Elements of Process Safety
The four pillars and the twenty elements of risk based process safety can be designed and implemented at varying levels of rigor to optimize process safety management, performance, efficiency, and effectiveness.
The March 2014 Beacon discussed the relationship between process safety and occupational safety, as well as the importance of both in ensuring a safe workplace. For many years, industry has used established measures of occupational safety...
Spotlight on Safety
Culture can be defined as a collective group of shared beliefs and values that shape how we act. We think of culture as it relates to the actions and reactions of a group, company, or society. However, it can also characterize an individual — what influences how you make day-to-day decisions or handle various situations. Personal process safety culture can be assessed by observing someone’s (yours or another person’s) response to situations involving a safety violation.
An understanding of organizational change management (OCM) — an often overlooked subject — is essential for successful corporate decision making with little adverse effect on the health and safety of employees or the surrounding community.
David Farese, Svetlana Ivanova
Understand the potential dangers associated with handling and storing hydrogen, and take the appropriate precautions to mitigate the risks.
Process safety management (PSM) systems are only as effective as the day-to-day ability of the organization to rigorously execute system requirements correctly every time. The failure of just one person in completing a job task correctly just one time can unfortunately lead to serious injuries and...
This book helps advance process safety in a key area of interest. Currently, no literature exists which is solely dedicated to process safety for the bioprocessing industry. There are texts, guidelines, and standards on biosafety at the laboratory level and for industrial hygiene, but no guidelines...
Understand basic concepts, different classes and categories of hazards, techniques and methodologies for identifying and evaluating hazards, making risk based decisions, learning and continuous improvement and more!
It is crucial for process safety professionals to be aware of best practices for post merger integration at any level. A compilation of industry best practices from both technical and financial perspectives, this book provides a single reference that addresses acquisitions and merger integration...
Written by a committee of safety professionals, this book creates a foundation document for the development and application of risk tolerance criteria. Helps safety managers evaluate the frequency, severity and consequence of human injury Includes examples of risk tolerance criteria used by NASA,...
Whether occurring accidentally or through acts of terrorism, catastrophic chemical releases must be identified early in order to mitigate their consequences. Continuous sensor monitoring can detect catastrophic chemical releases early enough to curb extreme amounts of damage. In several notable...
This CCPS Guideline book outlines current transportation risk analysis software programs and demonstrates several available risk assessment programs for land transport by rail, truck, and pipeline for consequences that may affect the public or the environment. Provides introductory transport risk...
Incidents That Define Process Safety describes approximately fifty incidents that have had a significant impact on the chemical and refining industries' approaches to modern process safety. Events are described in detail so readers get a fundamental understanding of the root causes, the...
This book explains the decision-making processes for the management of instrumented protective systems (IPS) throughout a project's life cycle. It uses the new IEC 61511 standard as a basis for the work processes used to achieve safe and reliable process operation. By walking the reader through a...
In recent years, process safety management system compliance audits have revealed that organizations often have significant opportunities for improving their Mechanical Integrity programs. As part of the Center for Chemical Process Safety's Guidelines series, Guidelines for Mechanical Integrity...
Almost all the major accident investigations--Texas City, Piper Alpha, the Phillips 66 explosion, Feyzin, Mexico City--show human error as the principal cause, either in design, operations, maintenance, or the management of safety. This book provides practical advice that can substantially reduce...
While there are many resources available on fire protection and prevention in chemical petrochemical and petroleum plants—this is the first book that pulls them all together in one comprehensive resource. This book provides the tools to develop, implement, and integrate a fire protection program...
A resource for individuals responsible for siting decisions, this guidelines book covers siting and layout of process plants, including both new and expanding facilities. This book provides comprehensive guidelines in selecting a site, recognizing and assessing long-term risks, and the optimal lay...
This book provides a valuable reference tool for technical and management personnel who lead or are a part of incident investigation teams. This second edition focuses on investigating process-related incidents with real or potential catastrophic consequences. It presents on-the-job information,...
Designed for chemical engineers and other technical personnel involved in the design, operation, and maintenance of facilities and equipment where deflagration and detonation flame arresters (DDFAs) may be required, this book fosters effective application and operation of DDFAs through treatment of...
