Amplify Your Process Safety (Amplify Process Safety, LLC)

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, 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-/.

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

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 engineering reports 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.

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. 

Update: On July 19, 2023, the CSB released a safety video on this incident.

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 Planning Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro Episode 56 - Implementing EPA's General Duty Clause (GDC) Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning

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, 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. 

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 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

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

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)

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/.

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. 

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. 

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)

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.

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.

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 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

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. 

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

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) & RAGAGEP Episode 7 - API 510 with Guest William McBride PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)

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.

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. 

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 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 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 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. 

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/.

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)

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.

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

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.

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.

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.  

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.

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. 

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 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.

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

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.

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. 

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.

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.

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 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.

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. 

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.  

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. 

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. 

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/. 

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.

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.

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 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, 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.

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, 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.

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 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).

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. 

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. 

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. 

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, 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.

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

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!

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).

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. 

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. 

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 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.

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. 

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. 

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.

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.

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.

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

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.

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.

1. Know the Basics

2. Choose Your Auditor Wisely

3. Understand Compliance Criteria

4. Preparation is Key

5. Prepare Personnel

6. Have an Agenda

7. Documentation is Critical

8. Focus on Improvement

9. Understand the Findings

10. 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.

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).

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)

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. 

1. Choose your facilitator wisely

2. Documentation in key

3. The method matters

4. Create nodes like Goldilocks

5. Valuable members make a valuable team

6. What risk are you willing to accept?

7. Ask, "what's the worst that could happen?"

8. Approach operator response realistically

9. 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.

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 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.  

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/

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. 

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 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, 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, 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. 

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.

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

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/ 

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. 

In our first episode to kick off 2022, Rob and Molly talk Management of Organizational 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.

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

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).  

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.