Skip to main content
Spotify for Podcasters
Amplify Your Process Safety

Amplify Your Process Safety

By Amplify Process Safety, LLC

Join industry professionals as they share insight into the world of process safety, including news related to updated codes and standards, recent incidents and what you can learn from them, and their take on all elements of process safety. With decades of combined experience in real, practical implementation, they aren’t just advisors, they practice what they preach. Whether you’re new to process safety, in a role where you interact with aspects of process safety, or an experienced process safety professional, this is the podcast for you.
Available on
Amazon Music Logo
Apple Podcasts Logo
Castbox Logo
Google Podcasts Logo
iHeartRadio Logo
Overcast Logo
Pocket Casts Logo
RadioPublic Logo
Spotify Logo
Stitcher Logo
TuneIn Logo
Currently playing episode

Episode 77 - Operator Training - Part 1: Initial Training

Amplify Your Process SafetyMay 26, 2023

00:00
30:52
Episode 77 - Operator Training - Part 1: Initial Training
May 26, 202330:52
Episode 76 - Incident Breakdown: 2020 Toxic Gas Release and Chemical Fire at Bio-Lab Facility
May 12, 202325:47
Episode 75 - Mechanical Integrity (MI) Inspection Requirements with Guest William McBride
Apr 28, 202335:35
Episode 74 - The Challenges of Engineering in a High Hazard Plant with Guest Doug McMahon

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

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

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

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

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

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


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

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

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

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

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

Find the CSB's final report here

Find the CSB's video on the incident here

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

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

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

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

Find the CSB's final report here

Find the CSB's video on the incident here

Find additional information about the CSB's investigation here

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

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

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

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

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

Episode 54 - Pressure Relief Device Concepts with Guest Eric Hirsch

In Episode 45, we covered the basics of piping requirements for pressure relief devices. In this episode, Rob is joined by Eric Hirsch, to take a deeper dive into pressure relief device concepts. Eric, a principal process engineer at Nexus Engineering Group, works in process design with a focus on pressure relief devices. In this episode, Eric and Rob cover basic requirements for pressure relief devices and the calculations that go with them. You'll learn about back pressures, considerations for common subheaders and global relief scenarios, impacts to the relief capacity of a system, identifying fire zones/circles, design issues with flare knock out pots, Eric's thoughts on the use of rupture disks for overpressure protection, SIS instrumentation, designing for 2-phase relief, and more. Then Eric gives his expert advice regarding a frequently asked question: Do I have to have overpressure protection on every pressure vessel and/or piping system and do I need calculations for all of those? He'll touch on what could get you in trouble with OSHA during an enforcement audit when it comes to your pressure relief scenarios, how often you should revalidate them, and more. Don't miss this content-packed episode from an expert on pressure relief devices. 

To contact Eric Hirsch directly, send an email to eric.hirsch@nexusegroup.com or give him a call at 216-456-8564.

Apr 08, 202235:51
Episode 53 - How Boots on the Ground Expertise Can Lead to PSM Success
Mar 25, 202223:20
Top 10 Talk: Amplify Your Compliance Audits, Recording of live event (3/22/2022)
Mar 22, 202242:30
Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro
Mar 12, 202234:23
Episode 51 - Combustible Dust Testing with Guest Michelle Murphy

Episode 51 - Combustible Dust Testing with Guest Michelle Murphy

In this episode, Molly is joined by guest Michelle Murphy, a chemical engineer who has worked in process safety for 25 years. Earlier in her career, Michelle designed, built, and managed a combustible dust testing laboratory, and now she is the newly appointed president of Sigma-HSE INC., the North American division of Sigma-HSE. Molly and Michelle cover the basics when it comes to combustible dust testing, including defining combustible dusts, discussing why dust testing is needed, and reviewing what types of tests are available. You'll learn how to select a combustible dust test, what commonly used tests tell you about your dust, how testing samples should be prepared and collected, tips for making the most of your testing budget, and how testing relates to your MOC and PHA processes. 