Layer of protection analysis (LOPA) is a recently developed, simplified method of risk assessment that provides the much-needed middle ground between a qualitative process hazard analysis and a traditional, expensive quantitative risk analysis. Beginning with an identified accident scenario, LOPA...
This book presents an approach—termed MERITT (Maximizing EHS Returns by Integrating Tools and Talents)—for enhancing process development through better integration of environmental, health, and safety evaluations. It draws upon critical components of inherent safety, pollution prevention, green...
The foundation of any successful process safety program is a current set of process hazard analyses (PHAs) for each of its processes. Revalidating PHAs to keep them up to date and applicable is a must. This book is derived from the experience of many companies in the chemical and hydrocarbon...
In today’s competitive economy, companies often augment in-house production by outsourcing chemical reaction processes and distillation, drying, formulating, blending, and packaging operations. While most of these tolling, or contracted manufacturing services, proceed without incident, recent major...
Quantitative Risk Analysis is a powerful tool used to help manage risk and improve safety. When used appropriately, it provides a rational basis for evaluating process safety and comparing alternative safety improvements. This guide, an update of an earlier American Chemistry Council (ACC)...
Written by Laurence Britton, who has over 20 years' experience in the fields of static ignition and process fire and explosion hazards research, this resource addresses an area not extensively covered in process safety standards or literature: understanding and reducing potential hazards associated...
This CCPS Concept book shows designers and operators of chemical facilities how to realistically estimate the flammable mass in a cloud of accidentally released material that is capable of igniting. It provides information on industry experience with flammable vapor clouds, basic concepts of fires...
Written by reliability data experts, the book gives plant managers and supervisors the guidance they need to collect, and use with confidence, process equipment reliability data for risk-based decisions. Focusing on the process industries, it provides the protocol and techniques to collect and...
Tom Pratt, a long-time process safety practitioner and lecturer in electrostatic safety, wrote this book to educate industry in the basics of electrostatics. It offers a selected collection of information designed to give readers the tools they need to examine the hazard potential of common...
Over the years, companies have developed independent systems for managing process safety, environment, health, safety, and quality. Many aspects of these management systems are similar. Integrating EHS management systems can yield economies and improved system effectiveness. This book explains how...
The second edition of this essential reference updates and combines two earlier titles to capture the many technological advances for predicting the "footprint" of a vapor cloud release. Cited by EPA in its 1996 document, "Off-Site Consequence Analysis Guidance," the aim of the book is to encourage...
This book puts together a body of very recent information never before presented in one volume on the design of post-release mitigation systems. The development of a fundamental knowledge base on post-release mitigation systems, through testing and data correlation, is very new. While further...
Written and edited by engineering contractors and industry project/maintenance managers as an easy-to-use guide for other industry professionals, this book identifies important process safety issues in the contractor-client relationship,which are not addressed by other groups and publications...
The EPA investigation of a 1994 chemical plant tragedy concluded that "the explosion resulted from a lack of written safe operating procedures…" While good written procedures can't guarantee zero accidents, they can reduce the number of accidents caused by human error. This new book shows how to...
A brief introduction to a complex topic, giving a description of the processes involved in an accidental or emergency release and the resulting downwind transport and dilution of gases, vapors, and aerosols.
Prevention, preparedness, response and recovery--the key components of emergency planning--form the major sections of this work. The book first describes PSM (Process Safety Management) as the key to prevention, then goes on to consider the main features of a preparedness program, including...
The process industry has developed integrated process safety management programs to reduce or eliminate incidents and major consequences, such as injury, loss of life, property damage, environmental harm, and business interruption. Good documentation practices are a crucial part of retaining past...
This Guidelines book provides technical information on how to conduct a consequence analysis to satisfy your company's needs and the EPA rules. It covers quantifying the size of a release, dispersion of vapor clouds to an endpoint concentration, outcomes for various types of explosions and fires,...
First-line managers have to maintain the integrity of facilities, control manufacturing processes, and handle unusual or emergency situations, as well as respond to the pressures of production demand. On a daily basis, they are closest to the operating personnel who may be injured by a process...
