Process Safety

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Process Safety Boot Camp

Public (classroom) Course
Offered in North America, this intensive and highly interactive 4-day course trains chemical engineers in the fundamentals of Process Safety. Taught...

Center for Chemical Process Safety (CCPS)

CCPS was established in 1985 to focus on engineering and management practices that can prevent and mitigate catastrophic accidents involving release of hazardous materials. CCPS is supported by sponsors in the chemical and hydrocarbon process industries and active worldwide via conferences, books, databases, education, research, and more.

LOPA – Going Down the Wrong Path

Conference Presentation
Global Congress on Process Safety
Sunday, March 21, 2010 - 8:00pm
Layer of Protection Analysis (LOPA) has quickly gained acceptance in the Chemical Processing Industries (CPI), and has risen to be one of the leading...

Training Management of Change Approvers

Conference Presentation
Global Congress on Process Safety
Sunday, March 21, 2010 - 8:00pm
Many companies have made great strides in change management systems since OSHA's Process Safety Management Standard 29 CFR 1910.119 was first...

HAZOP, LOPA, SIL: Be Careful What You Ask for!

Conference Presentation
Global Congress on Process Safety
Sunday, March 21, 2010 - 8:00pm
In recent years Process Safety Engineers have promoted the use of HAZOP to identify hazards and assess safeguards, followed by LOPA to identify if...

Managing Management of Change

Conference Presentation
Global Congress on Process Safety
Sunday, March 21, 2010 - 8:00pm
The Center for Chemical Process Safety (CCPS) has designated MOC as one of the areas where metrics need to be developed. One of the issues that CCPS...

Fire Study of Melting Fiberglass Using FLUENT CFD Software

Conference Presentation
Global Congress on Process Safety
Sunday, March 21, 2010 - 8:00pm
Thermal insulation is used in chemical plants primarily as a tool to prevent energy loss. However, if installed properly, an added benefit is that of...

Explosion Prevention and Mitigation

Conference Presentation
Global Congress on Process Safety
Thursday, April 30, 2009 - 4:00am
The analysis, prevention, protection and mitigation of fire, explosion, and reactivity hazards continue to be important to the loss prevention...

LNG Safety - II

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Wednesday, April 29, 2009 - 10:00am
This session presents advancements in LNG safety in LNG baseload and receiving terminals, LNG ships and other related areas. LNG Vapor Dispersion...

Case Histories and Lessons Learned

Conference Presentation
Global Congress on Process Safety
Wednesday, April 29, 2009 - 9:30am
Reviews of process safety incidents and near misses provide valuable learning opportunities. Papers dealing with incidents, near misses, and the...

Risk Criteria

Conference Presentation
Global Congress on Process Safety
Wednesday, April 29, 2009 - 6:15am
The new CCPS Guidelines for Establishing Risk Criteria will be published in mid-2009. This session includes papers regarding the development and...

Audits, Inspection and Regulation

Conference Presentation
Global Congress on Process Safety
Wednesday, April 29, 2009 - 4:00am
In the past few years, we have seen renewed emphasis on PSM through OSHA’s National Emphasis Programs and Homeland Security new Chemical Security’s...

Managing Organizational Change

Conference Presentation
Global Congress on Process Safety
Wednesday, April 29, 2009 - 4:00am
Management of Change has long been recognized as a fundamental cornerstone of a process safety program. Through the years, most companies have...

Applications of Risk Analysis Techniques

Conference Presentation
Global Congress on Process Safety
Wednesday, April 29, 2009 - 4:00am
Hazard identification and risk assessment continue to be a critical part of the process safety efforts in process plants. Papers highlighting methods...

Fire, Explosion, & Quantitative Analysis

Conference Presentation
Global Congress on Process Safety
Tuesday, April 28, 2009 - 11:30am
Fires and explosions result in the largest losses in process safety accidents. The increased sensitivity by industry, regulatory, and public sectors...