If you have additional questions about combustible dusts or combustible dust testing, Michelle invites you to visit Sigma-HSE.com, send an email to her at mmurphy@sigma-hse.com, or reach her by phone at 603-303-7863. 

Mar 03, 202224:20
Episode 50 - Managing Risk at Remote Facilities

Episode 50 - Managing Risk at Remote Facilities

In this episode, Rob and John talk about remote facilities - how a remote facility is defined, how risk is managed differently versus at a large, regularly populated plant, how operator response times differ, precautions taken for operators performing lone work, how incidents might be handled, security, and more. 

Feb 11, 202226:13
Episode 49 - Using Integrity Cards to Save Lives with Guest David Hatch

Episode 49 - Using Integrity Cards to Save Lives with Guest David Hatch

You may remember our guest David Hatch, from Episode 39, when he spoke to our listeners about using bow ties to manage risk. Today, David, a process safety expert and entrepreneur, is back to talk with Rob about the Integrity Cards that he has developed. In his process safety career, David had not seen a reduction in accidents and wondered to himself if maybe those in hazardous industries weren't focusing on the right things. He saw an opportunity to condense process safety knowledge into an accessible and familiar version - a pack of cards, where each card represented a different loss of containment, and thus the Integrity Cards were born. These Integrity Cards are meant to be used in a structured way to inform those on the front line of legitimate hazards that they face, and can be used in PHAs, toolbox talks, management meetings, and more. In this episode, David covers his inspiration for creating the cards, shares suggestions for using the cards, talks about how QR codes are expanding the knowledge each card can convey, shares how his cards can be used electronically, and touches on other opportunities outside the world of process safety in which customized decks can be utilized. 


To learn more, visit https://integrity.cards/ or find David Hatch on LinkedIn at https://www.linkedin.com/in/dh04tch/. 

Jan 28, 202227:51
Episode 48 - Management of Organizational Change (MOOC)
Jan 15, 202236:26
Your Process Safety Journey, Part 3 - Nearing the Summit

Your Process Safety Journey, Part 3 - Nearing the Summit

In the final installment of their three-part series, the A-Team shares advice for mature process safety programs. When your program reaches this phase, likely around the 10-year mark, it's important to continue maintenance of ongoing compliance and strive for continuous improvement. In this episode, Rob, Molly, John, and Jo cover best-in class practices for a mature PSM program, and touch on the unique challenges that you'll face in this phase of your journey.


Don't forget to listen to the first two parts of this series, Part 1 - The Foothills and Part 2 - Climbing the Mountain to learn more about our tips for newer PSM programs. 

Dec 24, 202147:24
Your Process Safety Journey, Part 2 - Climbing The Mountain
Dec 23, 202153:41
Top 10 Talk: Amplify Your PHAs, Recording of live event (12/7/2021)
Dec 07, 202158:36
Your Process Safety Journey, Part 1 - The Foothills

Your Process Safety Journey, Part 1 - The Foothills

In this very special episode, the first of a three-part series, the whole A-Team comes together to share their expert advice for facilities that are just beginning their process safety journey. In this episode, Rob, Molly, John, and Jo cover the main goals that you'll want to keep in mind when you begin establishing your process safety program, including the unique challenges that you may face during this part of your journey. 

Be sure to join us again in the next two parts when we cover our tips for PSM programs in the 3-10 year range, and then our final episode in the series covering continuous improvement for mature PSM programs. 

Dec 03, 202138:47
Episode 47 - What New Plant Managers Should Know with Guest Nat Weiner

Episode 47 - What New Plant Managers Should Know with Guest Nat Weiner

In this episode, Rob welcomes Nat Weiner to the podcast. Nat, who has extensive experience both as a plant manager and in a role managing plant managers tells us what advice he would give to someone who has recently taken on the "Plant Manager" title. Tune in to this episode to learn Nat's best tips for new plant managers, including how to best leverage the information contained in the last PHA, what you should focus on once basic PSM compliance is met, and what might keep a plant manager up at night. If you're in Ops, you won't want to miss this episode. 

