Amplify Your Process Safety
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© Amplify Process Safety, LLC
Description
Join industry professionals as they share insight into the world of process safety, including news related to updated codes and standards, recent incidents and what you can learn from them, and their take on all elements of process safety. With decades of combined experience in real, practical implementation, they aren’t just advisors, they practice what they preach. Whether you’re new to process safety, in a role where you interact with aspects of process safety, or an experienced process safety professional, this is the podcast for you.
117 Episodes
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In today's episode, Rob sits down with Blaine J. Hoffmann, from The SafetyPro Podcast, to discuss his new book, titled "Rethinking SAFETY Culture". Blaine details why he was motivated to write the book, how he defines safety culture, and discusses ways to implement the ideas he presents in "Rethinking SAFETY Culture". He also talks about his recommendations for digital safety management systems, how KPIs can be used to improve safety cultures, and more.
Find Blaine on LinkedIn here, find "Rethinking SAFETY Culture" on Amazon here, and be sure to check out Blaine's library of over 175 episodes at thesafetypropodcast.com or wherever you find your podcasts.
We also invite you to check out our previous episodes with Blaine, where we teamed up to discuss a variety of topics from both a process safety lens and an occupational safety lens.
Episode 23 - Incident Investigation with The SafetyPro 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
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In this episode, Rob is joined by the newest member of the Amplify Process Safety team, Magi Riech. Rob sits down with Magi to talk about her background and her journey into process safety throughout her career, and what fuels her passion for PSM/RMP. Welcome to the A Team, Magi!
To connect with Magi, find her on LinkedIn here or email her at magali.riech@amplifyconsultants.com.
To learn more about the rest of our team, visit www.amplifyconsultants.com/about or check out our other intro episodes below:
Episode 0 - Amplify Your Process Safety Introduction
Episode 30 - The A-Team
Episode 43 - Introducing Molly
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In this episode, Molly is joined by the newest member of the A Team, Magi Riech, to discuss the CSB's final investigation report on the 2020 fatal oil and gas well blowout in Burleson County, Texas. The incident occurred on January 29, 2020, and the CSB released their final investigation report on this incident on December 26, 2023. On the day of the incident, oil and gas escaped the well during workover operations, and found an ignition source, ultimately leading to a flash fire that burned and killed three contract workers. Today, Molly and Magi discuss what exactly happened, delve into the contributing factors, cover the CSB's recommendations, and highlight the takeaways that any company could learn from this incident.
Find the CSB's final report for the incident we discussed today here.
Find the CSB's final report on the Pryor Trust Fatal Gas Well Blowout and Fire that we mentioned in this episode here.
Stay tuned for Episode 98, in which we give Magi a proper introduction to our listeners.
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In this very special episode, Rob and Molly sit down with Mike Washington, who is the Director of Industrial Safety at Arkema Inc,. The Americas, and also an adjunct lecturer at Prairie View A&M University and the University of Houston. They discuss the challenges of educating the next generation of engineers and managers on process safety, and touch on what current gaps they see, best practices to fill those gaps, and their hopes for the future, including how higher education can help to better
better contribute to chemical engineers' knowledge of process safety.
Mike invites you to connect with him on LinkedIn at https://www.linkedin.com/in/michael-washington-m-b-a-067b2520/.
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On April 2, 2019, the KMCO production facility in Crosby, TX, was producing sulfurized isobutylene as a lubrication additive, when they experienced a leak from a fracture in a segment of piping. The leaking material formed a vapor cloud and then found an ignition source, resulting in the death of one employee and serious injuries to two other employees. In this episode, Rob and Molly discuss what happened in detail, cover the contributing factors, and finally touch on the key learnings that other facilities can take away from this tragic event. Find the CSB's final report on this incident at https://www.csb.gov/csb-releases-final-report-into-fatal-2019-explosion-and-fire/.
