Amplify Your Process Safety

In this episode, Rob and Magi break down the CSB's incident report on the Honeywell Geismar facility, which includes three significant hydrofluoric acid releases that occurred between 2021 and 2024. They review the CSB's analysis of each incident, highlight safety issues and failures in process safety management, and review the CSB's recommendations for improving safety practices and preventing future incidents. Tune in to find out more and read the CSB's full report ⁠here⁠.For more CSB final report breakdowns, check out the episodes below:Episode 122 - Incident Breakdown: 2023 Fire Heater Fire at Marathon Martinez Renewables Facility⁠Episode 105 - Incident Breakdown: 2022 Fatal Naphtha Release and Fire at BP-Husky Toledo Refinery in Ohio⁠Episode 97 - Incident Breakdown: 2020 Fatal Oil and Gas Well Blowout in Burleson County, Texas⁠

In this episode, Magi and Jackson discuss the importance of lockout/tagout procedures in process safety, analyzing several incidents that highlight failures in energy isolation and the consequences of neglecting safety protocols. They delve into the need for thorough procedures and best practices to prevent accidents in industrial settings.For more about the CSB's ARRR, or AR3 as we like to call it, read volume one here and volume two here,k out the other episodes in the AR3 Miniseries: Episode 121 - ARRR Summaries & Trends and Episode 125 - AR3 Volume Two.

In this episode, Rob interviews Alex Pawlowski, Vice President of Design and Operations at SPEC Process Engineering and Construction. They discuss the critical role of process safety in engineering and construction, particularly in projects involving hazardous materials. Alex shares insights on how SPEC integrates safety into their design and construction processes, the challenges faced in maintaining safety standards, and the differences between capital and maintenance projects.For more about SPEC, visit their website here, or find them on LinkedIn here. To connect with Alex, find him on LinkedIn here.

In this episode, Magi and Jackson discuss some of the incidents included in Volume 2 of the CSB's Accidental Release Reporting Rule, and some safeguards that can be put in place to prevent such incidents from happening.For more about the 2023 Heater Fire at Marathon Martinez Renewables Facility, check out episode 122 here.For more information about the ARRR, check out Volume 2 of the CSB's Accidental Release Reporting Rule here.

In this episode, Rob is joined by Tyson Alexander, head of sales at APSM. Tyson has been at APSM for over 18 years and he talks us through some of the history of APSM, including what the "A" stands for, the evolution of process safety management, and real-world application of APSM software. For more information about APSM, visit their website at https://apsm.net/ and for the latest APSM news, follow them on LinkedIn here, or read their blog at https://apsm.net/blog/ To connect with Tyson, email him at tyson@apsm.net or connect with him on LinkedIn here.

In this episode, Rob and Magi discuss the recently released Safe Work Practice from the Center for Chemical Process Safety (CCPS) about Simultaneous Operations (SIMOPS) for offshore and operating plants.  SIMOPS are defined as "two or more different activities occurring at the same time that are close enough to interfere with each other and transfer risk or performance implications."  They discuss a few incidents where SIMOPS played a tragic part, as well as how CCPS recommends that facilities improve management of the inherent risk of SIMOPS.For more information about the Wacker Polysilicon incident, check out the episode below:Episode 80 - Incident Breakdown: 2020 Fatal Chemical Release at Wacker Polysilicon Facility in TennesseeFor more about SIMOPS, visit the AIChE page below:Simultaneous Operations (SIMOPS) - CCPS Safe Work Practice

In this episode, Magi and Jackson breakdown the most recent CSB final report. They cover the 2023 fire at the Marathon Martinez Renewables Facility that resulted in a significant injury for one employee and $350 million in property damage. This breakdown includes a review of the event, contributing factors and recommendations from the CSB. Tune in to find out more or read the report here.For more CSB final report breakdowns, check out the episodes below:Episode 105 - Incident Breakdown: 2022 Fatal Naphtha Release and Fire at BP-Husky Toledo Refinery in OhioEpisode 97 - Incident Breakdown: 2020 Fatal Oil and Gas Well Blowout in Burleson County, TexasEpisode 95 - Incident Breakdown: 2019 Fatal Explosion and Fire at KMCO in Crosby, TX

In this episode Magi and Jackson break down the CSB's Accidental Release Reporting Rule (ARRR) - what it is and some of the incidents reported under this rule. The ARRR requires reporting certain incidents to the CSB and has led them to deploy to some incidents that they may not have otherwise investigated. For more information about the Accidental Release Reporting Rule (ARRR), check out CSB Incident Reports Volume One

