Amplify Your Process Safety
By Amplify Process Safety, LLC
Amplify Your Process SafetySep 29, 2023
Episode 100 - The Past, Present, & Future of Our Show
We've made it to episode 100, can you believe it? We invite you to celebrate this milestone with us in today's very special episode. Join the current Amplify team members as well as two former team members in reminiscing about the early days of the podcast, hear some fun facts about our audience, episodes, and past guests, learn which of our episodes made the top 10 most popular list, our goals for the future of the show, and more. Be sure to stick around to the end for some funny clips that have never before been aired. A special thank you to Wesley Carter and John Doan for joining us for the beginning of this episode. And thank you to you, our listeners, as we wouldn't be doing this without you. Thank you for sticking around for 100 episodes, and cheers to 100 more.
Time stamps:
Introduction: 00:00:36
Kick Off to Who is Who (Rob Bartlett, Molly Myers, Magi Riech, Jo Pastor, John Doan, Wesley Carter): 00:02:11
Fun Facts about Our Show (Listens, Guests, Listener Locations/Ages, Episodes): 00:33:17
Our Top 10 Episodes: 00:45:54
Feedback on the Show: 00:56:24
Closing & Where We're Headed: 00:57:12
Funny Clips: 1:03:10
We'd love to hear what you thought about this episode, which episode so far has been your favorite, or what you want to hear about next. Send the show an email at podcast@amplifyconsultants.com.
Episode 99 - Rethinking (Process) Safety Culture with Guest Blaine J. Hoffmann
In today's episode, Rob sits down with Blaine J. Hoffmann, from The SafetyPro Podcast, to discuss his new book, titled "Rethinking SAFETY Culture". Blaine details why he was motivated to write the book, how he defines safety culture, and discusses ways to implement the ideas he presents in "Rethinking SAFETY Culture". He also talks about his recommendations for digital safety management systems, how KPIs can be used to improve safety cultures, and more.
Find Blaine on LinkedIn here, find "Rethinking SAFETY Culture" on Amazon here, and be sure to check out Blaine's library of over 175 episodes at thesafetypropodcast.com or wherever you find your podcasts.
We also invite you to check out our previous episodes with Blaine, where we teamed up to discuss a variety of topics from both a process safety lens and an occupational safety lens.
Episode 23 - Incident Investigation with The SafetyPro Podcast
Episode 24 - Emergency Planning & Response with The SafetyPro Podcast
Episode 27 - Contractor Management with The SafetyPro Podcast
Episode 28 - Hot Work with The SafetyPro Podcast
Episode 98 - Introducing Magi
In this episode, Rob is joined by the newest member of the Amplify Process Safety team, Magi Riech. Rob sits down with Magi to talk about her background and her journey into process safety throughout her career, and what fuels her passion for PSM/RMP. Welcome to the A Team, Magi!
To connect with Magi, find her on LinkedIn here or email her at magali.riech@amplifyconsultants.com.
To learn more about the rest of our team, visit www.amplifyconsultants.com/about or check out our other intro episodes below:
Episode 0 - Amplify Your Process Safety Introduction
Episode 30 - The A-Team
Episode 43 - Introducing Molly
Episode 97 - Incident Breakdown: 2020 Fatal Oil and Gas Well Blowout in Burleson County, Texas
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.
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/.
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/.
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/
Episode 93 - Incident Breakdown: 2017 Fatal Dust Explosion and Fire at Didion Milling Facility in Cambria, WI
On December 6, 2023, the US Chemical Safety Board (CSB) released its final report into the 2017 fatal dust explosion and fire at the Didion Milling Facility in Cambria, WI. In today's episode, Rob and Jo give you an overview of the CSB's findings, covering what happened, the causes, the recommendations CSB made, what types of companies could be at risk from incidents like this one, and key lessons for the industry.
Find the resources we mention in this week's episode at the links below:
CSB Report Episode 88 - Why Senior Management Should Care About Process Safety
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.
