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Amplify Your Process Safety

Amplify Your Process Safety

By Wesley Carter & Rob Bartlett
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 more than 35 years 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.
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Episode 28 - Hot Work with The SafetyPro Podcast
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
28:43
September 13, 2020
Episode 27 - Contractor Management with The SafetyPro Podcast
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. 
33:48
August 28, 2020
Episode 26 - Natural Hazard Assessment and Planning
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
35:02
August 1, 2020
Episode 25 - After the EPA Inspector Leaves with Guest Mathew Todaro
An EPA inspector has just been at your site, now what? Time to sigh in relief or time to panic? In this episode we pick up where we left off after Episode 4 - Government Inspections, and we cover what to expect once the EPA inspector is gone. Special guest Mathew Todaro of Verill Law joins us in this episode, using his years of experience handling complex regulatory matters to clue you into what your next steps should be and what routes the EPA could choose to take. We'll cover the two things the inspector could reach out for after they leave, what the EPA takes into consideration when making their enforcement decisions, the difference between informal and formal enforcement routes, when you should seek counsel, how fines are calculated, and more. If you've always wondered what's involved in EPA inspection and enforcement or want to know what happens when we put an engineer and a lawyer in a (virtual) room together, then this is the episode for you. Learn more about Mathew Todaro here: https://www.verrill-law.com/mathew-j-todaro/
43:55
July 17, 2020
Episode 24 - Emergency Planning & Response with The SafetyPro Podcast
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)
23:52
July 3, 2020
Episode 23 - Incident Investigation with The SafetyPro Podcast
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)
37:27
June 19, 2020
PSM: Back to Basics, Part 4 - Management of Change (MOC)
In part four of our Back to Basics miniseries, we're talking MOC basics. You'll learn what MOC, or management of change, is, what the process is like, and who is typically involved in each step. We'll also cover two incidents that highlight the importance of MOC.  Find the two incidents we discussed and many others in Incidents that Define Process Safety. Learn more about MOC in Episode 5 - MOC & PSSR. 
13:58
June 5, 2020
PSM: Back to Basics, Part 3 - Process Hazard Analysis (PHA)
Wesley and Jo are back with part 3 of PSM: Back to Basics, with more content for those newest to PSM. In this episode, you'll learn what a Process Hazard Analysis, or PHA, is and what methodologies exist for conducting a PHA study. You'll also learn the basics of nodes and HAZOP studies, and then we'll discuss a gas plant incident at a facility where no HAZOP study was found to have been conducted.   Ready to learn more about PHAs after this episode? Check out the episodes below for a deeper dive into Process Hazard Analyses.   Episode 2 - Intro to PHAs  Episode 17 - Tips for a Successful PHA  Episode 19 - PHAs During the Project Life Cycle
14:38
May 29, 2020
PSM: Back to Basics, Part 2 - Open Source Resources
New to process safety and not sure where to start? In part 2 of our new miniseries, PSM: Back to Basics, Wesley and Jo cover a plethora of process safety resources, including websites, books, conferences, apps, and more.  OSHA Letters of Interpretation OSHA Compliance Directive AIChE Academy e-Learning  SAChE Mary Kay O'Connor Process Safety Center at Texas A&M Process Safety International Symposium  Instrumentation and Automation Symposium CCPS Conferences GPA Midstream Convention  U.S. Chemical Safety Board (CSB)  CCPS Process Safety Beacon  Our Podcast, Amplify Your Process Safety  Guidelines for Evaluating Process Plant Buildings for External Explosions, Fires, and Toxic Releases, 2nd Edition Guidelines for Risk Based Process Safety Guidelines for Asset Integrity Management CCPS Glossary (& App) CCPS Process Safety Incident Evaluation App Incidents That Define Process Safety Process Safety: Key Concepts and Practical Approaches Failure to Learn: The BP Texas City Refinery Disaster
24:21
May 22, 2020
PSM: Back to Basics, Part 1 - Acronyms
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. 
32:14
May 15, 2020
Episode 22 - Establishing an Alarm Management Program 101 with Guest Curt Snyder
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.)