Transportation Risk

Conference Presentation
Global Congress on Process Safety
Tuesday, April 28, 2009 - 9:30am
Transportation Risk Assessment (TRA) is an essential aspect of risk management. TRA manages transportation risks by considering hazards, routes, and...

Food and Consumer Products Process Hazards

Conference Presentation
Global Congress on Process Safety
Tuesday, April 28, 2009 - 9:30am
The Food and Consumer Products area has significant hazards and risks from dust and flammable liquid explosions as well as from toxic releases...

Process Safety - From the Top-Down and Bottom-up

Conference Presentation
Global Congress on Process Safety
Tuesday, April 28, 2009 - 9:30am
The theme of this session is implementing Process Safety systems from two different perspectives: (1) what Senior Management needs from process...

Mechanical Integrity - State of the Art

Conference Presentation
Global Congress on Process Safety
Tuesday, April 28, 2009 - 4:00am
This session presents papers on the latest mechanical integrity concepts, practices and programs. All aspects of mechanical integrity are covered,...

Process Safety Metrics and Culture

Conference Presentation
Global Congress on Process Safety
Tuesday, April 28, 2009 - 4:00am
This session features presentations focusing on using the new CCPS Process Safety Metrics and other metrics to drive continual improvement in a...

Hazard Evaluations and Layer of Protection Analyses

Conference Presentation
Global Congress on Process Safety
Tuesday, April 28, 2009 - 4:00am
Process hazard analyses (PHAs) and their extension into LOPAs and Safety Integrity Level (SIL) determinations continue to be central to loss...

Tools to Identify Hazards

Conference Presentation
Global Congress on Process Safety
Monday, April 27, 2009 - 11:30am
Personnel involved with day-to-day plant operations maintain an important role in the hazard identification and risk assessment (HIRA) process. These...

Consequence Modeling

Conference Presentation
Global Congress on Process Safety
Monday, April 27, 2009 - 9:30am
Consequence modeling has evolved as a result of accident investigations, government regulations, and the maturation of process hazards analysis and...

Implementing PSM Globally

Conference Presentation
Global Congress on Process Safety
Monday, April 27, 2009 - 9:30am
In the last several years there have been numerous changes in technical and analytical methods, process safety management systems, regulations,...

Safety Culture and Operational Discipline

Conference Presentation
Global Congress on Process Safety
Monday, April 27, 2009 - 9:30am
This session focuses on the cultural aspects of a successful Process Safety program. Papers that are presented cover new and innovative ideas on...

Auditing Process Safety

Conference Presentation
Global Congress on Process Safety
Monday, April 27, 2009 - 6:00am
The 2nd Edition of the CCPS Guidelines for Auditing Process Safety Management Systems is currently being prepared. This session will include papers...

Fires, Explosions and Reactive Chemicals

Conference Presentation
Global Congress on Process Safety
Monday, April 27, 2009 - 6:00am
The analysis, prevention, protection and mitigation of fire, explosion, and reactivity hazards continue to be important to the loss prevention...

Applications of Lopa (Layer Of Protection Analysis)

Conference Presentation
Global Congress on Process Safety
Monday, April 27, 2009 - 6:00am
Layer of Protection Analysis (LOPA) continues to be a powerful and popular tool for assessing risk. This session presents papers focusing on applied...

A Century of Process Safety: Process Safety at OSHA

Conference Presentation
AIChE Annual Meeting
Monday, November 17, 2008 - 12:00pm-12:30pm
This presentation will provide a brief history of OSHA's efforts in process safety management. It will include discussion of the PSM standard and...

Guidelines for Risk Based Process Safety

March, 2007
Guidelines for Risk Based Process Safety provides guidelines for industries that manufacture, consume, or handle chemicals, by focusing on new ways to design, correct, or improve process safety management practices.

CEP: Process Safety Beacon - What Is the Process Risk?