Episode 91 - Process Safety for Large Capital Projects with Guest Brad Bazargani
In this episode, Molly is joined by Brad Bazargani, who listeners may recognize as one of the process safety professionals who participated in Episode 84. Today, Molly and Brad discuss how to integrate process safety into large capital projects, including when PHAs should be conducted and which methodology should be used, managing changes, considerations for facility siting, development of operator training and procedures, establishment of MI programs, conducting PSSRs, and handling a large volume of process safety information. Listeners interested in connecting with Brad can find him on LinkedIn here.
Find another episode we mentioned today, Episode 74 - The Challenges of Engineering in a High Hazard Plant with Guest Doug McMahon, here.
Episode 90 - Incident Breakdown: 2021 Fatal Vapor Explosion and Fire at Yenkin-Majestic Facility in Columbus, OH
In this episode, Rob and Molly cover the latest CSB final report on the 2021 fatal vapor explosion and fire at the Yenkin-Majestic facility in Columbus, OH.
On April 8, 2021, a mixture of flammable naphtha solvent vapors and resin liquid escaped through the seal of a closed manway of an operating kettle and created a flammable vapor cloud, which quickly found an ignition source. The resulting explosion and fire led to the death of one employee, injuries to eight others, and over $90 million in property damage.
In this episode, Rob and Molly cover additional details related to the event, including contributing factors, share the CSB's recommendations, and then finally cover key lessons that any company can learn from this incident.
Find the CSB's final report for this incident here.
If you have a comment about this week's episode, an idea for a future episode, or any process safety related question, please drop us a line at amplifyconsultants.com.
Other episodes we mentioned today:
Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride
Episode 69 - Incident Breakdown: 2019 Explosion and Fire at AB Specialty Silicones
Episode 89 - Computerized Maintenance Management Systems (CMMS)
In this episode, Rob and Jo talk about CMMS, or computerized maintenance managements systems. You'll learn how to make the best CMMS platform selection for your facility, important considerations you should make when it comes to the set up of your CMMS platform, and how to ensure your CMMS gets updated as changes are made in your facility. They'll also talk customization options, mobile apps, permissions, contractor involvement, recordkeeping, reporting/dashboards, and more. If you're considering making the move from a paper-based work order system to a CMMS platform, or looking to see how you can leverage the data currently captured within your CMMS platform, then this is the episode for you.
Some other episodes mentioned today that we recommend:
Episode 88 - Why Senior Management Should Care About Process Safety
In today's episode Rob and Molly answer two important questions when it comes to senior management and process safety: 1) Why is it important for senior management to understand process safety, and 2) how can senior management lead the company to ensure that process safety is a high priority?
They cover historic catastrophic impacts when process safety has not been prioritized, the Business Case for Process Safety (CCSP whitepaper), what "good" looks like when prioritizing process safety, the impacts of staffing and budget decisions on process safety, and more. No matter where your role falls within your organization's hierarchy, any employee who works at a facility handling highly hazardous substances is sure to find value in this episode.
Resources mentioned in today's episode:
- CSB Best Practice Guidance for Corporate Boards of Directors and Executives in the Offshore Oil and Gas Industry for Major Accident Prevention
- Center for Chemical Process Safety (CCPS) : Inspiring Process Safety Leadership – The Executive Role
- Center for Chemical Process Safety (CCPS): The Business Case for Process Safety
- Episode 40 - The Evolution of Process Safety Culture with Guest Trish Kerin
- Episode 47 - What New Plant Managers Should Know with Guest Nat Weiner
- Episode 48 - Management of Organizational Change (MOOC)
- Episode 60 - How Organizational Structure Impacts Process Safety with Gilsa Monteiro
- Episode 70 - Improving Process Safety Culture with Guest Peter Hereña
Episode 87 - Chemical Reactivity Concerns with Guest Tom Kuechler
In this episode, Molly is joined by guest Tom Kuechler. Tom (Ph.D., inorganic chemistry) has over 35 years of experience in the water treatment industry (pool/spas, drinking water, and cooling towers), chiefly with chlorinated isocyanurates, including 15 years at Occidental Chemical Corporation’s trichloroisocyanuric acid plant. His responsibilities have included product and application research, field trials, technical service, manufacturing support, and regulatory support.