53:56
May 1, 2020
Episode 21 - ISA 84 & IEC 61511-1 with Guest Curt Snyder
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/
50:39
April 17, 2020
Episode 20 - Why "Boots on the Ground" are Vital to your Process Safety Program
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. 
22:11
March 27, 2020
Episode 19 - PHAs During the Project Life Cycle
Construction projects big and small are bound to happen at your facility. What if you have a long construction phase after your initial PHA? What if you don't have your arms around all the modifications that have been made during the project? How can you and your PHA team prep before a big project starts? What can go wrong if you wait until the end of a project to do a PHA? In this episode, Wesley and Rob discuss these topics and more to ensure you're adequately prepared to handle PHAs during the project life cycle. 
15:25
March 13, 2020
Episode 18 - PSM Management Systems
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. 
20:22
February 28, 2020
Episode 17 - Tips for a Successful PHA
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. 
29:01
February 14, 2020
Episode 16 - Combustible Dusts & DHAs
In this episode, Wesley and Rob talk combustible dusts - what they are, why they're hazardous, and which NFPA standards apply to them. They'll also talk about a major event related to combustible dusts, and about upcoming requirements involving Dust Hazard Analyses (DHAs). To view the CSB video mentioned in today's episode, please visit https://www.csb.gov/imperial-sugar-company-dust-explosion-and-fire/.
27:13
January 31, 2020
Episode 15 - Major Events in 2019
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.
26:23
January 18, 2020
Episode 14 - Weak Signals
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.
23:31
January 3, 2020
Episode 13 - Incident Investigation Framework
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. 
24:16
December 6, 2019
Episode 12 - Risk Matrices
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. 
22:47
November 23, 2019
Episode 11 - Interview with Dr. Jim Holste at the Mary Kay O'Connor Process Safety Center, Texas A&M University
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. 
27:51
November 8, 2019
Episode 10 - Facility Siting - Part 2
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
29:40
October 25, 2019
Episode 9 - Facility Siting - Part 1
Facility siting. These two words appear in OSHA's PSM standard in the midst of other requirements that your PHA study must address, but no other details are provided. In part 1 of this facility siting episode, Wesley and Rob dive into a catastrophic event that highlighted the importance of facility siting, and then give a brief overview of what a facility siting study focuses on and how the it can ultimately inform your PHA study. Join your hosts again in two weeks for part 2 of this episode, where they'll discuss facility siting more in-depth, including study approaches, and both short and long term solutions you can explore after receiving your facility siting report. Check out the CCPS book mentioned by Wesley here: https://www.aiche.org/ccps/resources/publications/books/guidelines-evaluating-process-plant-buildings-external-explosions-fires-and-toxic-releases-2nd This podcast is powered by Pinecast.
19:43
October 11, 2019
Episode 8 - RMP Regulatory Changes
In this episode, Wesley and Rob discuss the newest changes and revisions to the EPA's Risk Management Plan rule. You'll learn about new requirements involving emergency response plans, hazard reviews, training, compliance audits, incident investigations, and more. Wesley and Rob will also cover which changes have a future compliance obligation of March 15, 2021 and which changes your facility must be in compliance with now. For additional information regarding the regulations discussed in this episode, please visit the EPA's website here: https://www.epa.gov/rmp/final-amendments-risk-management-program-rmp-rule This podcast is powered by Pinecast.
24:20
September 27, 2019
Episode 7 - API 510 with Guest William McBride
In this special episode, Wesley welcomes our very first guest, William McBride, from CrossBridge Compliance. Will and Wesley discuss API 510, the recommended practice or inspection guideline for pressure vessels and talk about the importance of a vessel's U-1A. Will also explores the five important variables that go into calculating a vessel's remaining life from a mechanical integrity inspection standpoint: Maximum Allowable Working Pressure (MAWP), Stress Value for Materials of Construction, Joint Efficiency (JE), Corrosion Allowance (CA), and Corrosion Rate (CR). For additional information and guidance regarding asset integrity programs, please visit www.crossbridgecompliance.com or contact Will directly at wmcbride@crossbridgecompliance.com This podcast is powered by Pinecast.
