Chemical Processing recently hosted a webinar on the importance of process safety during transient operations. Normal operations include continuous and batch processes, while abnormal situations involve plant upsets or deviations from typical parameters. Loss of control can lead to unscheduled shutdowns, and emergency situations may require immediate action. For all scenarios, proper instrumentation, risk assessment and decision-making are critical.   Trish Kerin, director of the IChemE...

Welcome to the In Case You Missed It edition of Process Safety with Trish and Traci -- the podcast that aims to share insights from past incidents to help avoid future events. I’m Traci Purdum, EIC of Chemical Processing. Please subscribe to this free podcast on your favorite platform to continue learning with Trish & me in this series. This In Case You Missed It episode brings the written word to life. Today, Trish Kerin, the director of IChemE Safety Centre, and Stay Safe columnist for...

On the 35th anniversary of the deadly event we examine how routine maintenance can go horribly wrong.

Welcome to the In Case You Missed It edition of Process Safety with Trish and Traci -- the podcast that aims to share insights from past incidents to help avoid future events. I’m Traci Purdum, EIC of Chemical Processing. This In Case You Missed It episode brings the written word to life. Today, I will be reading a column by our editor at large Sean Ottewell “Safety Lessons from the Great Molasses Flood of 1919” -- Discover the catastrophic events of the Great Molasses Flood, where...

In this episode of Process Safety with Trish and Traci we interview Fiona Erskine, an engineer and crime novelist who has a passion for process safety. Fiona discusses balancing her engineering career with writing and how she uses her novels to educate readers about process safety and engineering concepts. Her Dr. Jaq Silver series combines thrilling plots with accurate technical details, making complex topics accessible to non-experts.

Our tendency to underestimate the likelihood of rare occurrences can lead us to dismiss the possibility of process safety incidents. This In Case You Missed It episode brings the written word to life. Today, Trish Kerin, the director of IChemE Safety Centre and Stay Safe columnist for Chemical Processing, will read her column “It’s Not Impossible That It’s Possible” Written By: Trish Kerin Read By: Trish Kerin  Read Article HERE 

The standard's industry-agnostic approach, its potential to influence global PSM practices and its role in setting benchmarks for organizations not covered by traditional legislation will impact safety practices worldwide. In this episode, Trish & Traci discuss the Canadian Process Safety Management (PSM) standard CSA Z767, the world's first national PSM standard. Adrian Pierorazio and Parnian Jadidian — part of the team that crafted the standard — explain its development, starting as a...

The plant floor at the West Pharmaceuticals facility in Kingston, N.C., was kept spotless to meet hygiene requirements. However, combustible polyethylene dust accumulated in the suspended ceiling. This led to a dust explosion on January 29, 2003, that killed six workers, injured 38, and destroyed the plant. The U.S. Chemical Safety and Hazard Investigation Board (CSB) couldn’t identify the ignition source. As I noted in a previous column, the CSB blames dust explosions for numerous fatalities...

Control system failures, alarm floods, maintenance issues and emergency response factored into this non-deadly incident.

In this guest podcast episode from our sister publication Processing, Senior Editor Nate Todd interviews Chris Cloney of Dust Safety Science. In this episode, we discover that awareness of dust hazards varies globally, often spiking after major incidents but waning over time. The company tracks dust-related incidents annually, noting significant events like the 2023 grain silo explosion in Brazil. Common hazards involve grain, wood and metal dusts, with equipment like dust collectors and...

The U.S. Chemical Safety Board identified five issues with the 2019 Philadelphia Energy Solutions Refinery fire and explosion: mechanical integrity, outdated equipment, lack of remote emergency isolation valves, safeguard reliability and the need for inherently safer design. https://www.chemicalprocessing.com/podcast/process-safety-with-trish-and-traci

Understanding the two kinds of change, deliberate and creeping, will aid you in keeping your facility a safe place to work. As we look back 50 years, we can see both deliberate and creeping change played significant roles in the catastrophic explosion and fire that tore through the Nypro plant in Flixborough, U.K., resulting in the tragic loss of 28 lives and leaving 89 others injured.

