Process Safety with Trish & Traci

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?

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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."

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.

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.

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.

Henry David Thoreau of Process Safety – Trevor Kletz 14.10.2025 25min

Trevor Kletz revolutionized process safety through HAZOP advocacy, inherent safety principles, learning from accidents, and emphasizing design simplification over complex add-ons. In this episode, Trish & Traci discuss his many contributions to the world of process safety.

Hidden Hazards: 10 Common PHA Oversights 23.09.2025 17min

When OSHA's Process Safety Management (PSM) standard took effect in 1992, it promised a new era of systematic hazard identification. Three decades later, process safety professionals are still witnessing the same critical oversights repeatedly compromising facility safety—oversights that have contributed to near misses, and far worse, major incidents. Editor-in-Chief Traci Purdum reads an article from Felicia Miller, senior principal engineer at ABSG Consulting and Darshankumar Lakhani, senior manager in engineering at ABSG. Original article: https://www.chemicalprocessing.com/safety-security/risk-assessment/article/55311485/hidden-hazards-10-common-pha-oversights

How Equipment Reliability Impacts Process Safety 09.09.2025 32min

This episode explores the critical role of equipment reliability in chemical processing, focusing on three major incidents: Longford, BP Texas City and Buncefield. Trish highlights how faulty instrumentation, poor maintenance and overlooked management of change led to catastrophic failures, fatalities and environmental impacts. The discussion emphasizes safety-critical elements, maintenance KPIs and the importance of accurate instrumentation.