Process Safety Boot Camp

Course ID:

CH900

Course Type:

Instructor-led (classroom) Course

Course Length:

4 Days

Process Safety Boot Camp was developed by AIChE’s Center for Chemical Process Safety especially for companies looking to train chemical engineers in the fundamentals of Process Safety. It is widely used by corporate training departments across different sectors of the chemical enterprise. Companies large, small and in-between all use the Process Safety Boot Camp to ramp-up staff knowledge to a common level quickly and easily.

This intensive 4-day course is also offered periodically throughout the year to the broader chemical engineering public. Taught jointly by process safety veterans with decades of experience at major companies from the process industries, the course is highly interactive.

Every boot camp is taught by two instructors, each with a minimum of 25 years experience. They cover key process safety areas including Risk based Process Safety, Process Hazard Analysis, Regulatory Compliance and Process Safety in Plant and Design Operations.

What Your Engineers Will Learn

The four pillars and 20 elements of Risk Based Process Safety.
The different types of Process Hazard Analysis, including an introduction to HAZOP.
An overview of OSHA’s PSM regulations and EPA’s RMP regulations.
How to incorporate Process Safety Management into Process Design and Plant Operations
The concept of Layers of Protection to prevent and/or mitigate loss of containment events
The principles of Risk Analysis and Risk Management
How to consider Inherently Safer Processes during plant design.

Who should attend

Process Engineers, project engineers, operations engineers, and safety engineers that need to move beyond an understanding of personnel safety and learn the basics of Process Safety and Process Safety Management.
Chemical engineers who interface with design teams, plant engineers, or plant operations personnel.

Course Overview

DAY 1

Introduction
- Occupational safety vs. process safety
- Business case for process safety
- Key principles of process safety

Anatomy of an Incident
Loss of Containment
- Containment and control
- Prevention
- Mitigation

DAY 2

Introduction to Management Systems and Risk Based Process Safety
Process Safety Culture Compliance with Standards
Inherently Safety Concepts
- Process Design

Process Safety Competency
- Workforce Involvement
- Human Factors

Stakeholder Outreach
Process Knowledge Management
Understanding Material Hazards

DAY 3

Specific Hazards
- Chemical hazards
- Reactivity
- Toxicity
- Corrosivity
- Inherent Safety

Hazard Identification and Risk Analysis
- Hazard evaluation techniques
- Consequence and Impact Frequency
- Risk Analysis
- Risk criteria
- Risk acceptance

Operating Procedures
Safe Work Practices

DAY 4

Hot Work Permits, etc.
Asset Integrity and Reliability
Contractor Management
Training and Performance Assurance
Management of Change (MOC)
Operational Readiness & PSSR
Conduct of Operations
Emergency Management
Incident Investigation
Measures and Metrics
Auditing Compliance
Management Review and Continuous Improvement
Additional EPA RMP regulations
Course Wrap up

Download Course Outline (PDF)

Continuing Education Units:

3.2

Professional Development Hours

32.0 PDHs

Instructor(s):

Brian Kelly

Brian Kelly has 35 years of engineering and operations experience and is a consultant with AIChE’s Center for Chemical Process Safety (CCPS). He has conducted numerous process safety audits and incident investigations and presented process safety workshops in North America, Europe and Asia. He previously was with Imperial Oil and Syncrude Canada Ltd. Brian joined CCPS in 2005 as a staff consultant after 34 years of service with Imperial Oil and Syncrude Canada Ltd. Brian received his BASc and MASc degrees in chemical engineering from the University of Ottawa (Canada). Brian has special... Read more

Byron Sun

Byron has over 24 years of experience in chemical industry including 9 years as chemical engineer, 6 years as production management and 9 years as safety, health and environment professional. Byron worked for China Petrochemical Company (now SINOPEC) for 9 years and DuPont Company for 15 years. From 2004 through 2012, he was Safety, Health and Environment Manager for DuPont China. In 2012, Byron Sun became a full time safety consultant and joined CCPS as staff consultant. Byron receive a diploma from Shanghai Science and Technology University and obtained a Master Degree from Tongji... Read more

Dennis Hendershot

Dennis C. Hendershot is a chemical engineer with 40 years of experience in process research and development, plant design and startup, and process safety. From 1970 until his retirement in 2005 as a Senior Technical Fellow, he worked at Rohm and Haas Company. He then joined Chilworth Technology Inc. as a Principal Process Safety Specialist (retiring again in 2009), and the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers as a Staff Consultant. With CCPS, he has worked with the Inherently Safer Design Subcommittee, the Risk Tolerance Criteria... Read more

Donald Abrahamson

Don Abrahamson has over 40 years of experience in operations and engineering roles to draw from process safety management, operations management, process safety engineering, technical management, quality assurance management, process development and research. He recently retired from Celanese as the Global Process Safety Manager. He also worked for Occidental Chemical for over 32 years. He has conducted PHAs, Audits, Incident Investigations and /or Training on three continents: Americas, Europe and Asia. He has four US Patents from his work in research and development. He holds a BS in... Read more

