Completed CCPS Projects | AIChE

You are here

Completed CCPS Projects

Completed CCPS Projects are listed below. After clicking on any project, you'll see a link to the book for the completed project. 

Each year the CCPS Technical Steering Committee develops a list of projects, and a Project Subcommittee is established for each approved CCPS project or group of associated projects. Members of the Technical Steering Committee suggest individuals with the appropriate experience and expertise for particular projects.

CCPS Project Subcommittees consist of at least eight professionals from sponsor manufacturers or users of chemicals, with no more than one representative from each company. Click here to view Roles & Responsibilities of CCPS teams.

Note: Only logged-in CCPS members can view project statuses. They may also download the active project list in MS Word format by clicking here (please wait a few seconds for the download to start after clicking this link).

Propose a Project | Volunteer for a Project | Active Projects

Benchmarking Process Safety Management Systems

A formal, systematic PSM benchmarking program that allows participants to understand the strengths and weakness of their current process safety management process, set definitive goals for improvement, and define their programs position relative to others.

Process Equipment Reliability Database (PERD)

PERD is looking for companies to download data for equipment of their choosing into an Excel spreadsheet or Access database for submittal to PERD. PERD will take the data and calculate reliability parameters for things like mean time to failure for specific failure modes where such data is sufficient.

Process Safety Beacon

Provide timely and informative process safety messages directly to manufacturing personnel to improve process safety awareness.

Project 219: Process Safety Moments Presentations

Create a library of short (1 to 4 slide) PowerPoint files. This will allow for easy sharing and presentation. Other media such as video clips (embedded in PowerPoint presentations) or podcasts would be considered. Another potential idea is to have TSC members record the moments to provide a personalized, reality feel. The material topic and/or intended audience would influence the media selection: i.e. PowerPoint (printouts) for a toolbox meeting v. podcasts for a business leader focused Process Safety Moment.

Project 248: Guide to Making Acute Risk Decisions

The purpose of this book is to provide a practical guide on the application of decision making tools for managing process safety risk and to drive the concept that managing process safety risk through informed decision making is beneficial for all stakeholders.

Project 249: Essential Practices for Developing, Strengthening and Implementing Process Safety Culture

Develop a Concept Book that will address developing, strengthening and implementing Process Safety Culture. This book will also provide guidance for various management level to assess and develop a culture improvement plan.

Project 250: Guideline for Integrating Process Safety in Engineering Projects

Use a project timeline to guide the reader through the issues of ensuring PS is included at each step (gate) of an engineering project. It will have case studies & incidents for emphasis. It will follow RBPS elements, provide templates for various “gate reviews”, and will lean heavily on GL’s for design, siting, consequence modeling and other references.

Project 259: CCPS's Seven Minute Seminars

Create a large database of short “seven minute seminars” that quickly inform a plant manager, engineer or operator about a specific piece of equipment. Much like the “Take Two… for Safety”, people are often willing to give up a guaranteed short amount of time for a cause. The videos will be broken down into two sections; The Mechanics, and The Science. The sections will talk about the mechanical parts and make up, and physical laws that apply and the relative chemical reactions that are happening within each part. These videos are meant to inform rather than transform, meaning, they are to be...

Project 270: Guidelines for Process Safety in Upstream Industry

This project will include the development of a concept book as well as application(s) or tool(s) for the upstream oil and gas and the shale oil and gas industries.

Project 275: Process Safety During Transient Operating Conditions (Start-Up/Shutdown)

The highest risk periods for most manufacturing facilities occur during start-ups and shutdowns. As a result, CCPS will publish a book to help members improve process safety management during transient operating conditions. This book will help industry better identify and understand the unique hazards that are involved during these events. The book will also assist in understanding risk management during these occasions.

Project 277: Guidelines for Inherently Safer Chemical Processes: A Life Cycle Approach, 3rd Ed.

The guideline book will clearly define Inherently Safer Design (ISD), explain how to develop ISD alternatives, and evaluate ISD vs. conventional alternatives. Special attention will be paid to As Low as Reasonably Practicable (ALARP) determinations in the safety case regime.

Project 278 : Risk Based Process Safety Web Application Tool

This project aims to create an easily accessible web-based tool for each of the 20 Risk Based Process Safety elements. A central “hub” of free Process Safety information, tools, and resources is now available at https://www.aiche.org/ccps/resources/rbps .

Project 279: More Incidents that Define Process Safety

This second edition to Incidents that Define Process Safety builds on the incidents that were outlined in the original book and is adding incidents from other countries and business sectors (e.g. foods) where Risk Based Process Safety is applicable and necessary to avoid catastrophic events. The chapters are largely aligned to major incident types (e.g. fires, toxics, etc.). Additionally, each incident is aligned to the primary elements of Risk Based Process Safety (RBPS), thus availing the reader to be able to identify incidents that exemplify where these elements could have played a role in...