The Flixborough disaster in 1974 resulted in 28 fatalities and significant damage, leading to the introduction of management of change processes, improved asset integrity practices, emphasis on competency management, and enhanced control room safety measures. This landmark incident highlighted the importance of multidisciplinary collaboration and continues to serve as a lesson in process safety.

Time is critical when tracking down hazardous substances. Whether it’s trying to mitigate safety incidents before they happen or being able to tap all the pertinent information during an emergency involving a chemical spill, fire or natural disaster, having an efficient way to trace every ingredient is paramount. This crossover episode first appeared in our Distilled podcast series. 

In this episode, Trish & Traci interview Stephen J. Wallace, a former investigator with the U.S. Chemical Safety Board and author of the book "Hazardous Lies." Wallace offers insights into the world of process safety investigations and the motivation behind his fictional thriller. Wallace draws from his real-life experiences to craft a realistic portrayal of the challenges faced by investigators, including companies' attempts to hide the truth, ethical dilemmas and the courage required to...

The incident at Formosa Plastics in 2004 highlighted critical lessons in process safety. Human factors, communication gaps and inadequate equipment played significant roles in the death of five workers.

This In Case You Missed It episode of Process Safety with Trish & Traci brings the written word to life. Today, I will be reading an excerpt from a column written a few years ago by John Bresland, president of Process Safety Risk Assessment LLC and former chair of the United States Chemical Safety Board. The column  “10 Rules To Succeed at Process Safety Management." Written by: John Bresland Read by: Traci Purdum URL:...

It's crucial to operate within our professional boundaries and effectively mitigate risks when operating beyond them. In this In Case You Missed It episode, Trish Kerin, director of the IChemE Safety Centre, reads her most recent column: Embrace Challenges, Recognize Limits, Manage Risks

In this episode, we offer 7 steps for better cybersecurity. If you are a process control engineer, an IT professional in a company with an automation division, or a business manager responsible for safety or security, you may be wondering how your organization can get moving on more robust cybersecurity practices. View the transcript for links to all the materials mentioned in this...

Boeing was known for its engineering excellence until a focus on profitability took over. Properly documenting management of change and recognizing weak signals could have prevented tragedy. In this episode of Process Safety with Trish & Traci, we discuss the aviation industry's Boeing 737 MAX crisis and how it revealed critical management failures, emphasizing the importance of rigorous management of change, prioritizing safety over profitability and identifying weak signals. The mishaps...

A hazard and operability study (HAZOP) mostly is a safety design check, not a design development review. Making and finalizing major design choices should occur long before a HAZOP. In this In Case You Missed It Episode, Traci Purdum reads a column from Plant InSites columnist Andrew Sloley.   Written By: Andrew SloleyRead By: Traci Purdum Read Article: https://www.chemicalprocessing.com/voices/plant-insites/article/21437737/use-hazops-properly

In today's episode, Trish and Traci discuss inherently safer design principles, emphasizing proactive safety measures. Trish shares examples, such as separating hazardous substances from work areas and minimizing potential risks through thoughtful design choices. They highlight challenges like maintaining design integrity throughout project phases and stress the importance of documenting safety rationale for future reference. The discussion extends to the intersection of inherently safer...

Daily experiences vary, but key events hold lessons. Reflection is vital for learning and shaping success.   Written By: Trish Kerin Read By: Trish Kerin  Read Article HERE https://www.chemicalprocessing.com/voices/stay-safe/article/33018718/the-difference-between-experiences-and-learning-in-process-safety

In their podcast, Trish and Traci discuss the importance of commemorating anniversaries of incidents, emphasizing the need to learn from the past. Trish highlights two reasons for reflection: learning from past events to prevent recurrence and honoring those who lost their lives. They delve into various historical incidents, such as the IChemE Safety Centre's 10th anniversary, the LNG explosion in Algeria, the Boston molasses spill, the flour dust explosion in Germany, the Valdez oil spill,...