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...

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...

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...

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...

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,...

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,...

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...

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...

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...

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...

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...

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...

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...

On Monday, November 21, 2022, hot work activities at an industrial trading company in China led to a fatal fire when cotton cloth located near the welding activities went up in flames. The fire killed 38, injured 2, and took over 4 hours to extinguish. In this episode, Rob and Molly bring you the latest information about the incident, and offer a reminder about the role that a robust hot work program plays in preventing loss of life.  Read more about the incident here and here.  View the...

In Episode 65, guest Michelle Murphy is back again with Molly - this time to talk about chemical reactivity testing. Molly and Michelle cover the basics of chemical reactivity testing, including who should consider this type of testing, where to start, what can be learned from testing, information about the samples needed, and much, much, more.  Listen to our previous episode with Michelle Murphy, Episode 51 - Combustible Dust Testing with Guest Michelle Murphy, here. To contact Michelle,...

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...

In this episode, Molly is joined by Chris Paskach, who is currently the Flare Master at the Phillips 66 Wood River Refinery in Roxana, Illinois. Although there are only a few short references to relief devices in the PSM standard, the amount of documentation that is required is quite expansive, so Molly and Chris break down the basics for you in this episode. They'll cover the relief system design and design basis information required for PSI, reference information needed to support a process...

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...

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.  CSB...

In this episode, Rob and Molly compare the requirements of combustible dust management systems with the requirements of the PSM standard. They walk through each similar element and then point out the three largest differences between the PSM standard and the NFPA combustible dust standard. Whether your facility is already PSM-covered, or isn't, you'll want to catch this episode if you handle combustible dusts. We also recommend that you check out Episode 16 - Combustible Dusts & DHAs and...

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...

On August 19, 2022, an explosion at a sugar refinery in Andhra Pradesh's Kakinada district took the lives of two workers and injured nine others. In this episode, Rob and Molly bring you the latest information about the incident, and offer a reminder about the role good housekeeping plays in keeping the people who work in facilities that handle combustible dusts safe. For additional information, check out the resources we've gathered below. News Releases: 2 dead, 6 hurt after explosion...

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...

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...

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...