Jack McCavit

Jack McCavit retired from Celanese Chemical Company after 35 years with experience in operations management and practical application of process safety management systems. Jack served as the BP Baker Panel’s technical project manager and was a part of the team that monitored BP’s implementation of the Baker Panel recommendations. Jack served as the committee chair for CCPS’s Guidelines for Risk Based Process Safety. He graduated from Texas Tech University with a BS in chemical engineering. Read more

James Conner

Jim Conner joined CCPS as a Staff Consultant in 2011. He has 35 years of experience in chemical process engineering, chemical manufacturing operations, and R&D across operations in Asia, Europe, Middle East, and North America. Most recently Jim held the position of Sr. Vice President, Operations for Enerkem, and a solid waste-to-chemicals startup venture. Prior to Enerkem, he served as Vice President, Operations and Technology for Celanese, with responsibility for domestic and international operations and R&D facilities. He also was accountable for the design and startup of a world-... Read more

Jerry Jones

Jerry Jones, PE joined CCPS as a staff consultant in 2012. He has >40 years of experience across industry sectors including chemicals, polymers, pharmaceuticals, and electronics industry materials. He has worked in process development and engineering, plant design, EHS, and process safety functions and supported manufacturing operations in over a dozen countries while an employee of Monsanto, SRI International, Raychem, and Genentech/Roche. He has extensive experience with the implementation of risk-based management systems including those for process safety. He earned BS and ME degrees in... Read more

John Herber

John Herber joined CCPS in 2009 after a 33-year career with 3M Company that included positions in process and project engineering, production operations and corporate safety. In Corporate Safety Services, John developed programs for improving PSM systems across 3M’s global operations, including PSM metrics, Process Hazard Management policy and implementation guidance. As PSM consultant, John has performed audits, facilitated PHAs and assisted with PSM program development and training. John has a BS in Chemical Engineering from Purdue. CCPS projects: Process Safety Boot Camp Training Program,... Read more

John Murphy

John Murphy has more than 40 years of experience in chemical manufacturing and process safety with jobs in the chemical industry, consulting and government. He has retired from the U.S. Chemical Safety and Hazard Investigation Board where he served as lead investigator. John also retired from Dow Chemical Company where he was a leader in process safety. He has a BS in Chemical Engineering from Tufts University and an MBA from Central Michigan University. John has special expertise in incident investigation and root cause analysis, reactive chemicals management, and process safety management... Read more

Louisa Nara

Louisa Nara is the Technical Director of the Center for Chemical Process Safety (CCPS) for the American Institute of Chemical Engineers (AIChE). She has over 30 years of experience in the chemical, petrochemical, pharmaceutical and food industries and has worked for and with over 65 companies domestically and internationally. Louisa comes to AIChE/CCPS after 15 years with Bayer where she held positions of increasing responsibility including: Manager Process Safety and Crisis Management; Director of HSE, Security and Emergency Response at Bayer’s largest US Manufacturing site; and, Director,... Read more

Robert Rosen

Bob has over 15 years in chemical production management, five years in project and process engineering management and 20 years in the safety, health and environment area. From 1997 through 2003, he was the Director of Emergency Response and Issue Management for BASF Corporation in Mount Olive, NJ. Since 2003, Bob has done Occupational Safety, Process Safety and Emergency Response consulting. Prior to 1997, Bob worked for Merck, Polaroid, Story Chemical, and Polysar. Bob received a B.Ch.E in 1966 from Clarkson University. He is a Fellow of the American Institute of Chemical Engineers. Read more

Pricing

	2013 Sessions	2014 Sessions
AIChE Members	$1,895	$1,995
AIChE Grad Student Members	$947.50	$997.50
AIChE Undergrad Student Members	$947.50	$997.50
Non-Members*	$2,095	$2,195

* Membership is just $199 a year. For more information on becoming an AIChE member click here

If you are interested in scheduling this course for In-Company Training, please complete the Request for Proposal Form and we will e-mail you a proposal.

Registration

April 28 - May 1, 2014

Houston, TX, US

PDF Registration Form

Venue: To be announced

June 9-12, 2014

New York City, NY, US

PDF Registration Form

Venue: To be announced

September 8-11, 2014

San Francisco, CA, US

PDF Registration Form

Venue: To be announced

October 20-23, 2014

Houston, TX, US

PDF Registration Form

Venue: To be announced

Questions? Check out the Frequently Asked Questions or email us at edu@aiche.org

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Process Safety Boot Camp

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What Your Engineers Will Learn

Who should attend

Course Overview

Pricing

Registration

April 28 - May 1, 2014

Houston, TX, US

June 9-12, 2014

New York City, NY, US

September 8-11, 2014

San Francisco, CA, US

October 20-23, 2014

Houston, TX, US