Today, Molly and Tom discuss chemical reactivity issues in the hope that they will help to prevent other companies from suffering through catastrophic process safety incidents like those at Bio-Lab and Optima Belle, which were recently reported on by the CSB. They discuss safety data sheets and their importance, define what a water-reactive compound is, talk about the importance of preserving process safety knowledge at a facility over time, and address some process scale-up precautions that should be taken when handling reactive chemicals.
You can reach Tom Kuechler with any further questions at tomkuechler@gmail.com. To learn more about the CSB incident investigations mentioned in today's episode, go to csb.gov or listen to Episode 76 - Incident Breakdown: 2020 Toxic Gas Release and Chemical Fire at Bio-Lab Facility and Episode 82 - Incident Breakdown: 2020 Fatal Explosion at Optima Belle Facility.
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.
Episode 85 - Participating in Your First PHA
So it's your first time on a Process Hazard Analysis (PHA) team, and you don't know what exactly to expect. Start with this episode! In this episode, Rob and Molly discuss everything you need to know as a first-time PHA team member. They cover the goals of a PHA, the basics of the most common PHA methodologies, PHA team members and requirements, ground rules for the study sessions, how the experience is valuable, what to expect after the study sessions end, and more. If you are an operator, I&E technician, or maintenance technician who has never participated in a PHA before, but you'd like to or you've been asked to be on the PHA team, this is the episode for you.
Find other related episodes that we mentioned in today's episode below. Episode 20 - Why "Boots on the Ground" are Vital to your Process Safety Program Episode 53 - How Boots on the Ground Expertise Can Lead to PSM Success
Plus two episodes on Training, coming soon (we'll update these show notes then).
If you have a comment or question about today's episode, please drop us a line at podcast@amplifyconsultants.com.
If you're curious about what we do at Amplify Process Safety, or think we can help your facility, please send your inquiry to info@amplifyconsultants.com.
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.
Episode 83 - Incident Breakdown: 2019 Tank Farm Fire at Intercontinental Terminals Company, LLC (ITC) in Deer Park, TX
Find the CSB's final report for this incident here.
If you have a comment about this week's episode, an idea for a future episode, or any process-safety related question, please drop us a line at podcast@amplifyconsultants.com.
Episode 82 - Incident Breakdown: 2020 Fatal Explosion at Optima Belle Facility
In this episode, Molly and Jo are back with another incident breakdown, covering the CSB's final report on the 2020 fatal explosion at the Optima Belle Facility in Belle, WV. On December 8, 2020, workers were drying CDB-56 in a press-rated rotary double cone dryer, when the material began to decompose and generate significant amounts of toxic gases, leading to an overpressure of the dryer and subsequent rupture, fire, and toxic chlorine release. In this episode, Molly and Jo cover the materials involved in the incident, what exactly happened and why, contributing factors identified by the CSB, the CSB's recommendations, and what companies can learn from this incident to improve the safety of their own operations.
Find the CSB's final report for this incident here.
Episode 65 - Chemical Reactivity Testing with Guest Michelle Murphy here.
Find the Chemical Reactivity Hazards website we mentioned here.
Episode 81 - Incident Breakdown: 2020 Fatal Explosion and Fire at Watson Grinding Facility
In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal explosion and fire at the Watson Grinding facility in Houston, Texas. On January 24, 2020, a propylene release in a coating booth at the facility resulted in a fire and explosion that killed two workers and one nearby resident, injured two workers, and damaged over 450 nearby structures. Today, Molly and Jo provide some background information on the facility, including previous incidents, precautions in place at the time of the incident, and contributing factors. Then they delve into how various elements of a process safety program could have helped to prevent this incident, discuss the CSB's recommendations, and end with three key learnings that facilities can learn from this incident.
Find the CSB's final report for this incident here.