Nov 19, 202135:07
Episode 46 - DHA Basics with Guest Mike Robertson

Episode 46 - DHA Basics with Guest Mike Robertson

In this episode, Rob welcomes process safety consultant Mike Robertson to the podcast. With over 30 years of experience in the chemical industry, Mike provides a thorough overview of what a Dust Hazard Analysis (DHA) is, why and when they are required, required versus preferred documentation to gather for DHA prep, and provides listeners with both similarities and differences between a DHA and a PHA (Process Hazard Analysis). Mike wraps up the episode by covering some typical DHA recommendations he often comes across and tells listeners two things he wishes everyone knew about Dust Hazard Analyses. We apologize in advance for a couple, brief, low-quality audio spots in this episode, but want you to know that this episode is full of content you don't want to miss!


To view the Imperial Sugar incident video from the CSB that is mentioned in this episode, visit https://www.csb.gov/imperial-sugar-company-dust-explosion-and-fire/. 


Get in touch with Mike Robertson at 678-815-7678 or at processesmatter@gmail.com.

Oct 22, 202131:03
Episode 45 - Piping Requirements for Pressure Relief Devices

Episode 45 - Piping Requirements for Pressure Relief Devices

In this episode, Rob and Molly talk piping requirements for pressure relief devices, including which Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) apply. With an extensive background as a pressure relief specialist, Molly walks through the basic requirements outlined in ASME Section VIII and API 520, Part II, tips for layouts, including safe discharging locations, and addresses some frequently asked questions regarding requirements for relief device calculations. 


Want to talk pressure relief devices further? Let us know what you'd like us to address in a future episode, or reach out to Molly directly at molly.myers@amplifyconsultants.com.

Oct 08, 202128:07
Episode 44 - Improving Safety Culture with Guest Nicholas Krump
Sep 24, 202134:46
Episode 43 - Introducing Molly
Sep 10, 202126:35
Process Safety Incident Alert: Fatal Chemical Leak at La Porte, TX Facility
Jul 30, 202104:21
Episode 42 - Human Factors Engineering with Guest Monica Philippart
Jun 18, 202130:51
Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy

Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy

In this episode, Rob sits down with Tim Murphy, the Process Safety Manager of Arkema Inc., responsible for providing PSM and RMP support for more than 25 facilities. With such a large number of sites to support, how does Tim ensure that each site values PSM and understands its importance? And what advice does Tim have for new engineers who might be considering a career in process safety? Tune in to this episode to find out.  

May 21, 202133:46
Episode 40 - The Evolution of Process Safety Culture with Guest Trish Kerin

Episode 40 - The Evolution of Process Safety Culture with Guest Trish Kerin

In this episode, Elena is joined by guest Trish Kerin, Director of the Institution of Chemical Engineers (IChemE), a multi-national institution tasked with advancing chemical engineering's contribution for the benefit of society. Elena and Trish discuss the specific incidents across the globe that highlighted the need for process safety in the past, touch on the importance of considering human factors, and caution against claiming  "double jeopardy" when talking about adequate process safety safeguards. Elena and Trish then delve into the challenges of improving process safety culture, and Trish explains iChemE's role and involvement. Elena and Trish also cover the importance of good leadership, their hopes for the future of process safety and collaboration within industries, then leave those new to process safety with a few words of helpful career advice. 


Learn more about IChemE at https://www.icheme.org/ 

May 08, 202137:42
Episode 39 - Using Bow Ties to Manage Risk with Guest David Hatch
Apr 23, 202137:08
Process Safety Incident Alert: Fatal Paint Plant Incident in Columbus, OH
Apr 10, 202109:13
Episode 38 - Best Practices for Remote Compliance Audits

Episode 38 - Best Practices for Remote Compliance Audits

In this episode, Rob, John, and Elena talk PSM compliance audits in the age of COVID-19. They'll talk you through how remote compliance audits work from start to finish, pros and cons about the remote audit format, and how remote audits compare to in-person compliance audits. Whether you participate in audits as part of a company team, or perform audits yourself, this is the episode for you. 