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On January 28, 2021, the Foundation Food Group facility in Gainesville, Georgia, experienced a liquid nitrogen release that ultimately resulted in six employee fatalities. The U.S. Chemical Safety Board (CSB) released their final investigation report into this incident on December 11, 2023, and today Molly and Jo are here to cover all of the report's highlights. We'll walk you through details regarding the day of the incident, the hazards of liquid nitrogen, the root cause of the incident and other contributing factors, and close with what any company can learn from this incident. As always, we thank the CSB for their thorough reporting on this incident, and invite you to read their final investigation report at the link below.
https://www.csb.gov/csb-releases-final-report-into-2021-fatal-liquid-nitrogen-release-at-foundation-food-group-facility-in-georgia/
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On December 6, 2023, the US Chemical Safety Board (CSB) released its final report into the 2017 fatal dust explosion and fire at the Didion Milling Facility in Cambria, WI. In today's episode, Rob and Jo give you an overview of the CSB's findings, covering what happened, the causes, the recommendations CSB made, what types of companies could be at risk from incidents like this one, and key lessons for the industry.
Find the resources we mention in this week's episode at the links below:
CSB Report
Episode 88 - Why Senior Management Should Care About Process Safety
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In this extra special episode, the whole Amplify crew is here to talk about how 2023 unfolded in terms of process safety. They cover an overview of CSB accidental release events as well as other process safety events they tracked across multiple countries and industries throughout the year, and what their big takeaways are from looking at all the data available for these incidents. In the second half of the episode, they share six process safety related New Years' resolutions you can adopt at your own facility in 2024 to help you have an incident-free year.
A huge thank you to all of our listeners for tuning in to our show this year. We wish you all the happiest of holidays and a safe 2024, and we look forward to bringing you more episodes in the new year.
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In this episode, Molly is joined by Brad Bazargani, who listeners may recognize as one of the process safety professionals who participated in Episode 84. Today, Molly and Brad discuss how to integrate process safety into large capital projects, including when PHAs should be conducted and which methodology should be used, managing changes, considerations for facility siting, development of operator training and procedures, establishment of MI programs, conducting PSSRs, and handling a large volume of process safety information. Listeners interested in connecting with Brad can find him on LinkedIn here.
Find another episode we mentioned today, Episode 74 - The Challenges of Engineering in a High Hazard Plant with Guest Doug McMahon, here.
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In this episode, Rob and Molly cover the latest CSB final report on the 2021 fatal vapor explosion and fire at the Yenkin-Majestic facility in Columbus, OH.
On April 8, 2021, a mixture of flammable naphtha solvent vapors and resin liquid escaped through the seal of a closed manway of an operating kettle and created a flammable vapor cloud, which quickly found an ignition source. The resulting explosion and fire led to the death of one employee, injuries to eight others, and over $90 million in property damage.
In this episode, Rob and Molly cover additional details related to the event, including contributing factors, share the CSB's recommendations, and then finally cover key lessons that any company can learn from this incident.
Find the CSB's final report for this incident here.
If you have a comment about this week's episode, an idea for a future episode, or any process safety related question, please drop us a line at amplifyconsultants.com.
Other episodes we mentioned today:
Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride
Episode 69 - Incident Breakdown: 2019 Explosion and Fire at AB Specialty Silicones
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In this episode, Rob and Jo talk about CMMS, or computerized maintenance managements systems. You'll learn how to make the best CMMS platform selection for your facility, important considerations you should make when it comes to the set up of your CMMS platform, and how to ensure your CMMS gets updated as changes are made in your facility. They'll also talk customization options, mobile apps, permissions, contractor involvement, recordkeeping, reporting/dashboards, and more. If you're considering making the move from a paper-based work order system to a CMMS platform, or looking to see how you can leverage the data currently captured within your CMMS platform, then this is the episode for you.