Related episodes we mentioned: Your Process Safety Journey, Part 1 - The Foothills Your Process Safety Journey, Part 2 - Climbing The Mountain
Your Process Safety Journey, Part 3 - Nearing the Summit
Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
Episode 80 - Incident Breakdown: 2020 Fatal Chemical Release at Wacker Polysilicon Facility in Tennessee
In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal chemical release at Wacker Polysilicon facility in Charleston, Tennessee. On November 13, 2020, a contractor on the fifth level of an operating platform tightened the bolts on a graphite heat exchanger to an incorrect torque setting, cracking the exchanger, which released gaseous HCl and obscured two contractor groups' access down the 70-foot platform's only staircase. Three of the contractors attempted to climb down the outside of the structure, and all fell during their attempts; one fatally, while two others sustained serious injuries. Today, Molly and Jo provide some background information on the facility, its hazardous chemicals, and the events leading up to the loss of containment. Additionally, they discuss the safety issues identified by the CSB, including some interesting details regarding the PHA completed only three months prior that identified the need for a second means of egress in a release scenario identical to the incident. They point out other contributing factors, cover the CSB's various recommendations, and finally provide key learnings that any company can glean from this incident.
Find the CSB's final report for this incident here.
Episode 79 - What is OperAid? with Guest Neil Beekie
In this episode, Rob is joined by guest Neil Beekie, CEO and co-founder of OperAid. Neil discusses his background in plant operations, and details how a significant event he experienced as a lead operator led him to the eventual development of OperAid, a software tool that assists operators with real-time verification of manual tasks. Operators and non-operators alike will be sure to find value in this episode.
To learn more about OperAid, visit https://operaidsoft.com/. To connect with Neil, find him on LinkedIn or send an email to neil@operaidsoft.com.
Episode 78 - Incident Breakdown: 2021 Fatal Acid Release at LyondellBasell La Porte Complex
In this episode, Molly and Jo discuss the CSB's final investigation report on the 2021 fatal acid release at LyondellBasell La Port Complex in La Porte, Texas. On July 27, 2021, contractors inadvertently removed pressure retaining components of a valve, releasing 164,000 pounds of acetic acid mixture, which fatally injured two contract workers. Today, Molly and Jo provide some background information on LyondellBasell and the substances involved in the release, talk about what exactly happened at the time of the incident, and discuss what a valve actuator is and why contractors were trying to remove one that day. Then they discuss other incidents that the CSB identified where similar mistakes were made with plug valves and removal of pressure retaining components, touch on the contributing factors, and talk about what other companies can learn from this incident. Finally, they cover the CSB's recommendations, which include those addressed to LyondellBasell, the contract company, and to various RAGAGEP entities.
Find the CSB's final report for the incident we discussed today here.
Find the CSB's final report and video about the ExxonMobil Baton Rouge Refinery Chemical Release and Fire here.
Episode 77 - Operator Training - Part 1: Initial Training
In this episode, Rob and Molly discuss the PSM requirements for initial operator training. They cover all of the requirements for content to cover in training, as well as their additional content suggestions, and talk about the different methodologies that can be used to perform verification and documentation of training.
Stay tuned for Part 2 in which Rob and Molly discuss refresher training for existing operators and other miscellaneous training topics.
If you haven't already, be sure to also check out Episode 31 -Effective Operator Training.
Episode 76 - Incident Breakdown: 2020 Toxic Gas Release and Chemical Fire at Bio-Lab Facility
In this episode, Rob and Jo discuss the CSB's investigation report on the 2020 toxic gas release and chemical fire at Bio-Lab Facility in Westlake, Louisiana. On August 27, 2020, strong winds from Hurricane Laura damaged buildings at the facility, causing rainwater to come into contact with the trichloroisocyanuric acid (TCCA) that was stored inside. A chemical reaction began, and the TCCA began to decompose, releasing heat that started a fire, while also releasing a large amount of hazardous gases that traveled offsite. Today, Rob and Jo provide some background about this Bio-Lab facility, discuss the events surrounding the incident, and cover the consequences of the incident. Then they discuss the CSB's five identified safety issues that contributed to the event, what types of companies might be at risk for similar events, and how any facility can prevent an incident like this one.
Find the CSB's final report here.
Listen to the other episodes we mentioned today at the links below:
Episode 26 - Natural Hazard Assessment and Planning Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro Episode 56 - Implementing EPA's General Duty Clause (GDC) Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning
Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride
In this episode, Molly is joined by our show's very first podcast guest, William McBride, who first joined us all the way back in Episode 7. Today, Will and Molly discuss the types of inspections that are required for process vessels and tanks. They'll cover what's involved in inspecting ASME pressure vessels and atmospheric storage tanks, and how equipment that doesn't fit ASME VIII or API 2000 is handled when it comes to inspections, including open-top mixing vessels, "equipment" fabricated from piping components, and vessels fabricated to ASME code but not stamped. They also touch on best practices related to MI at sites that are non-PSM covered.
