Process Safety with Trish & Traci

Epizode

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  Disaster Planning in Process Plants: Best Offense is a Passive Defense 11.08.2026 8min

  Smart design and layout choices, made well before a crisis hits, can protect plants from cyberattacks, sabotage and extreme weather without a major capital investment. This is based on an article from Amin Almasi, "Disaster Planning in Process Plants: Best Offense is a Passive Defense," Chemical Processing, July 20, 2026
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  Four Alarms in Three Weeks: A Safety Professional's Hotel Wake-Up Call 28.07.2026 5min

  From an 3 a.m. evacuation drill to a real fire alarm in Toronto, repeated emergencies reveal how — and how poorly — we prepare when we're away from home. Hear why Trish could be the Jessica Fletcher of the process safety world.
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  Who's Taking Care of the Safety Pro? 14.07.2026 43min

  On this episode of Processing Safety with Trish and Traci, General Atomics safety engineer Valerie Stakes returns to discuss well-being in the safety profession, building on her 2026 ASSP conference session. She, Trish Kerin and Traci Purdum explore why safety professionals — often wired to please and fix — struggle to set boundaries and how compassion fatigue, unappreciated efforts and repeated exposure to injuries and fatalities take a cumulative toll. They share personal stories of burnout, offer tips on debriefing, networking and using employee assistance programs and close with a guided breathing exercise. The episode also answers a listener’s question on the role of training in operations and emergency response.
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  When Alarms Stop Warning and Start Failing 30.06.2026 6min

  Decades of guidance on alarm management exist. So why are control rooms still drowning in noise?
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  GKN Aerospace Incident Offers Lessons in Reactive Hazard Management 16.06.2026 25min

  Trish Kerin breaks down the runaway reaction that triggered a mass evacuation in Orange County, California, and explains what facilities handling reactive chemicals can learn about instrumentation, warning signs and emergency communication. Editor's Note: We mention an upcoming webinar that Trish will be hosting: a webinar focused on leadership in uncertain times — looking at key strategies and tools we can use to navigate some of the challenges we're all facing globally right now. Use the code CPREADER for $5 off.
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  Process Safety: Meet Me Under the Clocks 26.05.2026 5min

  The analog timepieces at Melbourne's Flinders Street Station offer a timeless lesson: sometimes the simplest solution is the most elegant — and the most reliable. 
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  11 Fires, 60 Days: What's Really Behind the 2026 Refinery Crisis 12.05.2026 23min

  Eleven refinery and fuel facility fires across four continents in roughly 60 days — that's the alarming backdrop for this episode of Process Safety with Trish and Traci. Process safety expert Trish Kerin examines whether the 2026 incidents are a statistical anomaly or a symptom of deeper systemic pressure. She points to deferred maintenance, narrowing margins and the normalization of risk during periods of production stress as key contributing factors. Kerin also addresses the unique vulnerabilities of new facilities and aging infrastructure. Her bottom line: know your controls, check that they're working and talk to your people. Stick around for the bonus material at the end.
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  Leading Safely in a VUCA World 21.04.2026 28min

  When economic pressures mount, safety vigilance can quietly erode — and that's when incidents happen. In this episode, process safety expert Trish Kerin introduces APTBED, a practical decision-making framework for navigating volatile, uncertain, complex and ambiguous times. The acronym covers six critical areas: Authority (know who's in charge), Psychological Safety (create space for honest information), Tacit and Explicit Knowledge (bring all knowledge into the room), Biases (recognize and manage cognitive blind spots), Expectations (manage them or people will fill the void), and Document Decisions (if it's not written down, it never happened). Good decisions and strong safety culture aren't mutually exclusive — even in a crisis.
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  When Level Nozzle Placement and Operator Behavior Collide 07.04.2026 3min

  When operators inevitably push levels to their limits, a poorly placed vapor inlet nozzle can turn a routine excursion into a tower-wrecking event.
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  Could vs. Should: What 'Jurassic Park' Can Teach Us About Process Safety 24.03.2026 5min

  In this episode, Stay Safe Columnist Trish Kerin reads her latest article for Chemical Processing. She's a proud GenXer, and she points out that a line from Dr. Ian Malcolm cuts to the heart of a critical distinction in process safety — the difference between what we are allowed to do and what we ought to do. You can read the column here.
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  When Nature Attacks: Preparing Chemical Facilities for NATECH Events 10.03.2026 29min

  When natural disasters strike industrial facilities, the results can be catastrophic — and most companies aren't ready. In this episode of Process Safety with Trish and Traci, Trish Kerin and Traci Purdum explore NATECH events, where natural hazards collide with industrial risk. Drawing on real incidents including Arkema in Crosby, Texas, BioLab in Lake Charles and the Fukushima disaster, they examine why facilities consistently underestimate natural hazard risk, how to build truly complete ride-out and recovery plans, and why traditional PHAs fall short for NATECH scenarios. Kerin's bottom line: assume the event will happen, and prepare accordingly.
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  Human Factors Engineering: Designing Systems Around Our Limitations 24.02.2026 7min

