Process Safety with Trish & Traci

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 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.

David Strobar, founder of Bevel Engineering and the Center for Operator Performance, brings human factors engineering expertise. He highlights historic accidents tied to human limitations. Short segments explore perception illusions, cognitive limits like chunking, anthropometry, design-induced errors such as stove controls, and practical design choices to reduce mistakes.

Trish Caron, Director of Lead Like Caron and process-safety expert, discusses making PHA revalidations truly valuable. She covers Delta HAZOP for spotting creeping change. She explains when to redo versus revalidate and who should sit on teams. She outlines choosing methods and using AI to gather trends while keeping human judgment central.

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.

The discussion kicks off with a tense pre-launch meeting where engineers debated safety amid uncertainty. They delve into the tragic Challenger disaster, highlighting the failure of O-rings in freezing temperatures. A crucial takeaway emphasizes reversing the burden of proof, shifting the focus to requiring evidence of safety. They explore how simple demonstrations, like the famous iced-water test, can effectively convey risks. Lastly, the importance of protecting technical authority is stressed, ensuring engineers feel safe to halt unsafe operations.

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.

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."

Trish Kerin, director of Lead Like Kerin and a columnist for Chemical Processing, shares insights from her book, The Platypus Philosophy. She explains how weak signals can predict industrial incidents, challenging the idea of unforeseen events. Using the platypus as a metaphor, she illustrates how partial sightings can reveal hidden hazards. Trish's engaging storytelling highlights the importance of early signal recognition and offers practical tips for applying these concepts in safety practices. Tune in for a unique blend of biology and process safety wisdom!

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.