In this episode, Rob and Jackson lead listeners through NFPA 660; the new and improved combustible dust standard, which was released in late 2024. They discuss the reason for the new standard, other meaningful changes in the standard, general requirements of the standard, the titles of the industry specific chapters, which requirements are retroactive or not, and which annexes they found most valuable. For further listening related to Combustible Dusts, be sure to check out these past episodes. Episode 16 - Combustible Dusts & DHAsEpisode 46 - DHA Basics with Guest Mike RobertsonEpisode 51 - Combustible Dust Testing with Guest Michelle MurphyEpisode 61 - Combustible Dust Management Systems

In this episode, Rob is joined by Casey Houston, principal engineer of Chemitics, a consulting firm that specializes in overpressure protection and effluent handling system designs.  Casey has been a participant with the AIChE DIERS group since 2006 and has been a member with the API Subcommittee on Pressure Relief System designs since 2011.  He is also the co-chair for the API Task Force on Technical Report 522. In this episode, they discuss updating pressure relief device standards and what goes into making API standards updates. For more information about AIChE DIERS, visitwww.aiche.org/diers. To connect with Casey, email him atcasey@chemitics.com. For more on relief devices, check outEpisode 63 - Relief Devices Documentation with guest Chris Paskach andEpisode 72 - Incident Breakdown: 2018 Ethylene Release and Fire at Kuraray America, Inc. with Guest Christ Paskach.

In this episode, Rob and Magi discuss some of the natural disasters that have contributed to process safety incidents in recent years, including the impacts that Hurricanes Harvey, Laura, Ida, Ian, and Helene have had. For related content, please check out our past episodes below. Episode 26 - Natural Hazard Assessment and Planning Episode 103 - Quantitative and Qualitative Natural Disaster Preparation with Guest Mike Washington

In this episode, Rob is joined by Jackson Colley, the newest member of the Amplify Process Safety team. Rob sits down with Jackson to talk about his background and what ultimately led him to joining Amplify. Welcome to the team, Jackson! To connect with Jackson, find him on LinkedIn here or email him at jackson.colley@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 98 - Introducing Magi

In this special episode, Rob and Magi present 2024 (Process Safety) Wrapped. They cover regulatory changes that took place this year, major incidents the CSB has deployed to, metrics on other minor process safety incidents they've tracked this year, CSB reports issued this year, and their hopes for a renewed focus on process safety in 2025. Do you have a process safety related resolution for 2025? Or a topic you'd like us to delve deeper into in an episode next year? Reach out to us at podcast@amplifyconsultants.com. For full length episodes on topics mentioned in today's episode, please check out the links below: Episode 108 - 2024 EPA RMP Updates Episode 105 - Incident Breakdown: 2022 Fatal Naphtha Release and Fire at BP-Husky Toledo Refinery in Ohio

In this episode, Rob welcomes back Mathew Todaro, a partner at Verrill Law who defends and negotiates on behalf of his clients under statutes such as the Clean Water Act, EPCRA, and FIFRA, with a particular focus on Section 112(r) of the Clean Air Act. Today, Rob and Mat give listeners a crash course on the EPA's Risk Management Plan (RMP) Rule. They cover applicability, the three program levels, the components and requirements of RMP, and touch on some recent RMP rule changes. Be sure to check out Mat's previous appearances on our show at the links below: ⁠Episode 25 - After the EPA Inspector Leaves with Guest Mathew Todaro⁠ ⁠Episode 35 - Environmental Compliance Audits with Guest Mathew Todaro⁠ ⁠Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro⁠ ⁠Episode 56 - Implementing EPA's General Duty Clause (GDC)⁠ (Does not feature Mat, but is a companion episode to #52) ⁠Episode 106 - EPA's National Enforcement and Compliance Initiatives with Guest Mathew Todaro⁠ Connect with Mat on LinkedIn ⁠here⁠.

In this episode, Rob welcomes back guest Neil Beekie, CEO and Co-Founder of OperAid. Listeners may remember him from Episode 79 (listen here) back in the summer of 2023, where he introduced us to OperAid, a software tool that assists operators with real-time verification of manual tasks. Today, Rob gets an update on present-day OperAid, including successes, the type of feedback that's been received since deployment, recent updates/improvements, how AI is and could be incorporated, and more. To learn more about OperAid, visit https://operaid.ai. To connect with Neil, find him on LinkedIn or send an email to neil@operaid.ai.