  Chernobyl, Bhopal, Three Mile Island, Deepwater Horizon, Texas City — What do they have in common? Human error or human factors were identified as contributing to the incidents. But what are these factors? Understanding how people actually perceive, decide and act is essential to preventing catastrophic industrial accidents and everyday errors. This In Case You Missed It episode brings the written word to life from the column:  Human Factors Engineering: Designing Systems Around Our Limitations
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  Revalidating Process Hazard Analysis: Getting Real Value 10.02.2026 24min

  In this episode, Trish Kerin and Traci Purdum explore process hazard analysis revalidations and how to make them more effective. Kerin explains the difference between redoing a PHA and revalidating existing assessments, introducing the Delta HAZOP methodology that focuses on creeping change in facilities. She discusses triggers for revalidation, from legislative requirements to significant operational changes, and emphasizes the importance of selecting the right team and methodology. Kerin highlights how AI and machine learning can help gather data and identify trends, while stressing that human expertise remains essential. The key takeaway: approach revalidations with rigor and discipline, not as tick-box exercises, to truly identify hazards and manage risk effectively.
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  Calculate Risk to Capture Reward 27.01.2026 5min

  Applying risk management principles helps Process Safety Engineer Trish Kerin navigate her first successful year of self-employment. Listen in as Trish brings her January column to life. You can read her column here.
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  Challenger Disaster 40 Years Later: The Deadly Cost of Reversing Safety Burden 13.01.2026 23min

  Engineers couldn't prove danger, so managers launched anyway. Seven astronauts died when O-rings failed in freezing temperatures. Apply the lessons learned to help avoid future incidents.   Three Key Takeaways: Reverse the burden of proof: Require positive proof that something is safe before proceeding, rather than forcing engineers to prove it's unsafe. Simplify safety communication: Complex data failed to convince decision-makers, but a simple demonstration (O-ring in ice water) made the danger crystal clear. Protect technical authority: Engineers need more than just formal authority to stop unsafe operations — they need genuine psychological safety to exercise that power without career consequences.
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  Bird’s-Eye View Prevents Process Safety Groundings 23.12.2025 6min

  This In Case You Missed It episode brings the written word to life. Today, Trish Kerin, the director of Lead Like Kerin, and Stay Safe columnist for Chemical Processing, will read her column "Bird’s-Eye View Prevents Process Safety Groundings," which was published to chemicalprocessing.com on Dec. 17, 2025.
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  Young Engineer Champions Process Safety Via Social Media 09.12.2025 34min

  In this year-end episode, hosts Trish Kerin and Traci Purdum welcome Hayley Little, a U.K.-based process safety engineer who tracks quarterly catastrophic incidents on LinkedIn. The discussion explores origin stories in process safety, the critical gap in fundamental safety knowledge outside petrochemical industries, and the alarming frequency of preventable incidents in lower-hazard sectors. They discuss innovative solutions including AI tools, virtual reality training and social media outreach to democratize process safety education. The conversation emphasizes the urgent need for better university training, field presence over desk work and human factors integration to make it easier to "accidentally get it right."
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  Platypus, Duck or Weak Signal? Process Safety Lessons from Down Under 25.11.2025 22min

  This In Case You Missed It episode brings the written word to life. Today, Trish Kerin, the director of Lead Like Kerin, and Stay Safe columnist for Chemical Processing, will read the first few chapters from her book  “The Platypus Philosophy – how to identify and manage weak signals” This book explores weak signals and focuses on how to identify and manage them to prevent incidents. It uses fun storytelling about the unique platypus as a technique to explain complex concepts and tools.You can purchase this book on Amazon or snag a signed copy from Trish’s website, leadlikekerin.com.
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  Buncefield Explosion: 20 Years Later, Critical Lessons on Tank Storage Safety 11.11.2025 24min

  The Buncefield explosion occurred when a gasoline storage tank overfilled after both its level gauge and independent high-level switch failed. Gasoline vapor formed a massive cloud that ignited, causing significant damage to surrounding business parks. Fortunately, the Sunday morning timing prevented fatalities, though 43 injuries occurred. The incident revealed critical gaps in safety control verification, testing procedures, and maintenance regimes. Twenty years later, the disaster emphasizes the importance of recognizing weak signals, maintaining bund integrity, and ensuring operators actively monitor tank filling operations rather than relying solely on automated systems.
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  Aborted Landing Reveals Critical Lessons in Safety Communication 28.10.2025 5min

  In this episode, Trish Kerin reads her most recent column, which highlights the importance of immediate communication in safety situations, even when complete information isn't yet available to share. You can read the column here.