Apr 10, 202131:57
Episode 37 - Safety Culture with Guest Mike Burson

Episode 37 - Safety Culture with Guest Mike Burson

In this episode, Rob sits down with experienced EH&S Director, Mike Burson, to talk safety culture. Rob and Mike cover the challenges when it comes to developing a safety culture at different levels of an organization, talk strategies to improve an organization's safety culture, share stories about their experiences and struggles, and more. 

Mar 27, 202139:03
Episode 36 - Best Practices for Remote PHAs

Episode 36 - Best Practices for Remote PHAs

In the age of COVID-19, many services moved online to be held remotely, and Process Hazard Analyses (PHAs) were no exception. In this episode, consultants Rob and Elena talk about what they've learned over the past year when it comes to remote PHAs, including what works best and what unique challenges you might be faced with. You'll learn how remote PHA prep looks different, our thoughts on using cameras, how best to virtually "manage" the room, tips for dealing with P&IDs and other needed documentation, how we handle breaks, field verification, and "zoom fatigue", and our thoughts on efficiency and scheduling when it comes to longer PHAs. Whether you participate in PHA studies as a facilitator or just a member of the team, you're sure to find value in this episode. 


To hear more from us on the topic of PHAs, check out Episode 2 (Intro to PHAs), Episode 12 (Risk Matrices), Episode 17 (Tips for a Successful PHA), Episode 19 (PHAs during the Project Life Cycle), or PSM: Back to Basics, Part 3 (Process Hazard Analysis).

Mar 12, 202139:40
Episode 35 - Environmental Compliance Audits with Guest Mathew Todaro

Episode 35 - Environmental Compliance Audits with Guest Mathew Todaro

Mathew Todaro of Verrill joins us again in this episode - this time to talk about environmental compliance audits. Mat, an attorney that specializes in enforcement defense, explains how EPA enforcement and emphasis of the RMP regulation has changed in recent years, and how you can best prepare your facility should you become the next site of an EPA investigation. Rob and Mat talk about how performing internal compliance audits more often than the 3-year frequency required by PSM and RMP can be a valuable tool, but also cover how to protect that information and how a lawyer might be used to assist in these endeavors. If you're interested in learning more about protecting your facility while also ensuring compliance and the safety of employees, the surrounding community, and the environment, then this is the episode for you. 

Feb 26, 202137:32
Episode 34 - Introducing John

Episode 34 - Introducing John

In this episode, Rob sits down with John, the newest member of the Amplify team. John talks about his career experience, what led him to his current role, successes and difficulties he's witnessed with PSM implementation, and why he feels so passionate about process safety.

Feb 12, 202123:40
Process Safety Incident Alert: Fatal Liquid Nitrogen Incident in Gainesville, GA
Feb 02, 202109:46
PSM: Back to Basics, Part 6 - Mechanical Integrity (MI)
Jan 29, 202124:15
PSM: Back to Basics, Part 5 - Even More Acronyms

PSM: Back to Basics, Part 5 - Even More Acronyms

The world of process safety is STILL chock-full of acronyms. In part 1 of our beginner-friendly miniseries, PSM: Back to Basics, we tackled the essential acronyms that PSM newbies need to know, providing an explanation and context for each term. In this episode, Rob and Jo are back to cover even more acronyms: ALARP/ALARA, BPCS, BRM, CSO/CSC, DHA, EAP/ERP, ESD, FSS, IEL/IEF, IPL, ITPM, LEL, LOPC, MCE, NFPA, OEM, PFD, PRD, and PSV. 


Ready to learn more? Be sure to check out the previous four parts of the PSM: Back to Basics miniseries. 

Jan 15, 202133:47
Episode 33 - Quality Assurance

Episode 33 - Quality Assurance

In our last episode of 2020 Rob and Wesley talk quality assurance and quality control. Listen to learn what QA/QC means, what the PSM standard says, the importance of independent verification, and how things can go right (or very wrong) when it comes to QA/QC.

