder of the importance of rigorous risk assessment, effective control measures, continuous monitoring of safety systems, and fostering a culture where workers feel empowered to stop unsafe work. 

Weak signals occur all around us every day, but we often either fail to notice them -- or their significance. It might be an unexpected or unexplainable alarm, a lead indicator that may be easily dismissed as false, or an observation by a worker. Apply the Platypus Philosophy to recognize these signals and make your facility safer.

Inspired by a recent study about DuPont and 3M's knowledge of the toxicity of PFAS chemicals, this podcast discusses the importance of transparency and emphasizes the need for professionals to exercise their ethical judgment and stand up for what is right.

The cause of the explosion was traced back to a heat exchanger at the plant. Written procedures, checklists, redundancy and assessing risks for transient and unusual operations can help avoid catastrophe.

In this Fast Facts edition of Process Safety with Trish & Traci we discuss the lessons learned that led to the four principles of inherent safety as championed by the late Trevor Kletz.  Many lives could be saved if the rules are applied.

A corroded vapor line caused the deadly incident. This episode talks about ways to stay ahead of corrosion concerns and how to better protect workers in case of unthinkable catastrophe.

Storytelling as a means of communication is a valuable tool to help people learn and retain important lessons. It is not about making things up but rather creating a memorable interaction.

Cognitive biases lead to process-safety events. By getting our brains used to looking for the unusual, we can better manage safety in our facilities. Trish Kerin, director of the IChemE Safety Centre, has staked her entire professional engineering career on talking about a weird animal as a way to try and help people understand and manage their weak signals. Transcript can be found at https://www.chemicalprocessing.com 

Trish and Traci discuss the response to the East Palestine, Ohio, train derailment noting that environmental factors could be an issue for some time. Also, this episode unpacks how ExxonMobil was able to weather a hurricane just five miles from the epicenter without loss of containment. Access the full transcript at https://www.chemicalprocessing.com/podcasts/article/11354264/chemical-processing-podcasts

In this guest podcast episode from our sister publication Processing, Senior Editor Nate Todd interviews Chris Cloney of Dust Safety Science. In this episode, we discover that awareness of dust hazards varies globally, often spiking after major incidents but waning over time. The company tracks dust-related incidents annually, noting significant events like the 2023 grain silo explosion in Brazil. Common hazards involve grain, wood and metal dusts, with equipment like dust collectors and silos frequently implicated. Emerging industries like 3D printing and robotics present new challenges. Dust Safety Science emphasizes ongoing education and risk assessment to prevent future incidents.

Insight into rescue challenges and solutions at chemical facilities.

Visit https://www.chemicalprocessing.com for more tools and resources aimed at helping you be efficient and safe.

Turning tragedy into tools to help avoid future catastrophes will help keep workers safe.

The workplace can be so much more for colleagues than simply doing a job and going home. If you want to succeed, you need to listen and communicate as it's the currency of safety.

Practice, practice and more practice makes great emergency response but be careful of the message you are sending.

Unlike the oil industry, we can set the foundation of embedding inherently safer design into how we manage hydrogen going forward.

This can be a heated topic and it can get politicized. We need to make sure we're really applying inherently safer design principles when we pick the concept that we are going with, let alone do the engineering down the track

Grandfathered standards from the 1950s along with incorrect blueprints led to loss of life and reputation.

A revolutionary process safety program at a refinery in Blaine, Washington presents challenges in the best ways possible -- by helping operators develop new skills and flex new muscles. It’s always a good day when somewhere in the world a new process-safety champion has been formed.

This episode looks back on the deadly dust explosion that occurred at Didion Milling in Cambria, Wisconsin. On May 31, 2017, the explosion killed five workers and injured 15 others.

In mid-May 2022 a federal grand jury indicted the operator and six management officials on nine criminal counts, including two counts related to willful violations of federal workplace safety standards for grain handling.

The war in Ukraine and the anniversary of Chernobyl bring to light lessons learned from the past and unfortunate worries of today.

Process safety is impacted by automation, robotics, devices and solutions. Whether the impact is positive or negative remains in the hands of humans who implement the technology.

The U.S. Chemical Safety Board identified five issues with the 2019 Philadelphia Energy Solutions Refinery fire and explosion: mechanical integrity, outdated equipment, lack of remote emergency isolation valves, safeguard reliability and the need for inherently safer design.

https://www.chemicalprocessing.com/podcast/process-safety-with-trish-and-traci

What went wrong at the Piper Alpha oil rig has taught us a lot about permit-to-work systems. They are in place to ensure control of the ownership and activities of a particular piece of equipment -- it’s about keeping people safe and also understanding the status of your plant.

Good process safety means good reliability …  good reliability means good productivity … good productivity is what makes us money. Sometimes you have to talk about the bottom line in order to get buy-in for process-safety initiatives.

A review of 2021’s process-safety incidents points out that there's nothing new in any of these events; there's no new technology pathway, there's no new chemical reaction or law of chemistry or physics. That means these are all preventable incidents. What are you doing at your facilities to understand these hazards?

If you're relying on humans getting it right every time, you're going to have an incident. The key is making sure your systems are more resilient to humans making a mistake