The complexity of today's risk decisions is well known. Beyond cost and risk there are many other factors contributing to these decisions, including type of risk (such as human injury or fatality), the economic impact on the local community, profitability, availability of capital, alternatives for...
The causes of catastrophic accidents in the process industries, now recognized as complex and interrelated, need to be matched by multi-faceted technical management systems. These principles apply to companies of any size and to a full range of industries beyond the chemical industry, such as pulp...
OSHA (29 CFR 1910.119) has recognized AIChE/DIERS two-phase flow publications as examples of "good engineering practice" for process safety management of highly hazardous materials. The prediction of when two-phase flow venting will occur, and the applicability of various sizing methods for two-...
The book supplements Guidelines for Chemical Process Quantitative Risk Analysis by providing the failure rate data needed to perform a chemical process quantitative risk analysis.
Guidelines for Vapor Release Mitigation is a survey of current industrial practice for controlling accidental releases of hazardous vapors and preventing their escape from the source area.
Understand the electrostatic hazards of your process so you can limit the accumulation of charge and prevent static discharge in ﬂammable atmospheres. Select the appropriate combination of electrostatic mitigation measures to ensure safety from electrostatic ignition hazards.
Process flow failure modes (PFFM) analysis is an intuitive, process-flow-directed way to identify potentially hazardous scenarios. Learn how to apply this technique to your process hazard reviews.
Process Safety Beacon
Proper installation, maintenance, and inspection of metal tubing is important in preventing fires and toxic material releases in process plants. Do not forget about tubing just because it is usually small. Even a small leak can cause a fire that can...
Check out warning devices for hazardous areas and high-visibility work vests that reduce static electricity.
This book provides guidance on characterizing, recognizing, and responding to warning signs to help avoid process incidents and injuries before they occur. The guidance can be used by both process safety management (PSM) professionals in evaluating their processes and PSM systems as well as for...
At last, smaller chemical processing operations have truly easy access to process safety and risk management programs tailored to meet their needs. Written as a "how to" book with checklists, it offers sufficient information for managers of facilities with small chemical operations to implement a...
Richard P. Palluzi
Safety standards can significantly improve pilot plant safety and increase efficiency. This article addresses many of the issues involved in developing, deploying and using such standards.
Walter L. Frank
Changes to OSHA's PSM rule and EPA's RMP programs are underway, due to pressures from various groups and the need for greater security.
David K. Whittle, Kevin Smith
Process hazard analyses must be revamped — or redone from scratch — every five years by law. Following the guidance given here will facilitate this effort.
Heather Forgione, Henry Ozog
The Occupational Safety and Health Administration evaluates chemical facilities’ process safety management systems through a new national emphasis program. Follow these tips to reduce your risk of receiving citations, streamline the inspection process, and pave the way for future excellence.
The OSHA Process Safety Management National Emphasis Program will soon apply to the chemical industry, targeting compliance with safety standards associated with chemical hazards.
Bruce K. Vaughen, James A. Klein
Built on a solid foundation of leadership support and employee involvement, an operational discipline program can help to prevent serious incidents and injuries, and improve overall site safety and business performance.
Jack Chosnek, Victor H. Edwards, P.E.
Don't overlook opportunities to build more safety into a process that is already in operation.
Process Safety Beacon
The December 2011 Beacon described an incident where a missing plug on a vent line resulted in a flammable material leak that caught fire, causing a fatality. That incident reminded us of the importance of caps and plugs on process vent lines and...
This book discusses the fundamental skills, techniques, and tools of auditing, and the characteristics of a good process safety management system. A variety of approaches are given so the reader can select the best methodology for a given audit. This book updates the original CCPS Auditing...
Companies that handle powders or other particulate solids need to be aware of the potential for fire and explosions, and follow industry best practices, codes and standards to manage the risk.
Process Safety Beacon
A contract welder and a foreman were repairing an agitator support on top of an atmospheric-pressure storage tank. The tank contained a polyvinyl fluoride slurry with a flammable concentration if vinyl fluoride in the vapor space. An explosion...