Dec 04, 202025:13
Episode 32 - Process Safety Leading & Lagging Metrics
Nov 21, 202024:54
Episode 31 - Effective Operator Training

Episode 31 - Effective Operator Training

In this episode, Rob, Wesley, and Elena team up to talk about operator training. You'll learn what the PSM standard requires, how your operating procedures affect the quality of your training program, and some tips to improve your training program and its effectiveness, including the use of a competency matrix (not to be confused with The Matrix, though we do give a shout out to Keanu Reeves). Join us for a fun, informative episode covering all the dos and don'ts you need to know when it comes to operator training. 

Nov 06, 202029:15
Episode 30 - The A-Team

Episode 30 - The A-Team

Who are these people and why do they have a podcast? In a much needed follow-up to episode 0, you'll meet all the members of the Amplify team, hear about the very different journeys that led them to Amplify, and learn what makes them passionate about process safety. Tune in as our normally virtual team sits down together for the first time for an episode jam-packed with jabs, sarcasm, and laughs. We look forward to meeting you! Learn more about our team on our website at https://www.amplifyconsultants.com/about. 

Oct 09, 202039:56
Episode 29 - Insurance Surveys with Guest Bob Wasileski

Episode 29 - Insurance Surveys with Guest Bob Wasileski

In today’s episode, Wesley welcomes Bob Wasileski to the show, an Energy risk engineer from Allianz Global Corporate & Specialty (AGCS), who has sat on both sides of the table when it comes to insurance surveys. In this episode, you’ll learn what an insurance survey is and how it explores both sides of the bow tie diagram, the top 10 things risk engineers look for when they survey your facility, and how you can use  insurance risk engineering reports to make a positive impact on your PSM program and to your insurance premium. If you would like to get more involved with insurance surveys at your site and create value from the process then this is the episode for you.

Sep 25, 202046:46
Episode 28 - Hot Work with The SafetyPro Podcast

Episode 28 - Hot Work with The SafetyPro Podcast

We're back with Blaine Hoffmann from The SafetyPro Podcast, for part four of our collaborative series comparing and contrasting the PSM standard with OSHA general industry regulations. In this episode we cover the requirements surrounding Hot Work, any work that involves burning, welding, cutting, brazing, soldering, grinding, using fire- or spark-producing tools, or other work that produces a source of ignition. You'll learn what the PSM standard requires for hot work, its relationship with standard 1910.252 (for general industry), and even about what the OSHA construction standard says about hot work activities. You'll also hear an up close and personal story about hot work and associated hazards, and then we'll walk you through 7 key lessons from the CSB to prevent worker deaths during hot work in and around tanks. 


Listen to the Contractor Management episode we referenced a few times here: https://www.amplifyconsultants.com/podcast/episode/2ea6f639/episode-27-contractor-management-with-the-safetypro-podcast 

CSB Fact Sheet: Safe Hot Work Practices (Summary of 7 Key Lessons to Prevent Worker Deaths during Hot Work in and around Tanks)

Full CSB Safety Bulletin: Seven Key Lessons to Prevent Worker Deaths During Hot Work In and Around Tanks

Sep 13, 202028:44
Episode 27 - Contractor Management with The SafetyPro Podcast

Episode 27 - Contractor Management with The SafetyPro Podcast

In this episode we welcome back Blaine Hoffmann from The SafetyPro Podcast for another collaboration where we talk both occupational safety and process safety, and this time we cover contractor management. We'll talk about what OSHA says about contractor management for general industry, and what's required for PSM-covered facilities, how contractor management relates to both occupational and process safety, and why you should care. 