In this episode, inspired by the CSB investigation update into the 2023 explosion and toxic chemical release at the Honeywell facility in Geismer, LA, Rob and Molly discuss the challenges of aging equipment and infrastructure at chemical plants and refineries. They discuss the aforementioned Honeywell incident, as well as three others where poorly maintained equipment was a key factor that ultimately led to an incident. Then they move on to discuss managing the asset life cycle, warning signs related to aging equipment, equipment deficiency management, and some considerations for aging support equipment and infrastructure. Find the U.S. Chemical Safety Board Releases Investigation Update into 2023 Explosion and Toxic Chemical Release at Honeywell Facility in Geismer, LA here. Here are the CCPS books we mentioned that are great resources to look into: Dealing with Aging Process Facilities and Infrastructures Recognizing Catastrophic Incident Warning Signs in the Process Industries Guidelines for Asset Integrity Management And finally, here are a few related podcast episodes we recommend: Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP Episode 7 - API 510 with Guest William McBride Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)

In this episode, Rob and Magi discuss the CSB's new safety study titled "Remote Isolation of Process Equipment" that includes recommendations to regulators and emphasizes the need for greater adoption of remote isolation equipment at chemical facilities across the country. Rob and Magi run through the list of recent CSB investigations that are specifically highlighted in the safety study, where the CSB determined that lack of effective remote isolation equipment significantly contributed to incident consequences, discuss the recommendations the CSB made in their study to API, EPA, and OSHA, and talk about actionable next steps for listeners at applicable facilities. Find the CSB's "Remote Isolation of Process Equipment" safety study here. Check out our full episodes of some of the CSB investigations relating to lack of remote isolation equipment below. Episode 68 - Incident Breakdown: 2019 Refinery Fire and Explosions at Philadelphia Energy Solutions (PES) with Guest Tim Murphy Episode 73 - Incident Breakdown: 2019 Explosions and Fires at TPC Group (TPC) Port Neches Operations (PNO) Facility Episode 83 - Incident Breakdown: 2019 Tank Farm Fire at Intercontinental Terminals Company, LLC (ITC) in Deer Park, TX Episode 95 - Incident Breakdown: 2019 Fatal Explosion and Fire at KMCO in Crosby, TX

The final part of our mini deep dive into different aspects of Process Hazard Analyses (PHAs) is finally here. In today's episode, Molly and Magi talk PHA safeguards, including hierarchy of controls, common types of safeguards (including how and when operator response can be credited in a PHA), quantitative vs. qualitative risk assessment for safeguard effectiveness, independent protection layer (IPL) requirements, and their best tips for safeguard considerations based on their own PHA facilitation experience. If you haven't already, be sure to check out our other PHA-related episodes mentioned in today's show: Episode 55 - Movie Breakdown: Control Room Concerns in The China Syndrome Episode 109 - PHA Principles Part 1 - Causes Episode 110 - PHA Principles Part 2 - Consequences Thanks for listening, and please let us know what you think at ⁠podcast@amplifyconsultants.com⁠.

This episode is the second of a three part series in which Molly and Magi take a deep dive into different aspects of Process Hazard Analyses (PHAs). In today's episode, they talk PHA consequences, including some common pitfalls to avoid when it comes to considering consequences in a PHA, general types of impacts used for PHA consequences, tools to use for defining impacts, and some consequence-related PHA best practices. If you haven't already, be sure to check out our other PHA-related episodes mentioned in today's show: Episode 109 - PHA Principles Part 1 - Causes Episode 59 - Incident Breakdown: 2017 Pressure Vessel Explosion at Loy-Lange Box Company Episode 72 - Incident Breakdown: 2018 Ethylene Release and Fire at Kuraray America, Inc. with Guest Chris Paskach And please follow our show so you can tune in to the final, third part of this mini-series when it becomes available in two weeks. Thanks for listening, and please let us know what you think at podcast@amplifyconsultants.com.

This episode is the first of a three part series in which Molly and Magi take a deep dive into different aspects of Process Hazard Analyses (PHAs). In today's episode, they talk PHA causes, including identifying causes of deviation in HAZOP, What-If, and Checklist methodologies, some common pitfalls they've observed regarding causes in PHAs, and what makes a cause not credible. If you haven't already, be sure to check out our other PHA-related episodes: Episode 2 - Intro to PHAs Episode 17 - Tips for a Successful PHA Episode 19 - PHAs During the Project Life Cycle Episode 36 - Best Practices for Remote PHAs Episode 85 - Participating in Your First PHA PSM: Back to Basics, Part 3 - Process Hazard Analysis (PHA) Top 10 Talk: Amplify Your PHAs, Recording of live event (12/7/2021) And please follow our show so you can tune in to the next two parts as they become available. Thanks for listening, and please let us know what you think at podcast@amplifyconsultants.com.