23:36
September 13, 2019
Episode 6 - PSM & RMP Applicability
In this episode, Wesley and Rob get back to basics. How do you know if the PSM and RMP regulations apply to your facility? What is a process? What exemptions exist? Where can you find information about the threshold quantities that qualify you for certain programs? After listening, check out additional guidance from the EPA regarding RMP requirements here: https://www.epa.gov/rmp/guidance-facilities-risk-management-programs-rmp Read the PSM regulation here: https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.119 This podcast is powered by Pinecast.
20:38
September 3, 2019
Episode 5 - MOC & PSSR
In this episode, Wesley and Rob talk about Management of Change (MOC), including which types of changes require MOCs, the steps that should be included as part of the MOC workflow, and how operators can take ownership and become champions of the MOC process. You'll also learn about the Pre-Startup Safety Review element of MOCs, and why this is a vital step of the MOC process. Interested in learning more? Check out this book from the Center for Chemical Process Safety (CCPS): https://www.aiche.org/ccps/publications/books/guidelines-management-change-process-safety This podcast is powered by Pinecast.
22:15
August 19, 2019
Episode 4 - Government Inspections
In this episode, Wesley and Rob talk about government inspections. What can you expect when an inspector shows up at your door? What are you allowed to ask for? What's the ideal "audit attitude" to have? Hear the answers to these questions and more in today's episode, and feel more confident during your next inspection. This podcast is powered by Pinecast.
24:13
August 2, 2019
Episode 3 - Why Do We Have PSM & RMP?
In this episode, Wesley and Rob talk about several major industrial incidents that not only highlighted the need for better regulation of highly hazardous materials, but eventually led to the creation of both OSHA's Process Safety Management (PSM) standard and EPA's Risk Management Plan (RMP) rule. But these regulations are over 25 years old - do we still need them? Are they going away anytime soon? Listen as our hosts discuss why these regulations are not only necessary, but here to stay. Looking for a great read about one of the incidents that was mentioned in today's episode? Check out Failure to Learn by Andrew Hopkins. Buy it on Amazon here: https://www.amazon.com/Failure-Learn-Texas-Refinery-Disaster/dp/1921322446/ref=sr_1_2?dchild=1&keywords=failure+to+learn&qid=1588018647&s=books&sr=1-2 (Note: This is not an affiliate link and we do not receive commission for any purchases made.) This podcast is powered by Pinecast.
14:31
July 12, 2019
Episode 2 - Intro to PHAs
In this episode, Wesley and Rob talk through the PHA, or Process Hazard Analysis, element of OSHA's Process Safety Management (PSM) standard, especially as it applies to "boots on the ground" - the operators, maintenance personnel, I&E technicians, and other individuals who perform the physical work around a process. You'll learn about choosing a methodology, PHA team composition requirements, checklists included in a PHA, and other requirements, and then gain insight into how the information contained in the final report can be useful to you, and which pieces are most valuable. Interested in the API standard Wesley mentioned regarding tents? Check it out here: https://www.api.org/~/media/files/publications/whats%20new/756_e1%20pa.pdf This podcast is powered by Pinecast.
25:14
June 26, 2019
Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP
In this episode, Wesley and Rob give an overview of the Mechanical Integrity (MI) element of OSHA’s Process Safety Management (PSM) standard. And, what in the world is RAGAGEP? You’ll learn some background for the term with references to OSHA’s 2016 interpretation letter, and then they’ll sling some more acronyms at you as they explain a few examples of widely adopted codes, consensus documents, and non-consensus documents. Interested in the OSHA interpretation letter Rob mentioned? Check it out here: https://www.osha.gov/laws-regs/standardinterpretations/2016-05-11-0 This podcast is powered by Pinecast.
22:29
June 26, 2019
Episode 0 - Amplify Your Process Safety Introduction
Who are these guys and why do they have a podcast? In this episode you'll learn all about your hosts, Wesley Carter and Rob Bartlett, why they're putting process safety knowledge out into the world, and what you can expect in a typical episode. This podcast is powered by Pinecast.
17:38
June 25, 2019