Process Safety with Trish & Traci

Hosted by chemicalprocessingsafety

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Episodes

122

Latest episode

May 2026

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About the show

The Process Safety with Trish & Traci podcast shares insights from recent process-safety incidents to avoid accidents at chemical processing plants.

Listen to episodes

60 recent

June 16, 2026Episode 12425 min

GKN Aerospace Incident Offers Lessons in Reactive Hazard Management

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.

May 26, 2026Episode 1235 min

Process Safety: Meet Me Under the Clocks

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.

May 12, 2026Episode 12223 min

11 Fires, 60 Days: What's Really Behind the 2026 Refinery Crisis

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.

April 21, 2026Episode 12128 min

Leading Safely in a VUCA World

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.

April 7, 2026Episode 1203 min

When Level Nozzle Placement and Operator Behavior Collide

When operators inevitably push levels to their limits, a poorly placed vapor inlet nozzle can turn a routine excursion into a tower-wrecking event.

March 24, 2026Episode 1195 min

Could vs. Should: What 'Jurassic Park' Can Teach Us About Process Safety

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.

March 10, 2026Episode 11829 min

When Nature Attacks: Preparing Chemical Facilities for NATECH Events

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.

February 24, 2026Episode 1177 min

Human Factors Engineering: Designing Systems Around Our Limitations

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

February 10, 2026Episode 11624 min

Revalidating Process Hazard Analysis: Getting Real Value

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.

January 27, 2026Episode 1155 min

Calculate Risk to Capture Reward

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.