Amplify Your Process Safety

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 [email protected].

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.

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.

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

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 [email protected].

Be sure to check out Will's first appearance on our show, and our other MI-related episodes at the links below.

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!

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.

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 [email protected] or you can connect with Chris Paskach directly on LinkedIn here. 

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. 

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.