Find OSHA's Recommended Practices for Safety and Health Programs, Communication and Coordination for Host Employers, Contractors, and Staffing Agencies, here

Also, a special note about today's episode: While we regularly recommend videos from the U.S. Chemical Safety Board (CSB) and think they make excellent training material, in this episode we mistakenly said that there was a CSB animation video for the Phillips disaster of 1989 in Pasadena, TX. No such video exists, but you may learn more about the incident on its Wikipedia page, on Youtube, or from ABC13 Houston

Aug 28, 202033:48
Episode 26 - Natural Hazard Assessment and Planning
Aug 01, 202035:02
Episode 25 - After the EPA Inspector Leaves with Guest Mathew Todaro
Jul 17, 202043:56
Episode 24 - Emergency Planning & Response with The SafetyPro Podcast

Episode 24 - Emergency Planning & Response with The SafetyPro Podcast

We've teamed up with The SafetyPro Podcast again to bring you an episode on emergency planning and response. We'll cover general industry's requirements, what PSM says, and a bit about RMP's requirements. You'll also get to hear from Blaine, a former first responder, regarding his experience with emergency response and we'll cover two incidents that truly highlight the importance of emergency action plans. If you work at a PSM-covered facility, or in any industry where safety is essential, you don't want to miss this episode. 

CCPS Process Safety Beacon - Emergency Preparation - The Titanic Disaster (July 2012)

Jul 03, 202023:53
Episode 23 - Incident Investigation with The SafetyPro Podcast
Jun 19, 202037:27
PSM: Back to Basics, Part 4 - Management of Change (MOC)
Jun 05, 202013:58
PSM: Back to Basics, Part 3 - Process Hazard Analysis (PHA)
May 29, 202014:39
PSM: Back to Basics, Part 2 - Open Source Resources
May 22, 202024:21
PSM: Back to Basics, Part 1 - Acronyms

PSM: Back to Basics, Part 1 - Acronyms

The world of process safety is chock-full of acronyms. In part 1 of our new miniseries, PSM: Back to Basics, Wesley and Jo tackle the essential acronyms that PSM newbies need to know, providing an explanation and context for each term. In this episode, you'll learn about AIChE, API, ASME, CCPS, CCPSC, C&Es, CFR, CSB, CSP, EPA, ERP, II, MI, (e)MOC, NURF, PFDs, PHA, P&IDs, PSI, PSM, PSSR, RAGAGEP, and RMP. 


Encountered an acronym in the PSM world that we didn't cover? Send an email to podcast@amplifyconsultants.com and we'll give you a shout out in our follow-up to this episode, when we cover even more process safety acronyms. 

May 15, 202032:15
Episode 22 - Establishing an Alarm Management Program 101 with Guest Curt Snyder

Episode 22 - Establishing an Alarm Management Program 101 with Guest Curt Snyder

What do toothpaste, coffee, Superbowl Sunday, and Spock have to do with alarms? You'll find out in this episode, where we welcome back guest Curt Snyder, a certified functional safety expert, as we discuss building an alarm management program in your facility. We'll cover what goes into creating your alarm management program, why these programs matter, and more, along with plenty of anecdotes that will be sure to make you chuckle. If you're looking for some tips from a seasoned alarm management professional and want to know how operators can become "alarm champions" then this is the episode for you.


Looking for more resources regarding alarm management programs? Curt recommends the following:

Book: The Alarm Management Handbook - Second Edition: A Comprehensive Guide (buy it here on Amazon:
https://www.amazon.com/Alarm-Management-Handbook-Second-Comprehensive-ebook/dp/B00GR8HBS8) Book: EEMUA Publication 191 Alarm systems - A guide to design, management and procurement (buy a digital/PDF version here: https://www.eemua.org/Products/Publications/Digital/EEMUA-Publication-191.aspx) Book: Effective Alarm Management Practices (ASM Consortium Guidelines) (buy it here on Amazon: https://www.amazon.com/Effective-Management-Practices-Consortium-Guidelines/dp/1442184256)  Standard: ANSI/ISA-18.2-2016, Management of Alarm Systems for the Process Industries Standard: 49 CFR 195.446, Pipeline and Hazardous Materials Safety Administration (PHMSA), Control Room Management for Hazardous Liquids (See paragraph e for alarm management) Standard: 49 CFR 192.631, PHMSA Control Room Management for Gas (See paragraph e for alarm management) Standard: API RP 1167, Pipeline SCADA Alarm Management, API's version of alarm management written to support the PHMSA regulation Article: Understanding and Applying the ANSI/ ISA 18.2 Alarm Management Standard from ISA's InTech magazine (download as PDF here: https://www.isa.org/standards-and-publications/isa-publications/intech-magazine/white-papers/pas-understanding-and-applying-ansi-isa-18-2-alarm-management-standard/

(Note: No links above are affiliate links, and we do not receive commission for any purchases made.)