You can reach out to Will McBride directly at (903) 374-5806 or at wmcbride@xcelgrp.com.
Be sure to check out Will's first appearance on our show, and our other MI-related episodes at the links below. Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP Episode 7 - API 510 with Guest William McBride PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
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!
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.
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.
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.
Episode 70 - Improving Process Safety Culture with Guest Peter Hereña
In today's episode, Rob is joined by Peter Hereña, who currently serves as the process safety manager at CF Industries. Rob and Peter start their discussion by defining what process safety culture is, and what a good process safety culture looks like. Then Peter shares how his company organized a process safety week last October, and all of the components, planning, and branding that went into the event. Peter ends the episode by offering his advice to others who might also want to try a process safety week in an effort to reinforce a healthy process safety culture at their own companies.
For additional questions about his process safety week event, or to talk process safety culture further, please connect with Peter on LinkedIn here.
Episode 69 - Incident Breakdown: 2019 Explosion and Fire at AB Specialty Silicones
In this episode, Rob and Jo discuss the CSB's investigation report on the 2019 explosion and fire at AB Specialty Silicones in Waukegan, Illinois. On May 3, 2019, operators were performing a batch operation when two incompatible chemicals were added to the same tank, which produced hydrogen gas, and eventually led to a massive explosion and fire that killed four employees. The CSB released its final report on the incident on 9/24/2021 and then an incompatible chemicals video about the incident on 4/28/2022. Today, we provide some background details, delve more into what happened, and cover what safety issues at the facility likely contributed to the event. We'll also cover the types of industries and facilities that could be at risk for incidents like this one, and share nine key learnings from this tragic event.
Find the CSB's final report here.
Find the CSB's video on the incident, Incompatible Chemicals: Explosion at AB Specialty Silicones, here.
And as always, please contact us with any questions or comments at podcast@amplifyconsultants.com.
Episode 68 - Incident Breakdown: 2019 Refinery Fire and Explosions at Philadelphia Energy Solutions (PES) with Guest Tim Murphy
In this episode, Rob and Molly are joined by previous podcast guest, Tim Murphy, to discuss the 2019 fire and explosions at Philadelphia Energy Solutions (PES). In a previous role many years ago, Tim served as a process safety coordinator for the refinery, and although he was not employed there later when the incident occurred, he is able to provide additional context surrounding the incident due to this former role. In this episode, you'll learn a brief history of the facility, hear what happened on June 21, 2019 and why, and learn about the hazards associated with the refinery. You'll also hear the group's thoughts on a few of the US Chemical Safety board's findings, and the key lessons that other facilities in the process industry can take away from this incident.
Find the CSB's final investigation report and video here.
Listen to Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy here.
Find other episodes where we delve into CSB investigation reports by typing "incident breakdown" into the search bar on our website at www.amplifyconsultants.com/podcast.
Episode 67 - Incident Breakdown: 2016 Flash Fire at Sunoco Logistics Partners
On September 28, 2022, the US Chemical Safety Board (CSB) released its final report on the 2016 flash fire incident that injured 7 workers at Sunoco Logistics Partners in Nederland, TX. In today's episode, Rob and John provide context related to the hot work activities that were taking place at the time of the incident, go through the CSB's findings and recommendations, and then provide their thoughts on the hazards related to hot work and the use of contractors.
Find the resources we mention in this week's episode at the links below:
Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning
In this episode, our midwestern colleagues take the podcast by storm (pun intended). John and Molly talk about how tornadoes and other natural hazards can be accounted for in both emergency planning and as part of a robust Process Hazard Analysis (PHA). They'll cover routine drills, evacuation, and shelter in place practices, muster points and emergency response, and their opinions on complacency towards repeated drills. Whether you too, find yourself in Tornado Alley, or if you're located elsewhere, you'll want to stick around for this episode.
Also be sure to check out Episode 26 - Natural Hazard Assessment and Planning.
