Process Safety with Trish & Traci

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.

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.

Challenger Disaster 40 Years Later: The Deadly Cost of Reversing Safety Burden

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:

1. Reverse the burden of proof: Require positive proof that something is safe before proceeding, rather than forcing engineers to prove it's unsafe.
2. Simplify safety communication: Complex data failed to convince decision-makers, but a simple demonstration (O-ring in ice water) made the danger crystal clear.
3. 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

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

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

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

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

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

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

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