May 01, 202053:57
Episode 21 - ISA 84 & IEC 61511-1 with Guest Curt Snyder

Episode 21 - ISA 84 & IEC 61511-1 with Guest Curt Snyder

In this episode, we welcome guest Curt Snyder, a certified functional safety expert. Wesley and Curt discuss ISA 84,  RAGAGEP prescribed by CCPS for the mechanical integrity element of SIS, while also referring to IEC 61511-1, which is a nearly identical standard. In this jam-packed, highly technical episode, you'll learn why these standards exist, their objectives, and then we'll provide a high-level walk-through of the SIS life cycle for a greenfield capital project. 

Find the article Curt recommends in this episode here: https://www.isa.org/standards-and-publications/isa-publications/intech-magazine/2012/june/cover-story-understanding-isa-84/

Apr 17, 202050:39
Episode 20 - Why "Boots on the Ground" are Vital to your Process Safety Program

Episode 20 - Why "Boots on the Ground" are Vital to your Process Safety Program

Operators, maintenance technicians, and I&E technicians - those we deem "boots on the ground" - are vital to the success of your process safety program. In this episode, Wesley and Rob discuss the key roles these individuals play when it comes to Process Hazard Analyses (PHAs), operating procedures, operator training, incident investigation, near miss reporting, compliance audits, Management of Change (MOC), and more. Whether you're at the corporate or management level looking to add value to your process safety program, or a "boots on the ground" individual who wants to get more involved and become a champion of process safety, this is the episode for you. 

Mar 27, 202022:12
Episode 19 - PHAs During the Project Life Cycle

Episode 19 - PHAs During the Project Life Cycle

Construction projects big and small are bound to happen at your facility. What if you have a long construction phase after your initial PHA? What if you don't have your arms around all the modifications that have been made during the project? How can you and your PHA team prep before a big project starts? What can go wrong if you wait until the end of a project to do a PHA? In this episode, Wesley and Rob discuss these topics and more to ensure you're adequately prepared to handle PHAs during the project life cycle.
Mar 13, 202015:26
Episode 18 - PSM Management Systems

Episode 18 - PSM Management Systems

In this episode, Wesley and Rob talk about PSM management systems. They'll compare paper and electronic systems, and cover what factors you should consider when choosing a management system for your MOCs, action item tracking, and more. If you're starting a PSM program from scratch or you're looking to overhaul your current program, this is the episode for you. 

Feb 28, 202020:23
Episode 17 - Tips for a Successful PHA

Episode 17 - Tips for a Successful PHA

In this episode, Wesley and Rob present some guidelines for a successful Process Hazard Analysis (PHA) based on their years of experience as PHA participants and facilitators. They'll cover tips related to prep, study sessions, and more, ensuring you're ready for your next PHA. 

Feb 14, 202029:01
Episode 16 - Combustible Dusts & DHAs

Episode 16 - Combustible Dusts & DHAs

In this episode, Wesley and Rob talk combustible dusts - what they are, why they're hazardous, and which NFPA standards apply to them. They'll also talk about a major event related to combustible dusts, and about upcoming requirements involving Dust Hazard Analyses (DHAs).

To view the CSB video mentioned in today's episode, please visit https://www.csb.gov/imperial-sugar-company-dust-explosion-and-fire/.

Jan 31, 202027:14
Episode 15 - Major Events in 2019

Episode 15 - Major Events in 2019

In this episode, Wesley and Rob cover a few major events that happened in industry in 2019, and update you on the latest ruling regarding RMP regulation changes. 

