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Amplify Your Process Safety

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.
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Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP

Amplify Your Process SafetyJun 26, 2019

00:00
22:29
Episode 98 - Introducing Magi
Mar 22, 202420:25
Episode 97 - Incident Breakdown: 2020 Fatal Oil and Gas Well Blowout in Burleson County, Texas

Episode 97 - Incident Breakdown: 2020 Fatal Oil and Gas Well Blowout in Burleson County, Texas

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.
Mar 08, 202423:53
Episode 96 - Educating the Next Generation of Process Safety Experts with Guest Mike Washington

Episode 96 - Educating the Next Generation of Process Safety Experts with Guest Mike Washington

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/.


Feb 23, 202424:20
Episode 95 - Incident Breakdown: 2019 Fatal Explosion and Fire at KMCO in Crosby, TX

Episode 95 - Incident Breakdown: 2019 Fatal Explosion and Fire at KMCO in Crosby, TX

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/.

Feb 09, 202443:04
Episode 94 - Incident Breakdown: 2021 Fatal Liquid Nitrogen Release at Foundation Food Group Facility in Georgia

Episode 94 - Incident Breakdown: 2021 Fatal Liquid Nitrogen Release at Foundation Food Group Facility in Georgia

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/

Jan 26, 202445:55
Episode 93 - Incident Breakdown: 2017 Fatal Dust Explosion and Fire at Didion Milling Facility in Cambria, WI
Jan 12, 202444:17
Episode 92 - 2023 Incident Recap & Process Safety Resolutions for 2024

Episode 92 - 2023 Incident Recap & Process Safety Resolutions for 2024

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.

Dec 29, 202328:40
Episode 91 - Process Safety for Large Capital Projects with Guest Brad Bazargani
Dec 15, 202338:03
Episode 90 - Incident Breakdown: 2021 Fatal Vapor Explosion and Fire at Yenkin-Majestic Facility in Columbus, OH
Dec 08, 202342:21
Episode 89 - Computerized Maintenance Management Systems (CMMS)
Nov 11, 202337:23
Episode 88 - Why Senior Management Should Care About Process Safety

Episode 88 - Why Senior Management Should Care About Process Safety

Oct 28, 202336:05
Episode 87 - Chemical Reactivity Concerns with Guest Tom Kuechler
Oct 13, 202335:09
Episode 86 - Operator Training - Part 2: Refresher Training

Episode 86 - Operator Training - Part 2: Refresher Training

Molly and Rob are back with Part 2 of Operator Training in this companion episode to Episode 77 - Operator Training - Part 1: Initial Training.

Today they're talking operator refresher training; what's required by PSM & RMP, what's considered a best practice, and some training considerations for facilities with infrequent turnarounds.

If you haven't already, be sure to also check out Episode 31 -Effective Operator Training.

Sep 29, 202320:27
Episode 85 - Participating in Your First PHA
Sep 16, 202331:15
Episode 84 - Why Process Safety Should Matter to You

Episode 84 - Why Process Safety Should Matter to You

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.

Sep 01, 202354:17
Episode 83 - Incident Breakdown: 2019 Tank Farm Fire at Intercontinental Terminals Company, LLC (ITC) in Deer Park, TX
Aug 18, 202323:52
Episode 82 - Incident Breakdown: 2020 Fatal Explosion at Optima Belle Facility
Aug 04, 202335:31
Episode 81 - Incident Breakdown: 2020 Fatal Explosion and Fire at Watson Grinding Facility
Jul 21, 202341:16
Episode 80 - Incident Breakdown: 2020 Fatal Chemical Release at Wacker Polysilicon Facility in Tennessee
Jul 08, 202343:47
Episode 79 - What is OperAid? with Guest Neil Beekie
Jun 23, 202323:04
Episode 78 - Incident Breakdown: 2021 Fatal Acid Release at LyondellBasell La Porte Complex
Jun 09, 202321:60
Episode 77 - Operator Training - Part 1: Initial Training
May 26, 202330:52
Episode 76 - Incident Breakdown: 2020 Toxic Gas Release and Chemical Fire at Bio-Lab Facility
May 12, 202325:47
Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride
Apr 28, 202335:35
Episode 74 - The Challenges of Engineering in a High Hazard Plant with Guest Doug McMahon

Episode 74 - The Challenges of Engineering in a High Hazard Plant with Guest Doug McMahon

In this episode, Rob is joined by guest Doug McMahon, who is a chemical engineer with 15 years of experience in the industry. Doug is currently the process technology manager at a site that produces organic peroxides, so he knows firsthand about the challenges of engineering in a high hazard plant. Today, Rob and Doug cover five of these challenges - which include choosing the right thing to do, making the right choices for how you will do it, managing details throughout the entire process, dealing with folks finding problems with your solution, and dealing with unintended consequences. Listeners from any type of site are sure to find value in this episode, so be sure to tune in.