Some other episodes mentioned today that we recommend:
Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP
PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
Episode 18 - PSM Management Systems
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In today's episode Rob and Molly answer two important questions when it comes to senior management and process safety: 1) Why is it important for senior management to understand process safety, and 2) how can senior management lead the company to ensure that process safety is a high priority?
They cover historic catastrophic impacts when process safety has not been prioritized, the Business Case for Process Safety (CCSP whitepaper), what "good" looks like when prioritizing process safety, the impacts of staffing and budget decisions on process safety, and more. No matter where your role falls within your organization's hierarchy, any employee who works at a facility handling highly hazardous substances is sure to find value in this episode.
Resources mentioned in today's episode:
CSB Best Practice Guidance for Corporate Boards of Directors and Executives in the Offshore Oil and Gas Industry for Major Accident Prevention
Center for Chemical Process Safety (CCPS) : Inspiring Process Safety Leadership – The Executive Role
Center for Chemical Process Safety (CCPS): The Business Case for Process Safety
Episode 40 - The Evolution of Process Safety Culture with Guest Trish Kerin
Episode 47 - What New Plant Managers Should Know with Guest Nat Weiner
Episode 48 - Management of Organizational Change (MOOC)
Episode 60 - How Organizational Structure Impacts Process Safety with Gilsa Monteiro
Episode 70 - Improving Process Safety Culture with Guest Peter Hereña
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In this episode, Molly is joined by guest Tom Kuechler. Tom (Ph.D., inorganic chemistry) has over 35 years of experience in the water treatment industry (pool/spas, drinking water, and cooling towers), chiefly with chlorinated isocyanurates, including 15 years at Occidental Chemical Corporation’s trichloroisocyanuric acid plant. His responsibilities have included product and application research, field trials, technical service, manufacturing support, and regulatory support.
Today, Molly and Tom discuss chemical reactivity issues in the hope that they will help to prevent other companies from suffering through catastrophic process safety incidents like those at Bio-Lab and Optima Belle, which were recently reported on by the CSB. They discuss safety data sheets and their importance, define what a water-reactive compound is, talk about the importance of preserving process safety knowledge at a facility over time, and address some process scale-up precautions that should be taken when handling reactive chemicals.
You can reach Tom Kuechler with any further questions at tomkuechler@gmail.com. To learn more about the CSB incident investigations mentioned in today's episode, go to csb.gov or listen to Episode 76 - Incident Breakdown: 2020 Toxic Gas Release and Chemical Fire at Bio-Lab Facility and
Episode 82 - Incident Breakdown: 2020 Fatal Explosion at Optima Belle Facility.
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Molly and Rob are back with Part 2 of Operator Training in this companion episode to Episode 77 - Operator Training - Part 1: Initial Training.
Today they're talking operator refresher training; what's required by PSM & RMP, what's considered a best practice, and some training considerations for facilities with infrequent turnarounds.
If you haven't already, be sure to also check out Episode 31 -Effective Operator Training.
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So it's your first time on a Process Hazard Analysis (PHA) team, and you don't know what exactly to expect. Start with this episode! In this episode, Rob and Molly discuss everything you need to know as a first-time PHA team member. They cover the goals of a PHA, the basics of the most common PHA methodologies, PHA team members and requirements, ground rules for the study sessions, how the experience is valuable, what to expect after the study sessions end, and more. If you are an operator, I&E technician, or maintenance technician who has never participated in a PHA before, but you'd like to or you've been asked to be on the PHA team, this is the episode for you.
Find other related episodes that we mentioned in today's episode below.
Episode 20 - Why "Boots on the Ground" are Vital to your Process Safety 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.
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Today's episode is an extra special one. We know we say that a lot, but we really mean it. In this episode, we bring you a collection of 11 stories from folks who share with us why process safety matters to them, and why you should care too. If you're new to the world of process safety, we hope this will inspire you, and if you're an experienced process safety professional, we think you'll enjoy these passionate stories that are sure to echo your own.
A huge thank you to everyone who participated in this episode.