In this episode, Rob and Magi cover the recent changes made to the Environmental Protection Agency's (EPA's) Risk Management Program (RMP) Final Rule. The changes fall into four categories: the prevention program, emergency response, availability of information, and other areas of technical clarification. In this episode, they discuss each change, what each could mean for your facility going forward, and when each requirement must go into effect at your facility. If your site is subject to the RMP rule, you won't want to miss this episode. Have a question 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.

In today's episode, Rob is joined by guest Shawn Marsh, Vice President of ESHQ Services North America at Evonik, a specialty chemicals manufacturer based in Germany, with production plants in 27 countries on six continents. Shawn explains how Evonik manages process safety and how he fits into that process, key metrics he uses to manage and measure process safety, the challenges of communicating process safety issues to individuals at different levels within his organization, his role in addressing process safety challenges at Evonik's North American sites, his advice for people in similar roles at other companies, and more. For more on managing PSM from a corporate perspective, be sure to listen to Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy.

In this episode, Rob sits down with Mat Todaro of Verrill Law, who listeners may remember from his previous guest appearances on the show related to EPA's Risk Management Program and General Duty Clause. Today Rob and Mat discuss EPA's National Enforcement and Compliance Initiatives (NECI) for 2024, including what they are and which initiatives are new, modified, and continued, what is different about how NECI will be managed this time around, what this means for RMP facilities who have ammonia, HF, or are near an overburdened community, and Mat's thoughts on the Supreme Court's recent overturning of the Chevron doctrine. If you haven't listened to our previous episodes featuring Mat, be sure to check them out at the links below: Episode 25 - After the EPA Inspector Leaves with Guest Mathew Todaro Episode 35 - Environmental Compliance Audits with Guest Mathew Todaro Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro Episode 56 - Implementing EPA's General Duty Clause (GDC) (Does not feature Mat, but is a companion episode to #52) Connect with Mat on LinkedIn here.

