Amplify Your Process Safety

In this episode of Amplify Your Process Safety, Rob and Magi wrap up the year by summarizing changes made to the RAGEGAP guidelines in 2025 and discussing some of the biggest incidents featured in our podcast this year. Stay tuned through the end of episode to hear Rob get up on his infamous soap box, something our clients know well, to deliver his speech on why process safety is so important!

As we reflect on the year, it is important to remember the lives lost to process safety incidents in 2025. May they rest in peace, and may their memories always be a reminder of how much more work needs to be done to ensure that everybody gets to go home to their families at the end of the day. If you think your company could use our assistance in process safety management, please do not hesitate to reach out.

For a deeper dive into some of the incidents discussed in this episode, check out the episodes below:

Episode 122 - Incident Breakdown: 2023 Heater Fire at Marathon Martinez Renewables Facility

Episode 128 - Incident Breakdown: Honeywell Geismar, LA Incidents

Episode 129 - Incident Breakdown: Explosion, Molten Salt Eruption, and Fatal Injury at TS USA Liquid Nitriding Facility

For more about the 2024 updates to the EPA RMP, check out:

Episode 108 - 2024 EPA RMP Updates

In this episode, Rob and Magi dive into batch operations and the unique complexities they pose when compared to continuous processes. They discuss following guidelines from the book Guidelines for Process Safety in Batch Reaction Systems, written in 1999, and other safeguards that can be added when dealing with batch processes. Tune in to find out more!

Interested in learning more about Batch Systems? Order Guidelines for Process Safety in Batch Reaction Systems here!

In this episode, Rob is joined by Tim Murphy, the Manager of the Corporate Process Safety Department at one of our longtime clients, Arkema. Rob and Tim discuss Cornerstones of Process Safety, a Process Safety training workshop that Amplify partnered with Arkema to create and bring to their engineers annually. Tune in to hear about the advantages the Cornerstones of Process Safety training brings to Arkema engineers all over the country, and how to implement a similar training at your company!

To connect with Tim, email him at [email protected].

For more episodes featuring Tim, check out:

Episode 41 - Managing Process Safety from Afar with Guest Tim Murphy

Episode 68 - Incident Breakdown: 2019 Refinery Fire and Explosions at Philadelphia Energy Solutions (PES) with Guest Tim Murphy

Episode 107 - Communicating Process Safety in a Matrix Organization with Guest Tim Murphy

In this episode, Jackson and Magi discuss some of the incidents in the CSB's most recent volume of the Accidental Release Reporting Rule, or AR3 as we like to call it. This episode is all about the importance of pressure relief systems and thorough hazard evaluations to ensure the safety of workers. Tune in to find out more!

For more about the CSB's AR3, read volume one here, volume two here, and volume 3 here, and be sure to check out the other episodes in our AR3 miniseries:

Episode 121 - ARRR Summaries & Trends

Episode 125 - AR3 Volume Two.

Episode 127 - CSB AR3 Breakdown - Preventing Incidents with Proper Lockout/Tagout (LOTO)

Episode 130 - CSB AR3 Breakdown: Preventing Injury with Proper PPE

Episode 131 - CSB AR3 Breakdown: Human Error and Incompatible Chemicals

Episode 132 - AR3 Volume Three

In this episode, Rob and Jackson discuss the findings of the CSB report regarding an ammonia release incident at Cuisine Solutions in Sterling, Virginia. They delve into the details of the incident, the safety highlights from the report, and the recommendations made by the CSB to improve safety protocols. This episode highlights the importance of emergency preparedness, effective communication, and the need for robust safety systems in facilities handling hazardous materials. And as always, if Amplify can help your organization address these issues, please don't hesitate to reach out!

Tune in to find out more and read the CSB's full report here!