To learn more about these major events and others currently under investigation, visit the U.S. Chemical Safety Board's website at csb.gov.

Jan 18, 202026:23
Episode 14 - Weak Signals

Episode 14 - Weak Signals

In this episode, Wesley and Rob talk about how the people who know the process best, such as operators, maintenance technicians, and I&E technicians, can use weak signals, or leading indicators, to help prevent process safety events. They'll define what weak signals are, share some personal experiences, and shed light on what you can do when you discover something that doesn't seem right at your facility.

Jan 03, 202023:31
Episode 13 - Incident Investigation Framework

Episode 13 - Incident Investigation Framework

In this episode, Wesley and Rob discuss the basic elements of an incident investigation, while also addressing how blame and investigation findings should be handled. 

Dec 06, 201924:16
Episode 12 - Risk Matrices

Episode 12 - Risk Matrices

In this episode, Wesley and Rob present a crash course on risk matrices. They'll cover what a risk matrix is, its role in Process Hazard Analyses (PHAs), limitations to consider regarding matrix size, and more. If you're new to PSM, this is the episode for you. 

Nov 23, 201922:48
Episode 11 - Interview with Dr. Jim Holste at the Mary Kay O'Connor Process Safety Center, Texas A&M University

Episode 11 - Interview with Dr. Jim Holste at the Mary Kay O'Connor Process Safety Center, Texas A&M University

In this very special episode, Wesley returns to his alma mater to sit down with Dr. Jim Holste, interim director of the Mary Kay O'Connor Process Safety Center at Texas A&M University in College Station, Texas, during this year's International Symposium. Dr. Holste talks about the center's formation and mission, its satellite campuses and ties to industry, and the various degrees and certificates offered through the center. 

If you'd like to learn more about the Mary Kay O'Connor Process Safety Center, please visit http://psc.tamu.edu or contact the center at mkopsc@tamu.edu. 

Nov 08, 201927:51
Episode 10 - Facility Siting - Part 2

Episode 10 - Facility Siting - Part 2

In part 1 we covered some background and consensus standards regarding facility siting. In this episode, part 2, Wesley and Rob will break down the whole facility siting process from start to finish. First, they'll cover two different approaches to a facility siting study and they'll compare a consequence based approach with a quantitative risk assessment (QRA) approach. Then they'll discuss what other information is important for your study, including what release scenarios to incorporate, defining your maximum credible events (MCEs), and identifying the scope of the study. Finally, you'll learn about what to expect in your report, the importance of requesting a closing meeting, and how the study can inform various aspects of your PSM program in addition to its primary goal of saving lives. 

To learn more, check out this book from CCPS: https://www.aiche.org/ccps/resources/publications/books/guidelines-evaluating-process-plant-buildings-external-explosions-fires-and-toxic-releases-2nd

API 752: https://www.api.org/oil-and-natural-gas/health-and-safety/refinery-and-plant-safety/process-safety/process-safety-standards/rp-752

API 753: https://www.api.org/oil-and-natural-gas/health-and-safety/refinery-and-plant-safety/process-safety/process-safety-standards/rp-753

API 756: https://www.api.org/~/media/files/publications/whats%20new/756_e1%20pa.pdf


Oct 25, 201929:41
Episode 9 - Facility Siting - Part 1
Oct 11, 201919:43
Episode 8 - RMP Regulatory Changes
Sep 27, 201924:20
Episode 7 - API 510 with Guest William McBride
Sep 13, 201923:36
Episode 6 - PSM & RMP Applicability
Sep 03, 201920:38
Episode 5 - MOC & PSSR
Aug 19, 201922:15
Episode 4 - Government Inspections
Aug 02, 201924:13
Episode 3 - Why Do We Have PSM & RMP?
Jul 12, 201914:31
Episode 2 - Intro to PHAs
Jun 26, 201925:14
Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP
Jun 26, 201922:29
Episode 0 - Amplify Your Process Safety Introduction
Jun 25, 201917:38