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

In this episode, Rob and Molly discuss the PSM requirements for initial operator training. They cover all of the requirements for content to cover in training, as well as their additional content suggestions, and talk about the different methodologies that can be used to perform verification and documentation of training. Stay tuned for Part 2 in which Rob and Molly discuss refresher training for existing operators and other miscellaneous training topics. If you haven't already, be sure to also check out Episode 31 -Effective Operator Training. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Rob and Jo discuss the CSB's investigation report on the 2020 toxic gas release and chemical fire at Bio-Lab Facility in Westlake, Louisiana. On August 27, 2020, strong winds from Hurricane Laura damaged buildings at the facility, causing rainwater to come into contact with the trichloroisocyanuric acid (TCCA) that was stored inside. A chemical reaction began, and the TCCA began to decompose, releasing heat that started a fire, while also releasing a large amount of hazardous gases that traveled offsite. Today, Rob and Jo provide some background about this Bio-Lab facility, discuss the events surrounding the incident, and cover the consequences of the incident. Then they discuss the CSB's five identified safety issues that contributed to the event, what types of companies might be at risk for similar events, and how any facility can prevent an incident like this one. Find the CSB's final report ⁠here. Listen to the other episodes we mentioned today at the links below: Episode 26 - Natural Hazard Assessment and Planning Episode 52 - EPA's General Duty Clause with Guest Mathew Todaro Episode 56 - Implementing EPA's General Duty Clause (GDC) Episode 66 - Tornadoes, Natural Hazards, and Emergency Planning --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Molly is joined by our show's very first podcast guest, William McBride, who first joined us all the way back in Episode 7. Today, Will and Molly discuss the types of inspections that are required for process vessels and tanks. They'll cover what's involved in inspecting ASME pressure vessels and atmospheric storage tanks, and how equipment that doesn't fit ASME VIII or API 2000 is handled when it comes to inspections, including open-top mixing vessels, "equipment" fabricated from piping components, and vessels fabricated to ASME code but not stamped. They also touch on best practices related to MI at sites that are non-PSM covered. You can reach out to Will McBride directly at (903) 374-5806 or at wmcbride@xcelgrp.com. Be sure to check out Will's first appearance on our show, and our other MI-related episodes at the links below. Episode 1 - Intro to Mechanical Integrity (MI) & RAGAGEP Episode 7 - API 510 with Guest William McBride PSM: Back to Basics, Part 6 - Mechanical Integrity (MI) --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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

In this episode, Rob and Molly discuss the CSB's investigation report on the 2019 popcorn polymer accumulation, pipe rupture, explosions, and fires at the TPC Group (TPC) Port Neches Operations (PNO) facility in Port Neches, Texas. On November 27, 2019, a pump that had been taken out of service for 114 days created a deadleg where butadiene polymer developed. The polymer filled the pipe and developed enough pressure to rupture the piping, releasing flammable butadiene which then ignited, resulting in explosions and fires. The fires burned for over 1 month and 2 employees, 1 contractor, and 5 members of the public reported injuries. Additionally, a mandatory evacuation order was issued for a 4-mile radius, affecting people in 4 nearby towns. The incident resulted in significant property damage both on-site and off-site, and TPC filed for bankruptcy in 2022. Today, Rob and Molly provide some background details about TPC, explain what a deadleg is and talk about how they should be managed in Butadiene facilities, discuss how TPC's PHA considered the potential for this hazard, touch on remotely operated isolation valves, and point to relevant RAGAGEP that provide guidance regarding this hazardous butadiene polymer formation. They also discuss contributing factors, what types of companies could be at risk from incidents like these, and what any type of facility could learn from this accident. Find the CSB's final report here, and be sure to check out our other Incident Breakdown episodes where we cover additional CSB final reports.  Update: On July 19, 2023, the CSB released a safety video on this incident. --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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

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

In today's episode, Rob is joined by Peter Hereña, who currently serves as the process safety manager at CF Industries. Rob and Peter start their discussion by defining what process safety culture is, and what a good process safety culture looks like. Then Peter shares how his company organized a process safety week last October, and all of the components, planning, and branding that went into the event. Peter ends the episode by offering his advice to others who might also want to try a process safety week in an effort to reinforce a healthy process safety culture at their own companies.  For additional questions about his process safety week event, or to talk process safety culture further, please connect with Peter on LinkedIn here.   --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Rob and Jo discuss the CSB's investigation report on the 2019 explosion and fire at AB Specialty Silicones in Waukegan, Illinois. On May 3, 2019, operators were performing a batch operation when two incompatible chemicals were added to the same tank, which produced hydrogen gas, and eventually led to a massive explosion and fire that killed four employees. The CSB released its final report on the incident on 9/24/2021 and then an incompatible chemicals video about the incident on 4/28/2022. Today, we provide some background details, delve more into what happened, and cover what safety issues at the facility likely contributed to the event. We'll also cover the types of industries and facilities that could be at risk for incidents like this one, and share nine key learnings from this tragic event.  Find the CSB's final report here.  Find the CSB's video on the incident, Incompatible Chemicals: Explosion at AB Specialty Silicones, here.  And as always, please contact us with any questions or comments at podcast@amplifyconsultants.com.  --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

In this episode, Rob and Molly are joined by previous podcast guest, Tim Murphy, to discuss the 2019 fire and explosions at Philadelphia Energy Solutions (PES). In a previous role many years ago, Tim served as a process safety coordinator for the refinery, and although he was not employed there later when the incident occurred, he is able to provide additional context surrounding the incident due to this former role. In this episode, you'll learn a brief history of the facility, hear what happened on June 21, 2019 and why, and learn about the hazards associated with the refinery. You'll also hear the group's thoughts on a few of the US Chemical Safety board's findings, and the key lessons that other facilities in the process industry can take away from this incident.  Find the CSB's final investigation report and video here. Listen to Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy here.  Find other episodes where we delve into CSB investigation reports by typing "incident breakdown" into the search bar on our website at www.amplifyconsultants.com/podcast.  --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message

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: CSB Report CSB Hot Work Safety Bulletin --- Send in a voice message: https://podcasters.spotify.com/pod/show/amplifyyourprocesssafety/message