If you have a comment or question about today's episode, please drop us a line at podcast@amplifyconsultants.com.
If you're curious about what we do at Amplify Process Safety, or think we can help your facility, please send your inquiry to info@amplifyconsultants.com.
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In this episode, Rob and Jo team up to cover another CSB final report. In this incident breakdown, they cover the 2019 tank farm fire at the Intercontinental Terminals Company, LLC (ITC) bulk liquid storage terminal in Deer Park, Texas. On March 17, 2019, a circulation pump failure led to the release of a butane-enriched naptha product from a large aboveground storage tank, and the flammable vapors eventually ignited. The resulting fire spread to the other 14 nearby tanks and then burned for three days before being extinguished. In this episode, Jo and Rob cover additional details regarding offsite consequences, discuss the five safety issues that the CSB highlighted in their report, share the CSB's recommendations, and then finally cover key lessons for industry.
Find the CSB's final report for this incident here.
If you have a comment about this week's episode, an idea for a future episode, or any process-safety related question, please drop us a line at podcast@amplifyconsultants.com.
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In this episode, Molly and Jo are back with another incident breakdown, covering the CSB's final report on the 2020 fatal explosion at the Optima Belle Facility in Belle, WV. On December 8, 2020, workers were drying CDB-56 in a press-rated rotary double cone dryer, when the material began to decompose and generate significant amounts of toxic gases, leading to an overpressure of the dryer and subsequent rupture, fire, and toxic chlorine release. In this episode, Molly and Jo cover the materials involved in the incident, what exactly happened and why, contributing factors identified by the CSB, the CSB's recommendations, and what companies can learn from this incident to improve the safety of their own operations.
Find the CSB's final report for this incident here.
Episode 65 - Chemical Reactivity Testing with Guest Michelle Murphy here.
Find the Chemical Reactivity Hazards website we mentioned here.
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In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal explosion and fire at the Watson Grinding facility in Houston, Texas. On January 24, 2020, a propylene release in a coating booth at the facility resulted in a fire and explosion that killed two workers and one nearby resident, injured two workers, and damaged over 450 nearby structures. Today, Molly and Jo provide some background information on the facility, including previous incidents, precautions in place at the time of the incident, and contributing factors. Then they delve into how various elements of a process safety program could have helped to prevent this incident, discuss the CSB's recommendations, and end with three key learnings that facilities can learn from this incident.
Find the CSB's final report for this incident here.
Related episodes we mentioned:
Your Process Safety Journey, Part 1 - The Foothills
Your Process Safety Journey, Part 2 - Climbing The Mountain
Your Process Safety Journey, Part 3 - Nearing the Summit
Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
Episode 56 - Implementing EPA's General Duty Clause (GDC)
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In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal chemical release at Wacker Polysilicon facility in Charleston, Tennessee. On November 13, 2020, a contractor on the fifth level of an operating platform tightened the bolts on a graphite heat exchanger to an incorrect torque setting, cracking the exchanger, which released gaseous HCl and obscured two contractor groups' access down the 70-foot platform's only staircase. Three of the contractors attempted to climb down the outside of the structure, and all fell during their attempts; one fatally, while two others sustained serious injuries. Today, Molly and Jo provide some background information on the facility, its hazardous chemicals, and the events leading up to the loss of containment. Additionally, they discuss the safety issues identified by the CSB, including some interesting details regarding the PHA completed only three months prior that identified the need for a second means of egress in a release scenario identical to the incident. They point out other contributing factors, cover the CSB's various recommendations, and finally provide key learnings that any company can glean from this incident.
Find the CSB's final report for this incident here.
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What a great contribution you have in process safety. I really appreciate your effort. Kindly, I was wondering, for those who have hearing obstacles, do you have any written blog or script of the podcasts?🙏🏻🌸
each episode gets more interesting 👍🏻🙏🏻👌🏻
so informative thx 🙏🏻
thank you for your podcasts! It has been very useful on my job. keep going