Amplify Your Process Safety

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 [email protected]. 

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. 

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

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. 

Also be sure to check out Episode 26 - Natural Hazard Assessment and Planning. 

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 CSB's Dangers of Hot Work video here. 

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, send an email to her at [email protected], or reach her by phone at 978-880-2915 (office) or 603-303-7863 (cell).

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.

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 hazard analysis (PHA), relief, vent systems, and device information needed for your mechanical integrity (MI) program, and more. If you have further questions about today's episode, feel free to send us an email at [email protected] or you can connect  with Chris Paskach directly on LinkedIn here.

Also be sure to check out Episode 54 - Pressure Relief Device Concepts with Guest Eric Hirsch and Episode 45 - Piping Requirements for Pressure Relief Devices if you're interested in taking a deeper dive into pressure relief topics.

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 [email protected]. 

And if you haven't already, check out our previous Top 10 Talks here (PHAs), here (Compliance Audits), and here (P&IDs).

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 Deploys Team to Fatal Refinery Incident in Ohio