Project 280: Risk Analysis Screening Tool (RAST) and Chemical Hazards Evaluation Fundamentals Tool (CHEF)

CHEF is a compilation of simple methods, models, and techniques for performing a process safety analysis. Additionally, RAST is a software application that utilizes the methods and techniques described in CHEF to identify hazards and analyze process risk. These tools, donated to CCPS by The Dow Chemical Company, provide users with the capability to identify hazards (CHEF) and to perform risk screening tests with basic dispersion modeling on chemical releases (RAST). The intent is to help smaller companies without extensive process safety experience or resources better understand the specific...

Project 281: Human Factors for Process Plant Operations: A Handbook

This project will create a guideline that enables Process Safety professionals to build their understanding of human performance topics. This effort will also build on the highlight joint industry documents, tools, and educational offers. The project will expand on the Human Factors Methods for Improving Performance in the Process Industries book.

Project 282: Project 282: Guidelines for Investigating Chemical Process Incidents, 3rd Ed.

This project will be the 3rd edition of the Guidelines for Investigating Chemical Process Incidents book and updated the previous 2003 edition. This book will focus on investigating process-related incidents with real or potential catastrophic consequences. Issues related to preservation and control of an accident scene, collecting and documenting evidence, and maintaining a chain of custody will be addressed in this edition. Identifying root causes, working with multiple regulatory agencies (CSP, OSHA, EPA, BATF, etc.), dealing with the 24/7 news cycle, and providing litigation support will...

Project 283: Guidelines for Updating & Revalidating PHAs 2nd Ed.

This project is an update on the 2001 book, Revalidating Process Hazard Analyses. This second edition will provide improved guidelines for identifying missing or undervalued elements of the prior PHA (such as facility siting, effective consideration of human factors, security, and other elements that were not in use at the time of the first edition’s composition). The book will also guide those developing revalidation protocols to identify improvement opportunities with the use of today’s tools and techniques (e.g. LOPA and layers of protection, identification of passive vs. active, and...

Project 285: Process Safety: Leadership From the Boardroom to the Frontlines

This project will produce a third edition of the pamphlet, “The Business Case for Process Safety and Sustainability” and will generate a book entitled The Leadership Challenge for Process Safety. The existing “The Business Case for Process Safety” pamphlet will be updated to incorporate a current perspective of the positive and negative business impacts of process safety focus and performance. Additionally, the impact of process safety on sustainability and sustainable growth will be included. The Leadership Challenge for Process Safety book will be for corporate leaders, giving them concrete...

Project 290: Process Safety Toolbox

Develop a sharing forum and online set of process safety tools for use by practicing engineers, along the lines of toolbox.com (which serves the IT community).

Project 291: Abnormal Situation Management

Develop guidance for and a reference guide to techniques for Abnormal Situation Management (ASM). This project would develop a guidebook, with references, for concepts, tools and techniques to identify, control and mitigate abnormal process safety conditions.

Project 292: Driving Continuous Process Safety Improvement from Investigated Incidents

Over the years, the US Chemical Safety Board (CSB) has made numerous recommendations to various parties in an attempt to improve Process Safety performance and to ensure that catastrophic incidents are prevented. This project will take a look at the best recommendations and learnings brought forward by the CSB and will provide content to help companies institutionalize these learnings within their own organizations. The CSB, through using actual incidents, often does a great job as to demonstrating why companies need to take action relative to certain hazards. This project would then build...

Project 293: Guidelines for Documenting, Implementing and Maintaining Process Knowledge Management

Developing, documenting, and maintaining process knowledge is one of two elements in the Risk Based Process Safety (RBPS) pillar of understanding hazards and risk. Developing a high level of Process Knowledge Management throughout the organization is key to operating a safe and profitable manufacturing facility in compliance with applicable regulations and near-by residential area inhabitants needs and expectations. The knowledge element of RBPS primarily focuses on information that can easily be recorded in documents, such as (1) written technical documents and specifications, (2)...

Project 294: Managing Cybersecurity – A Risk Based Approach Building on the Process Safety Framework

This project will produce a concept book that describes the case for the application of cyber security principals for process safety. Chemical manufacturing relies on a number of Safety, Controls, Alarms, and Interlocks (SCAI) to manage process hazards. A cyber-attack can compromise one or more of these protection layers causing an incident while simultaneously defeating protective and mitigative measures.

Project 295: Assessment of and Planning for Natural Hazards

CCPS published the 2 nd edition of the Pamphlet addressing natural disasters, soon after Hurricane Sandy. There have been several other severe weather events that have impacted process safety. The body of knowledge created since Sandy has grown sufficiently to necessitate taking another look at and update the pamphlet and also expand the scope to include learnings from such incidents, including hurricane Harvey. The new edition will also address guidance and recommendations provided by CSB, insurance industry, and a variety of other sources both US based and outside.

