Amplify Your Process Safety
By Amplify Process Safety, LLC
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.
Episode 56 - Implementing EPA's General Duty Clause (GDC)
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 firstname.lastname@example.org. 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)
May 06, 2022
Episode 55 - Movie Breakdown: Control Room Concerns in The China Syndrome
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 email@example.com.
April 22, 2022
Episode 54 - Pressure Relief Device Concepts with Guest Eric Hirsch
In Episode 45, we covered the basics of piping requirements for pressure relief devices. In this episode, Rob is joined by Eric Hirsch, to take a deeper dive into pressure relief device concepts. Eric, a principal process engineer at Nexus Engineering Group, works in process design with a focus on pressure relief devices. In this episode, Eric and Rob cover basic requirements for pressure relief devices and the calculations that go with them. You'll learn about back pressures, considerations for common subheaders and global relief scenarios, impacts to the relief capacity of a system, identifying fire zones/circles, design issues with flare knock out pots, Eric's thoughts on the use of rupture disks for overpressure protection, SIS instrumentation, designing for 2-phase relief, and more. Then Eric gives his expert advice regarding a frequently asked question: Do I have to have overpressure protection on every pressure vessel and/or piping system and do I need calculations for all of those? He'll touch on what could get you in trouble with OSHA during an enforcement audit when it comes to your pressure relief scenarios, how often you should revalidate them, and more. Don't miss this content-packed episode from an expert on pressure relief devices. To contact Eric Hirsch directly, send an email to firstname.lastname@example.org or give him a call at 216-456-8564.
April 08, 2022
Episode 53 - How Boots on the Ground Expertise Can Lead to PSM Success
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.
March 25, 2022
Top 10 Talk: Amplify Your Compliance Audits, Recording of live event (3/22/2022)
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.
March 22, 2022
Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
Mathew Todaro of Verrill Law joins us for a third time in this episode - this time to talk about EPA's General Duty Clause (GDC). In this episode, Mat, an attorney that specializes in enforcement defense, provides an overview of the objectives of EPA's GDC. But with such broad language and no specific list of covered substances, what are the real requirements for facilities when it comes to this GDC? And with so many similarities between the requirements of PSM/RMP and the GDC, are there even advantages for a facility to keep less than the threshold quantity of a hazardous substance that would require a PSM/RMP program? Mat and Rob cover the answers to these important questions and more in this episode. Find the GUIDANCE FOR IMPLEMENTATION OF THE GENERAL DUTY CLAUSE CLEAN AIR ACT SECTION 112(r)(1) here: https://www.epa.gov/sites/default/files/documents/gendutyclause-rpt.pdf Be sure to check out Mat's previous appearances on our podcast by listening to episodes 25 and 35. Connect with Mat on LinkedIn here.
March 12, 2022
Episode 51 - Combustible Dust Testing with Guest Michelle Murphy
In this episode, Molly is joined by guest Michelle Murphy, a chemical engineer who has worked in process safety for 25 years. Earlier in her career, Michelle designed, built, and managed a combustible dust testing laboratory, and now she is the newly appointed president of Sigma-HSE INC., the North American division of Sigma-HSE. Molly and Michelle cover the basics when it comes to combustible dust testing, including defining combustible dusts, discussing why dust testing is needed, and reviewing what types of tests are available. You'll learn how to select a combustible dust test, what commonly used tests tell you about your dust, how testing samples should be prepared and collected, tips for making the most of your testing budget, and how testing relates to your MOC and PHA processes. If you have additional questions about combustible dusts or combustible dust testing, Michelle invites you to visit Sigma-HSE.com, send an email to her at email@example.com, or reach her by phone at 603-303-7863.
March 03, 2022
Episode 50 - Managing Risk at Remote Facilities
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.
February 11, 2022
Episode 49 - Using Integrity Cards to Save Lives with Guest David Hatch
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/.
January 28, 2022
Episode 48 - Management of Organizational Change (MOOC)
In our first episode to kick off 2022, Rob and Molly talk Management of Organization 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.
January 15, 2022
Your Process Safety Journey, Part 3 - Nearing the Summit
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.
December 24, 2021
Your Process Safety Journey, Part 2 - Climbing The Mountain
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.
December 23, 2021
Top 10 Talk: Amplify Your PHAs, Recording of live event (12/7/2021)
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.