Process Safety Incident Alert: Fatal Fire at Industrial Trading Company in China
On Monday, November 21, 2022, hot work activities at an industrial trading company in China led to a fatal fire when cotton cloth located near the welding activities went up in flames. The fire killed 38, injured 2, and took over 4 hours to extinguish. In this episode, Rob and Molly bring you the latest information about the incident, and offer a reminder about the role that a robust hot work program plays in preventing loss of life.
Read more about the incident here and here.
View the CSB's Dangers of Hot Work video here.
Episode 65 - Chemical Reactivity Testing with Guest Michelle Murphy
In Episode 65, guest Michelle Murphy is back again with Molly - this time to talk about chemical reactivity testing. Molly and Michelle cover the basics of chemical reactivity testing, including who should consider this type of testing, where to start, what can be learned from testing, information about the samples needed, and much, much, more.
Listen to our previous episode with Michelle Murphy, Episode 51 - Combustible Dust Testing with Guest Michelle Murphy, here. To contact Michelle, send an email to her at mmurphy@sigma-hse.com, or reach her by phone at 978-880-2915 (office) or 603-303-7863 (cell).
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.
Episode 63 - Relief Device Documentation with Guest Chris Paskach
In this episode, Molly is joined by Chris Paskach, who is currently the Flare Master at the Phillips 66 Wood River Refinery in Roxana, Illinois. Although there are only a few short references to relief devices in the PSM standard, the amount of documentation that is required is quite expansive, so Molly and Chris break down the basics for you in this episode. They'll cover the relief system design and design basis information required for PSI, reference information needed to support a process hazard analysis (PHA), relief, vent systems, and device information needed for your mechanical integrity (MI) program, and more. If you have further questions about today's episode, feel free to send us an email at podcast@amplifyconsultants.com or you can connect with Chris Paskach directly on LinkedIn here.
Also be sure to check out Episode 54 - Pressure Relief Device Concepts with Guest Eric Hirsch and Episode 45 - Piping Requirements for Pressure Relief Devices if you're interested in taking a deeper dive into pressure relief topics.
Episode 62 - Top 10 Talk: Process Safety Red Flags
In today's episode, we bring you another Top 10 Talk, this time on practices we deem to be "process safety red flags". In this episode, John and Rob cover what they consider to be red flags pointing to the potential for systemic issues in a facility's process safety program. They'll cover management's attitude, prioritization, and resource allocation, approaches to documentation, including reliance on paper-based systems, lack of attention to detail and poor operational discipline, lack of urgency in maintaining safety critical assets, lack of understanding when it comes to hazards and how to properly manage them, change management processes, attitudes toward action item closures, contractor involvement, and more.
We want to know what you think; did we miss any process safety red flags, or have you experienced any of these at your facility? Leave us a voice message at the link below or send a note to podcast@amplifyconsultants.com.
And if you haven't already, check out our previous Top 10 Talks here (PHAs), here (Compliance Audits), and here (P&IDs).
Process Safety Incident Alert: Fatalities at BP-Husky Refinery in Oregon, OH
On Tuesday, September 20, 2022, an accidental release event occurred at the BP-Husky Toledo refinery in Oregon, OH, which ultimately resulted in two employee fatalities, the release of sulfur dioxide and hydrogen sulfide, and significant property damage. In this episode, John and Rob bring you the latest information about the incident, and offer a reminder about the role that PHAs, operating procedures, MOCs, and PSSRs play when it comes to shutdown/turnaround operations and safety.
Episode 61 - Combustible Dust Management Systems
In this episode, Rob and Molly compare the requirements of combustible dust management systems with the requirements of the PSM standard. They walk through each similar element and then point out the three largest differences between the PSM standard and the NFPA combustible dust standard. Whether your facility is already PSM-covered, or isn't, you'll want to catch this episode if you handle combustible dusts. We also recommend that you check out Episode 16 - Combustible Dusts & DHAs and Episode 51 - Combustible Dust Testing with Guest Michelle Murphy too to learn more.