Safety and Chemical Engineering Education (SACHE)

SAChE is a standing CCPS subcommittee responsible for: Evaluating requests for CCPS to participate in other organizations’ events or projects, identifying how CCPS would participate, and recruiting volunteers or identifying staff to support these activities.

Process Safety Boot Camp - 2nd Generation

Expand present Process Safety Boot Camp Course to a series of associated courses that address different audiences. Depending on the audience needs, the courses would range from Awareness, to Executive overview for Decision Making to Engineering Design, Operation and Maintenance, to introductions for Students and Professors. Team Composition: Select a core team of current Boot Camp Instructors and Industry Representatives that have gone through the Boot Camp or are associated with other Training / Education activities. Having one or two representatives from the Training Departments of CCPS...

Project 253: Effective Process Safety Communications

Based on information presented at the 8th Global Congress by T.J. Larkin, most process safety communication is too complex for rapid and complete understanding. The Beacon was called out in this presentation as a good example of how to provide effective communication. This project would identify ways of improving process safety communication, from operating procedures to warning signs, so that key, life-saving information is transmitted and received in an effective manner.

Project 258: Training Course for Conduct of Operations and Operational Discipline

Proposal: Prepare a training program for the book Conduct of Operation and Operational Discipline. Benefits: Support CCPS mission to foster knowledge, understanding and implementation of process safety by executives, management, technicians, engineers, students, government officials and the public. Approach: This project is on hold.

Project 267: Process Safety Leadership Challenge

Create a short, well-designed book or pamphlet for corporate leaders giving them concrete actions they can perform daily for at least 30 working days to demonstrate process safety leadership. The book may have separate sections for plant/operations based leaders, executive leaders, and engineering leaders, as determined by the subcommittee. Each activity will be accompanied by illustrations to help explain/reinforce the leadership concept being described.

Project 264: Guidelines for Process Safety in Outsourced Manufacturing Operations, 2nd Edition

Update current Guideline, published in 2000, to incorporate the CCPS Risk-Based Process Safety elements and inherently safer design concepts; update guidance on legal and insurance (risk transfer) issues, and speak to international differences. Ensure the new edition addresses both the perspective of the client company and the toller/contract company and impacts to the supply chain.

Project 245: Business Case for Process Safety and Sustainability

The original material for the Business Case for Process Safety (available on-line on the CCPS web-site for member companies) will be updated with current examples and will be expanded to include the concept of sustainability.

Project 271: Process Safety Applications for Electronic Devices (Smart Phones/Tablets/Desktop, etc)

This project would include the identification, prioritization and development of software “apps” for process safety professionals and others as appropriate for use on smart phones, tablets, and other computer devices. Many CCPS documents and books are available in an electronic format, but are not easily searchable or in user-friendly format. Providing new tools on process safety can increase both the timeliness and the use of process safety information, particularly in situations when quick access to information and quick response is needed.

Project 237: Guidelines for Barrier Risk Management (Bow Tie Analysis)

This Concept Book would review the foundation of the method, provide instructions on how to draw the bow tie correctly and how to avoid common errors. Typical constructs for typical process threats – corrosion, impact, improper operation / human error, operational upsets, etc. would be demonstrated. The risk management information associated with every barrier would be explained, e.g. barrier owner, performance expectation, pending actions, related documents. The Guideline would address how to convene a team to develop the bow tie diagram and how the review process. Its use in ongoing...

Project 252: Combustible Dust Hazard Assessment: A Risk based Approach

This project will develop and publish a concept book providing guidance how to control and mitigate dust hazards in the workplace. It is intended to focuses on the methodologies for predicting and measuring dust hazard parameters, design of suppression and venting systems, and other related topics.

Project 255: Evergreen LOPA/IPL Database

Provide up-to-date, reviewed / approved datasheets of IEs and Independent Protection Layers (IPLs) and perhaps Conditional Modifiers for use in basic Layers of Protection Analysis (LOPA), and perhaps beyond basic LOPA. The site could contain downloadable tools, such a blank IPL forms, IPL & IE checklists, etc. The datasheets will be like those in the upcoming Guidelines for IEs and IPLs (2011), but will be kept evergreen. This will be an evergreen appendix to the LOPA books. Access will be online via by password, which expires each year. It is anticipated that will be an ongoing project,...

Project 246: Guidelines for Siting and Layout of Facilities, 2nd Edition

This project would revise and update the current CCPS publication “Guidelines for Facility Siting and Layout”, including information on occupied portable buildings, facility and plant layout. Reference documents would include but not limited to API 752 and 753 as well as OSHA/EPA interpretation letters and recently published CCPS books touching on this subject.

