Amplify Your Process Safety

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.

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.

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.

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.

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.

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.

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.

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.

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.

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. 

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. 

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. 

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. 

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. 

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:

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. 

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. 

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. 

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. 

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. 

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:

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:

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:

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. 

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:

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. 

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. 

Operators, maintenance technicians, and I&E technicians - those we deem "boots on the ground" - are a vital and often untapped resource when it comes to a successful Process Safety Management (PSM) program. In this episode, John and Molly discuss how to set yourself up for successful buy-in and a positive PSM culture with boots on the ground personnel and talk about how experienced operators can be utilized to build, review, and optimize Standard Operating Procedures (SOPs). John and Molly also touch on how operators can assist with field labeling and P&ID updates, delivering relevant and engaging refresher training, and how experienced operators can be involved in the Management of Change (MOC) process, Process Hazard Analyses (PHAs), and in Incident Investigations. Whether you manage "boots on the ground" personnel, or you are one yourself, you'll want to catch this episode to learn more about how this important resource can contribute to overall PSM program success. 

Join us for a recording of another Top 10 Talk event. During this event, Rob Bartlett and John Doan, presented their top ten tips for successful Compliance Audits. A list of the tips that Rob and John elaborate on is presented below.

1. Know the Basics

2. Choose Your Auditor Wisely

3. Understand Compliance Criteria

4. Preparation is Key

5. Prepare Personnel

6. Have an Agenda

7. Documentation is Critical

8. Focus on Improvement

9. Understand the Findings

10. The Final Report is not the Finish Line

Mathew Todaro of Verrill Law joins us for a third time in this episode - this time to talk about EPA's General Duty Clause (GDC). In this episode, Mat, an attorney that specializes in enforcement defense, provides an overview of the objectives of EPA's GDC. But with such broad language and no specific list of covered substances, what are the real requirements for facilities when it comes to this GDC? And with so many similarities between the requirements of PSM/RMP and the GDC, are there even advantages for a facility to keep less than the threshold quantity of a hazardous substance that would require a PSM/RMP program? Mat and Rob cover the answers to these important questions and more in this episode. 

Find the GUIDANCE FOR IMPLEMENTATION OF THE GENERAL DUTY CLAUSE CLEAN AIR ACT SECTION 112(r)(1) here: https://www.epa.gov/sites/default/files/documents/gendutyclause-rpt.pdf 

In our first episode to kick off 2022, Rob and Molly talk Management of Organizational Change (MOOC). Management of Organizational Change is a systematic way to ensure that adherence to process safety policies doesn't suffer when any sort of organizational change takes place that could potentially affect process safety, including but not limited to pandemic effects on staffing and remote work, other personnel changes due to resignations, new hires, or promotions, work stoppage due to union strikes, and more. In this episode you'll learn what MOOCs are, when they should be used, differences and similarities between MOOCs and other Management of Change (MOC) used for process safety compliance, and how organizational changes can act as enabling events for PSM incidents. 

In the second part of our three-episode series covering facilities' process safety journeys, the team is back to share information pertinent to programs that are still "climbing the process safety mountain" - more specifically, those who are about 3-10 years into the development and deployment of their PSM program. In this episode, Rob, Molly, John, and Jo cover the main goals during this phase, including improving compliance and refining your existing programs, and then go on to discuss process safety culture, PSI, operator participation, policy updates, electronic systems, pressure relief audits, emergency response plans, MOC expansion, facility siting, mechanical integrity programs, and much, much more. Don't forget to join us for the last episode in the series, in which we touch on continuous improvement for mature PSM programs. 

Join us for a recording of Amplify's first Top 10 Talk. During this event, Rob Bartlett and Molly Myers, P.E., presented their top ten tips for successful Process Hazard Analyses (PHAs). A list of the tips that Rob and Molly elaborate on is presented below. 

1. Choose your facilitator wisely

2. Documentation in key

3. The method matters

4. Create nodes like Goldilocks

5. Valuable members make a valuable team

6. What risk are you willing to accept?

7. Ask, "what's the worst that could happen?"

8. Approach operator response realistically

9. The final report is not the finish line

10.Don't procrastinate

A Q&A session follows the presentation.