Episode 60 - How Organizational Structure Impacts Process Safety with Guest Gilsa Monteiro
In this very special episode, Rob is joined by guest Gilsa Monteiro, a process safety expert with nearly nineteen years of experience in the Oil & Gas industry, to discuss how an organization's decentralized structure may undermine process safety. In this episode, you'll learn the defining features of both a centralized and decentralized organizational structure, the process safety dangers of a decentralized structure and how to avoid those dangers, and other factors to consider when it comes to process safety, like how bonus structures can impact risk and process safety.
Useful links from today's episode:
Read Gilsa's paper (part 1) How do organizational structures impact operational safety? Part 1 – Understanding the dangers of decentralization
Request a copy of Gilsa's paper (part 2) How do organizational structures impact operational safety? Part 2 - Designing structures that strengthen safety
Check out Organising for Safety: How structure creates culture by Andrew Hopkins
Connect with Gilsa Monteiro on LinkedIn.
Process Safety Incident Alert: Fatal Sugar Refinery Explosion in India
On August 19, 2022, an explosion at a sugar refinery in Andhra Pradesh's Kakinada district took the lives of two workers and injured nine others. In this episode, Rob and Molly bring you the latest information about the incident, and offer a reminder about the role good housekeeping plays in keeping the people who work in facilities that handle combustible dusts safe. For additional information, check out the resources we've gathered below.
News Releases:
2 dead, 6 hurt after explosion rocks sugar refinery in Andhra Pradesh’s Kakinada
Andhra Pradesh: Two dead, 9 injured in sugar factory explosion in Kakinada
In this episode we also referred to the CSB's video for the Imperial Sugar Company Dust Explosion and Fire, which you can view here.
Episode 59 - Incident Breakdown: 2017 Pressure Vessel Explosion at Loy-Lange Box Company
On August 2, 2022, the US Chemical Safety Board (CSB) released its final report into the 2017 pressure vessel explosion at Loy-Lange Box Company in St. Louis, MO. In today's episode, Molly and Jo take a deep dive into that report and break it down for you. So what can you expect in this breakdown? We'll cover some background information about the facility and its process, give you details about the day of the incident, and then break down the factors that ultimately led to the vessel's failure on April 3, 2017. Finally, we'll discuss how certain elements of a robust process safety program could have helped to prevent this tragedy, and provide you with three big takeaways that we think you'll find valuable, regardless of the industry or materials you work with.
Find the resources we mention in this week's episode at the links below:
Episode 58 - Top 10 Talk: Amplify Your P&IDs
We're back with another Top 10 Talk, this time to discuss how to Amplify Your P&IDs. In this episode, Rob and Molly cover their top ten tips for how to improve your P&IDs, and touch on consistent standards, drawing details, managing revisions, reference flags, tag numbers, line numbering, instrumentation, equipment information, relief devices, referencing P&IDs across your PSM program, and more. Then they break the rules and throw in two more bonus tips at the end (so I guess this is a Top 12 Talk). If you're looking to improve your process safety information (PSI) documentation, or improve the quality of your PHAs, then this is the episode for you.
We want to know what you think; did we miss any P&ID best practices, or do you have any questions about what we covered? Leave us a voice message at the link below or send a note to podcast@amplifyconsultants.com.
If you haven't already, check out our previous Top 10 Talks here (PHAs) and here (Compliance Audits).
Episode 57 - What Really Requires an MOC?
In this episode, Molly and John discuss the subtleties of Management of Change (MOC). If you're familiar with MOC, then you already know that in order to comply with the PSM standard, you need to "establish and implement written procedures to manage changes (except for 'replacements in kind') to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process". But what if the line between a real change and a replacement in kind isn't totally clear? For example, what if you replace a pressure relief device with another of the same size, but the replacement is from a different manufacturer than the original device? Tune in to this episode to learn more about this specific situation and other similar cases, where you might find yourself on the fence about whether an MOC is truly required.
Have a specific scenario that we didn't discuss? Send an email to podcast@amplifyconsultants.com and our consultants will respond with their expert advice.
For those not familiar with MOCs, we suggest checking out these previous episodes of our show:
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 info@amplifyconsultants.com.
Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
The General Duty Clause Fact Sheet (pdf) (April 2020)
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 podcast@amplifyconsultants.com.
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.