For more CSB final report breakdowns, check out the episodes below:Episode 129 - Incident Breakdown: Explosion, Molten Salt Eruption, and Fatal Injury at TS USA Liquid Nitriding Facility

Episode 128 - Incident Breakdown: Honeywell Geismer, LA Incidents

Episode 122 - Incident Breakdown: 2023 Fire Heater Fire at Marathon Martinez Renewables Facility

⁠Episode 105 - Incident Breakdown: 2022 Fatal Naphtha Release and Fire at BP-Husky Toledo Refinery in Ohio⁠

In this episode, Rob is joined by Bruno de Kort, a Chemical Process Engineer and technical leader at Arkema. They discuss the importance of process safety in process design, and walk through the steps of designing a process with process safety as the top priority. Tune in to find out more!

To connect with Bruno, find him on LinkedIn here!

In this episode, Rob is joined by Gilsa Monteiro to discuss Brazil's Human Reliability Analysis (HRA) and the advantages the guidelines bring to the process safety industry. Gilsa is a process safety expert based in Brazil with both a Masters and a PhD in Nuclear Engineering. Tune in to hear all about how the HRA helps to prevent incidents!To connect with Gilsa, find her on LinkedIn here, or email her at [email protected]

Read more about the Petro-HRA project here, and find the Petro HRA Guidelines here (volume 1) and here (volume 2).

For more information about incidents cause by human factors, check out these videos:

Human Factors in Five MinutesExplosion at Formosa Plastics - IllinoisMixed Connection - Toxic Result

And finally, click the link below to listen to Gilsa's other podcast episode:Episode 60 - How Organizational Structure Impacts Process Safety with Guest Gilsa Monteiro

In this episode, Magi and Jackson discuss several incidents documented in the Chemical Safety Board's third volume of the Accidental Release Reporting Rule, or AR3 as we like to call it. This episode is focused on the importance of process safety training, hazard analysis, and proper procedures during startup and shutdown.

Stay tuned through the end of the episode for an important message about the CSB!

For more about the CSB's ARRR, or AR3 as we like to call it, read volume one here, volume two here, and volume three here, and be sure to check out the other episodes in our AR3 miniseries:

Episode 121 - ARRR Summaries & Trends

Episode 125 - AR3 Volume Two

Episode 127 - CSB AR3 Breakdown - Preventing Incidents with Proper Lockout/Tagout (LOTO)

Episode 130 - CSB AR3 Breakdown - Preventing Injury with Proper PPE

Episode 131 - CSB AR3 Breakdown: Human Error and Incompatible Chemicals

In this episode, Jackson and Magi continue their miniseries on the CSB's Accidental Release Reporting Rule (AR3). They break down incidents that highlight the critical importance of identifying incompatible mixtures in chemical processes, including incidents at Domtar Paper Company, Darling Ingredients, and Tronx. This episode is about the consequences of human error and the need for rigorous safety measures.

Stay tuned through the end of the episode for an important message about the CSB!

For more about the CSB's ARRR, or AR3 as we like to call it, read volume one here and volume two here, and be sure to check out the other episodes in our AR3 miniseries:

Episode 121 - ARRR Summaries & Trends

Episode 125 - AR3 Volume Two

Episode 127 - CSB AR3 Breakdown - Preventing Incidents with Proper Lockout/Tagout (LOTO)

Episode 130 - CSB AR3 Breakdown - Preventing Injury with Proper PPE

For the CCPS Chemical Reactivity Worksheet, visit https://www.aiche.org/ccps/resources/chemical-reactivity-worksheet

In this episode, Jackson and Magi continue their miniseries on the CSB's Accidental Release Reporting Rule (AR3). They discuss incidents where the release of hydrogen cyanide, chlorine gas, and other toxic gasses lead to injuries, and even fatalities, that could have been prevented by use of proper personal protective equipment (PPE). This episode is all about the importance of proper training, risk awareness, and adherence to safety protocol.

Stay tuned through the end of the episode for an important message about the CSB!

For more about the CSB's ARRR, or AR3 as we like to call it, read volume one here and volume two here, and be sure to check out the other episodes in our AR3 miniseries:

Episode 121 - ARRR Summaries & Trends

Episode 125 - AR3 Volume Two.

Episode 127 CSB AR3 Breakdown - Preventing Incidents with Proper Lockout/Tagout (LOTO)