Project 268: Dealing with Aging Process Facilities and Infrastructure

Chemical process and petrochemical facilities utilize a range of equipment and infrastructure to operate optimally and generate value for enterprises. The aging of process equipment and infrastructure introduce opportunities for loss of containment and resulting accidental releases. A number of factors are considered when managing aging equipment and infrastructure to assess and manage the associated risks. This book would be designed to help those responsible for maintaining and evaluating equipment (maintenance, equipment and asset integrity) to understand and assess the added risks of...

Project 269: Preventing Normalization of Deviation

This guidelines book, “Prevention of Normalization of Deviations “ would address the initial and long term effects of normalization of deviations in reduced efficiencies, reduced product quality, extended batch run time and other near misses which lead up to loss of containment releases and catastrophic events.

Project 233: Key Performance Indicators for Risk Based Process Safety

This project will develop a software upgrade tool for the process safety incident evaluation tool spreadsheet. The new tool will include the new standards established for API 754.

Project 191: Guidelines for Pressure Relief & Effluent Handling 2nd Edition

This book presents a methodology which helps properly size all the components in a pressure relief system from the relief device through vapor liquid separation equipment up to the stack. It is the only book in this field that covers the topic of 2-Phase flow, based on the most up to date research and studies by the Design Institute for Emergency Relief Systems (DIERS). Along with the CCFlow suite of design tools and the new Superchems for DIERS® Lite software included with the, this book is essential for engineers designing chemical plants, refineries, and similar facilities

Project 196: Independent Protection Layers and Initiating Events

The publication will provide process automation engineers, process engineers, facility operators, and safety professionals with the appropriate treatment and requirements applicable to equipment design, administrative procedures, or other “credits” that are treated as an independent protection layer and initiating event from a Layer of Protection Analysis (LOPA) perspective.

Project 211: Executive Process Safety Seminars

Seminar targeted at improving awareness of process safety amongst industry executives while educating them on their role. Companion project to 2008 project targeted at Culture.

Project 212: Guidelines for Determining the Probability of a Released Flammable Mass

Define a set of approaches for calculating the likelihood of ignition for selected categories of scenarios, and publish a Guidelines or Concept series book of instructions and tools (including a CD of calculation methodologies and structure for input data) to do so. Ideally, three categories of resources needed and matching precision of calculations will be developed (e.g. low, medium, and high degree of precision and accompanying required effort).

Project 224: Hazard Identification eLearning

While “Top-down” emphasis of PSM & other safety programs is necessary, the daily “enforcement” is at the worker and supervisor levels. This project will increase the understanding and buy-in for PSM at the first-line supervisory level through better understanding of PSM, its benefits and the interactions of the various elements.

Project 225: Process Safety Management for Front Line Supervisors

While “Top-down” emphasis of PSM & other safety programs is necessary, the daily “enforcement” is at the worker and supervisor levels. This project will increase the understanding and buy-in for PSM at the first-line supervisory level through better understanding of PSM, its benefits and the interactions of the various elements.

Project 227: Guidelines for Organization Change Management for Process Safety

Many companies continue to struggle with effective implementation of Management of Organizational Change. This project will address these issues and help companies bring their MOC systems to the same degree of maturity as other process safety management systems.

Project 229: Conditional Modifier and Enabling Events

A short publication providing information and considerations on developing and using conditional modifiers and enabling conditions. This will be a companion book to the LOPA Book.

Project 235: Managing the Impact of Natural Disasters on the Process Industries

Proposal: Deal with the subject of catasctrophic natural disasters and their potential impact on chemical and petrochemical process particularly with regard to common mode failures and supply chains. Address issues related to and the importance of planning. Including impact to infrasctructures. Benefits: Natural disasters can cause a wide spread damage and affect operations at a site in addition to internal and external infrasctructure damage. Impacts can easily extend to a company's own supply chain. Understanfing how these occurrences can affect operations allows the site and compnay to...

Project 236: Economic Recovery Preparation Project

As the global economy revives, there will be a number of stressors on hte EHS and in particular PSM systems. HCnages in operations and personnel have occurered to address the economic conditions. The premise is to develop two (2) shoer publicaitons to raise awareness of this issue and provide guidance on how to assess the present condition of the PSM systems and develop a plan for revitalize the PSM systems as the recovery occurs; not after an event. Team Composition: Populate with appropiate personnel with expertise in project management, economic recovery and process safety management...

Project 239: Guidelines for Process Safety Knowledge and Expertise

Present the framework of process safety knowledge and expertise versus the desired competency level in a “super-matrix” format. This would be targeted at multiple audiences, ranging from front line chemical operators, mechanics and instrument technicians through senior management, including financial and business executives. Gaps between existing and desired training levels can then be identified, and potential remedies suggested. Customization for specific company will be permitted.

Pages