We apologize in advance for a couple, brief, low-quality audio spots in this episode, but want you to know that this episode is full of content you don't want to miss!

Apr 14, 202323:03
Episode 73 - Incident Breakdown: 2019 Explosions and Fires at TPC Group (TPC) Port Neches Operations (PNO) Facility

Episode 73 - Incident Breakdown: 2019 Explosions and Fires at TPC Group (TPC) Port Neches Operations (PNO) Facility

In this episode, Rob and Molly discuss the CSB's investigation report on the 2019 popcorn polymer accumulation, pipe rupture, explosions, and fires at the TPC Group (TPC) Port Neches Operations (PNO) facility in Port Neches, Texas. On November 27, 2019, a pump that had been taken out of service for 114 days created a deadleg where butadiene polymer developed. The polymer filled the pipe and developed enough pressure to rupture the piping, releasing flammable butadiene which then ignited, resulting in explosions and fires. The fires burned for over 1 month and 2 employees, 1 contractor, and 5 members of the public reported injuries. Additionally, a mandatory evacuation order was issued for a 4-mile radius, affecting people in 4 nearby towns. The incident resulted in significant property damage both on-site and off-site, and TPC filed for bankruptcy in 2022.


Today, Rob and Molly provide some background details about TPC, explain what a deadleg is and talk about how they should be managed in Butadiene facilities, discuss how TPC's PHA considered the potential for this hazard, touch on remotely operated isolation valves, and point to relevant RAGAGEP that provide guidance regarding this hazardous butadiene polymer formation. They also discuss contributing factors, what types of companies could be at risk from incidents like these, and what any type of facility could learn from this accident.

Find the CSB's final report here, and be sure to check out our other Incident Breakdown episodes where we cover additional CSB final reports. 

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

Apr 01, 202327:36
Episode 72 - Incident Breakdown: 2018 Ethylene Release and Fire at Kuraray America, Inc. with Guest Chris Paskach

Episode 72 - Incident Breakdown: 2018 Ethylene Release and Fire at Kuraray America, Inc. with Guest Chris Paskach

In this episode, Molly is joined a second time by guest Chris Paskach, who is currently the Flare Master at the Phillips 66 Wood River Refinery in Roxana, Illinois. Molly and Chris discuss the CSB's investigation report on the 2018 ethylene release and fire at the Kuraray America, Inc. EVAL facility in Pasadena, Texas. During the event on May 19, 2018, 2,347 pounds of ethylene were released in approximately three minutes, after high pressure conditions inside the reactor resulted in the use of the reactor's emergency pressure relief system. Unfortunately, the flammable ethylene vapor was released in an area where many contractors happened to be working, including those who were involved in welding activities, which most likely provided an ignition source for the vapor. While some workers were injured as they jumped and fled from the second or third story of the plant structure, others who wore fall protection equipment could not immediately escape the fire. As a result, two were life-flighted from the site, and a total of 23 workers were injured. CSB released an animated video detailing the events and its final report on the incident in December 2022. Today, Molly and Chris provide background into Kuraray, cover the details of what exactly happened leading up to the event, discuss contributing causes, and more. Finally, they'll wrap up by covering what they believe companies can learn from this accident. 