December 07, 2021
Your Process Safety Journey, Part 1 - The Foothills
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.
December 03, 2021
Episode 47 - What New Plant Managers Should Know with Guest Nat Weiner
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.
November 19, 2021
Episode 46 - DHA Basics with Guest Mike Robertson
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 firstname.lastname@example.org.
October 22, 2021
Episode 45 - Piping Requirements for Pressure Relief Devices
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 email@example.com.
October 08, 2021
Episode 44 - Improving Safety Culture with Guest Nicholas Krump
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.
September 24, 2021
Episode 43 - Introducing Molly
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.
September 10, 2021
Process Safety Incident Alert: Fatal Chemical Leak at La Porte, TX 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
July 30, 2021
Episode 42 - Human Factors Engineering with Guest Monica Philippart
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.
June 18, 2021
Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy
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.
May 21, 2021
Episode 40 - The Evolution of Process Safety Culture with Guest Trish Kerin
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/
May 08, 2021
Episode 39 - Using Bow Ties to Manage Risk with Guest David Hatch
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.
April 23, 2021
Process Safety Incident Alert: Fatal Paint Plant Incident in Columbus, OH
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
April 10, 2021
Episode 38 - Best Practices for Remote Compliance Audits
In this episode, Rob, John, and Elena talk PSM compliance audits in the age of COVID-19. They'll talk you through how remote compliance audits work from start to finish, pros and cons about the remote audit format, and how remote audits compare to in-person compliance audits. Whether you participate in audits as part of a company team, or perform audits yourself, this is the episode for you.
April 10, 2021
Episode 37 - Safety Culture with Guest Mike Burson
In this episode, Rob sits down with experienced EH&S Director, Mike Burson, to talk safety culture. Rob and Mike cover the challenges when it comes to developing a safety culture at different levels of an organization, talk strategies to improve an organization's safety culture, share stories about their experiences and struggles, and more.
March 27, 2021
Episode 36 - Best Practices for Remote PHAs
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).
March 12, 2021
Episode 35 - Environmental Compliance Audits with Guest Mathew Todaro
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.
February 26, 2021
Episode 34 - Introducing John
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.
February 12, 2021
Process Safety Incident Alert: Fatal Liquid Nitrogen Incident in Gainesville, GA
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.
February 02, 2021
PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
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.
January 29, 2021
PSM: Back to Basics, Part 5 - Even More Acronyms
The world of process safety is STILL chock-full of acronyms. In part 1 of our beginner-friendly miniseries, PSM: Back to Basics, we tackled the essential acronyms that PSM newbies need to know, providing an explanation and context for each term. In this episode, Rob and Jo are back to cover even more acronyms: ALARP/ALARA, BPCS, BRM, CSO/CSC, DHA, EAP/ERP, ESD, FSS, IEL/IEF, IPL, ITPM, LEL, LOPC, MCE, NFPA, OEM, PFD, PRD, and PSV. Ready to learn more? Be sure to check out the previous four parts of the PSM: Back to Basics miniseries.
January 15, 2021
Episode 33 - Quality Assurance
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.
December 04, 2020
Episode 32 - Process Safety Leading & Lagging Metrics
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
November 21, 2020
Episode 31 - Effective Operator Training
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.
November 06, 2020
Episode 30 - The A-Team
Who are these people and why do they have a podcast? In a much needed follow-up to episode 0, you'll meet all the members of the Amplify team, hear about the very different journeys that led them to Amplify, and learn what makes them passionate about process safety. Tune in as our normally virtual team sits down together for the first time for an episode jam-packed with jabs, sarcasm, and laughs. We look forward to meeting you! Learn more about our team on our website at https://www.amplifyconsultants.com/about.
October 09, 2020
Episode 29 - Insurance Surveys with Guest Bob Wasileski
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.
September 25, 2020
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
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.
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
August 01, 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/
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)
July 03, 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)
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.
June 05, 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
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
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 firstname.lastname@example.org and we'll give you a shout out in our follow-up to this episode, when we cover even more process safety acronyms.
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.)
May 01, 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/
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.
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.
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.
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.
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/.
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.
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.
January 03, 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.
December 06, 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.
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 email@example.com.
November 08, 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
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.
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.
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 firstname.lastname@example.org This podcast is powered by Pinecast.
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.
September 03, 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.
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.
August 02, 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.
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.
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.
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.
June 25, 2019