In this episode Magi and Jo team up to cover a recent CSB final report. In this incident breakdown, they cover the 2022 accidental release of naphtha that resulted in a fire, two worker fatalities, and significant property damage at the BP-Husky refinery in Oregon, Ohio, including what happened leading up to the event, contributing factors, recommendations the CSB made in their final report, and what companies can learn from this incident. Find the CSB's final report for this incident here. If you haven't listened to our episodes where we interviewed the CSB, please check out Episode 101 and Episode 102. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In today's episode, Molly sits down with Stephen J. Wallace, the author of a newly released process safety thriller titled "Hazardous Lies". Although his book is a work of fiction, Stephen discusses how his book relates to real aspects of process safety and how it was informed by his real career experience in the process safety field, how he came up with the idea for the novel, his leap from technical writing in his career to creative writing, and how he made technical topics in the book accessible to non-technical readers. Stephen also shares his advice for those branching out from a technical field into a more creative role, and his advice for those who wish to steer their careers toward process safety. You can purchase "Hazardous Lies" on Amazon here, or you can visit https://stephenjwallace.com/ to purchase the book or to learn more about Stephen. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Rob is joined again by guest Mike Washington, who is the Director of Industrial Safety at Arkema Inc., The Americas. Mike recently gave a talk at the AIChE Global Congress on Process Safety in New Orleans in March 2023 titled, “Quantitative Natural Disaster Assessment and Scorecard for Chemical Plants," and today discusses some of what he covered in that talk. Rob and Mike cover his motivation for presenting at the AIChE Global Congress on Process Safety, the basic approach of the assessment and scorecard, how Arkema is using the tool and how the plants have reacted to it, and advice he has for other companies struggling with planning for and reducing the risks of natural hazards. If you haven't caught our previous episode with Mike, be sure to listen to Episode 96 - Educating the Next Generation of Process Safety Experts with Guest Mike Washington. Mike invites you to connect with him on LinkedIn at https://www.linkedin.com/in/michael-washington-m-b-a-067b2520/ To hear more about this topic, be sure to listen to these episodes: Episode 26 - Natural Hazard Assessment and Planning Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, we sit down for another conversation with the U.S. Chemical Safety and Hazard Investigation Board (CSB). This time, Molly and Jo talk with Supervisory Chemical Incident Investigator Lauren Johnson, Chemical Incident Investigator Melike Yersiz, P.E., and Video Producer and Public Affairs Specialist Shauna Lawhorne. We discuss how each CSB employee ended up at the agency, what a company can expect when the CSB comes to investigate an incident, some examples of how and when subject matter experts are used to assist with investigations, what has most surprised each of them during the course of their investigations, and how recommendations are tracked and managed. Then we get to ask everything we've been wondering about the CSB videos; how the CSB decides which investigations get a video, how they condense the investigation's material down, some details about the iconic narrator, and more. A heartfelt thank you to all three CSB guests for their appearances on this episode, and to CSB Communications Manager, Hillary Cohen. To learn more about the CSB, please visit csb.gov, and if you haven't already be sure to check out our previous episode with the CSB: "Episode 101 - Conversations with the CSB - Part 1". To learn more about the CSB's accidental release reporting rule, and to access the published data, visit https://www.csb.gov/news/incident-report-rule-form-/. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Molly and Magi sit down with two U.S. Chemical Safety and Hazard Investigation Board (CSB) chemical incident investigators, Lauren Grim, P.E., CFEI and Drew Sahli. Lauren and Drew detail how each of their career paths led them to their current roles, what their jobs as chemical incident investigators are like, and, for those interested in also working at the CSB, the type of background and experience best suited for the job. Next, Molly and Magi ask about the size of the CSB agency, the challenges, surprises, and takeaways they've had during investigations, and their thoughts on how the CSB final investigation reports and videos should be utilized. Finally, Molly and Magi get to ask what all of us have been dying to know; now that the CSB has cleared their backlog of reports, what are they up to next? Be sure to tune in to this episode to find out, and subscribe to the show so you'll be the first to hear "Conversations with the CSB - Part 2" when it becomes available. A huge thank you to Lauren Grim and Drew Sahil for their guest appearances on this episode, and to CSB Communications Manager, Hillary Cohen. To learn more about the CSB, please visit csb.gov. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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 --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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 --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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/. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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/. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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/ --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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 --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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 naptha 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 --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Rob and Jo talk about CMMS, or computerized maintenance managements systems. You'll learn how to make the best CMMS platform selection for your facility, important considerations you should make when it comes to the set up of your CMMS platform, and how to ensure your CMMS gets updated as changes are made in your facility. They'll also talk customization options, mobile apps, permissions, contractor involvement, recordkeeping, reporting/dashboards, and more. If you're considering making the move from a paper-based work order system to a CMMS platform, or looking to see how you can leverage the data currently captured within your CMMS platform, then this is the episode for you. Some other episodes mentioned today that we recommend:     Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP PSM: Back to Basics, Part 6 - Mechanical Integrity (MI) Episode 18 - PSM Management Systems --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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 --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Rob and Jo team up to cover another CSB final report. In this incident breakdown, they cover the 2019 tank farm fire at the Intercontinental Terminals Company, LLC (ITC) bulk liquid storage terminal in Deer Park, Texas. On March 17, 2019, a circulation pump failure led to the release of a butane-enriched naptha product from a large aboveground storage tank, and the flammable vapors eventually ignited. The resulting fire spread to the other 14 nearby tanks and then burned for three days before being extinguished. In this episode, Jo and Rob cover additional details regarding offsite consequences, discuss the five safety issues that the CSB highlighted in their report, share the CSB's recommendations, and then finally cover key lessons for industry. Find the CSB's final report for this incident ⁠⁠⁠⁠⁠⁠here⁠⁠⁠⁠⁠. If you have a comment about this week's episode, an idea for a future episode, or any process-safety related question, please drop us a line at podcast@amplifyconsultants.com. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal explosion and fire at the Watson Grinding facility in Houston, Texas. On January 24, 2020, a propylene release in a coating booth at the facility resulted in a fire and explosion that killed two workers and one nearby resident, injured two workers, and damaged over 450 nearby structures. Today, Molly and Jo provide some background information on the facility, including previous incidents, precautions in place at the time of the incident, and contributing factors. Then they delve into how various elements of a process safety program could have helped to prevent this incident, discuss the CSB's recommendations, and end with three key learnings that facilities can learn from this incident. Find the CSB's final report for this incident ⁠⁠⁠⁠here⁠⁠⁠. Related episodes we mentioned: Your Process Safety Journey, Part 1 - The Foothills Your Process Safety Journey, Part 2 - Climbing The Mountain Your Process Safety Journey, Part 3 - Nearing the Summit Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro Episode 56 - Implementing EPA's General Duty Clause (GDC) --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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.  --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message