Find the CSB's final report here

Find the CSB's video on the incident here

If you have further questions about today's episode, feel free to send us an email at podcast@amplifyconsultants.com or you can connect with Chris Paskach directly on LinkedIn here

Mar 17, 202330:48
Episode 71 - Incident Breakdown: 2018 Explosion and Asphalt Fire at Husky Superior Refinery

Episode 71 - Incident Breakdown: 2018 Explosion and Asphalt Fire at Husky Superior Refinery

In this episode, Jo and Molly discuss the CSB's final investigation report on the 2018 explosion and asphalt fire at the Husky Superior Refinery in Superior, Wisconsin. During a shutdown on April 26, 2018, flammable material got into a section of equipment which contained oxygen and ignited, causing two vessels to explode into fragments, one of which punctured a nearby asphalt storage tank. The resulting asphalt spill spread through several production units and then caught fire. Fortunately there were no casualties, but the incident did result in the injury of 36 refinery and contract workers, the evacuation of more than 2,500 residents, $550 million in property damage, and the release of 39,000 pounds of a flammable hydrocarbon vapor mixture.  The CSB released an animated video detailing the events in December 2019, and then released its final report on the incident in December 2022. Today, we provide some background details, delve more into what happened, and cover how the refinery's shutdown, lack of knowledge, and inadequate PHA contributed to the event. Additionally, we'll cover all of the CSB's recommendations, which include recommendations addressed to the refinery, the Cenovus Corporation, OSHA, EPA, API, and Honeywell UOP. Finally, we'll cover five of our own big process safety takeaways from the incident, related to PSI, operating procedures and training, emergency response, learning from industry and the past, and the hazards of transient operations. 

Find the CSB's final report here

Find the CSB's video on the incident here

Find additional information about the CSB's investigation here

Mar 03, 202336:02
Episode 70 - Improving Process Safety Culture with Guest Peter Hereña
Feb 17, 202333:33
Episode 69 - Incident Breakdown: 2019 Explosion and Fire at AB Specialty Silicones
Feb 04, 202330:29
Episode 68 - Incident Breakdown: 2019 Refinery Fire and Explosions at Philadelphia Energy Solutions (PES) with Guest Tim Murphy
Jan 20, 202333:16
Episode 67 - Incident Breakdown: 2016 Flash Fire at Sunoco Logistics Partners
Jan 06, 202320:10
Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning
Dec 09, 202226:48
Process Safety Incident Alert: Fatal Fire at Industrial Trading Company in China
Nov 29, 202205:34
Episode 65 - Chemical Reactivity Testing with Guest Michelle Murphy
Nov 11, 202220:18
Episode 64 - Top 10 Talk: What the PSM All-Stars Are Doing

Episode 64 - Top 10 Talk: What the PSM All-Stars Are Doing

In Episode 62, we covered PSM practices that we considered to be red flags indicating the potential for a weak process safety program. In today's episode, we tackle just the opposite - the PSM All-Stars. What can we learn from the best of the best, and what exactly are these All-Stars doing that makes their process safety programs so great? John and Molly break it down for you in today's episode, and cover the top 10 best practices they've seen from the most impressive PSM champions across industry.

Check out our other Top 10 Talks on your favorite podcast platform, or by using the search bar on our website's podcast page at www.amplifyconsultants.com/podcast.

Oct 28, 202223:26
Episode 63 - Relief Device Documentation with Guest Chris Paskach
Oct 14, 202226:32
Episode 62 - Top 10 Talk: Process Safety Red Flags
Oct 05, 202229:11
Process Safety Incident Alert: Fatalities at BP-Husky Refinery in Oregon, OH
Sep 27, 202216:33
Episode 61 - Combustible Dust Management Systems
Sep 16, 202227:27
Episode 60 - How Organizational Structure Impacts Process Safety with Guest Gilsa Monteiro
Sep 02, 202243:59
Process Safety Incident Alert: Fatal Sugar Refinery Explosion in India
Aug 22, 202209:32
Episode 59 - Incident Breakdown: 2017 Pressure Vessel Explosion at Loy-Lange Box Company
Aug 19, 202231:28
Episode 58 - Top 10 Talk: Amplify Your P&IDs
Jun 03, 202234:28
Episode 57 - What Really Requires an MOC?
May 20, 202226:39
Episode 56 - Implementing EPA's General Duty Clause (GDC)
May 06, 202226:09
Episode 55 - Movie Breakdown: Control Room Concerns in The China Syndrome
Apr 22, 202225:23
Episode 54 - Pressure Relief Device Concepts with Guest Eric Hirsch

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 eric.hirsch@nexusegroup.com or give him a call at 216-456-8564.

Apr 08, 202235:51
Episode 53 - How Boots on the Ground Expertise Can Lead to PSM Success
Mar 25, 202223:20
Top 10 Talk: Amplify Your Compliance Audits, Recording of live event (3/22/2022)
Mar 22, 202242:30