January
2015
Process Safety Beacon
The worst process incident that can happen in your plant may not be the same as the highest process risk. Risk is a combination of how likely an incident is and how bad the consequences could be. The process incident in your plant with the worst consequences may be very unlikely to occur. Other less-severe incidents may be more likely, making the risk of these events higher than the incident with the worst consequences. You should be aware of all process risks in your plant, and your role in managing all of them.

CEP: Spotlight on Safety - Personal Growth and Lessons Learned from Two Global Tragedies

November
2014
Spotlight on Safety
Louisa Nara
The 30-year anniversaries of two events of significance to the chemical engineering profession, particularly the process safety community, occur in November and December — the PEMEX disaster outside of Mexico City, Mexico, and the Union Carbide Corp. tragedy in Bhopal, India. These two incidents, two-and-a-half weeks apart, molded my professional career and ultimately motivated me to work for the Center for Chemical Process Safety (CCPS) at AIChE, where our mission is to prevent such tragedies from occurring.

CEP: Process Safety Beacon - Ignition Sources

August
2014
Process Safety Beacon
The best way to prevent fires and flammable vapor explosions, either inside or outside process piping and equipment, is to avoid creating a flammable mixture. However, we must also recognize that our equipment and operating procedures can fail and a...

CEP: Spotlight on Safety - Be Prepared, Be Safe, and Have Fun

August
2014
Spotlight on Safety
Louisa Nara
One of my favorite warm weather activities is kayaking. The river provides a respite away from crowds and electronic distractions. Daily stressors are erased by the warm sun, a light breeze, and the sound of water lapping at my boat. A recent weekend with great weather afforded the perfect opportunity to go out on the river with my husband. Earlier that week, severe storms blew through the area with significant rainfall and flash flooding. This increased the volume of water in the river, so conditions would be perfect for a fast and exciting ride. It also called for a more-mindful approach to safety hazards, like swift currents and debris in the water.

CEP: Process Safety Beacon - Persistence – Good or Bad?

July
2014
Process Safety Beacon
Some process safety incidents have occurred because operating personnel failed to recognize that a process was not responding as expected. They attempted to keep a process in operation by deviating from standard procedures, or put themselves in danger by attempting to correct an out-of-control process condition rather than evacuating.

Cybersecurity for Executives: A Practical Guide

June, 2014
This essential cybersecurity text for executives in all sectors and at all levels provides practical advice that equips executives with the knowledge they need to make the right cybersecurity decisions. In plain language, you’ll learn how to recognize and act on threats to you and your business, along with how to act decisively to mitigate and recover from cyber incidents.

(Chinese) Guidelines for Risk Based Process Safety

August, 2013
《基于风险的过程安全》系统介绍了CCPS新一代过程安全管理体系的架构,阐述了基于风险的过程安全管理的4大原则,详细描述了过程安全体系中的20个基本要素。

(Chinese) Guidelines for the Management of Change for Process Safety

January, 2013
《工艺安全管理:变更管理导则》的主要意图就是向读者讲述清楚变更管理系统的基本内容。变更管理系统帮助确保对装置的设计、操作、维护和机构变更等不会对雇员、公众或者环境造成不利影响。

(Chinese) Layer of Protection Analysis: Simplified Process Risk Assessment

May, 2010
保护层分析:简化的过程风险评估》系统介绍了保护层分析(LOPA)的基本原理及其发展历史,详细描述了LOPA分析的相关概念和分析过程,如场景开发、初始事件及频率、独立保护层的识别等,并使用贯穿全书的两个案例对LOPA分析的过程及要点进行了展示,有利于读者理解掌握LOPA分析的方法和要点。

CEP: Process Safety Beacon - Major Spills and Environmental Incidents

May
2014
Process Safety Beacon
We may think of process safety incidents as fires, explosions, and immediate injuries from exposure to toxic, corrosive, or otherwise hazardous materials. However, major spills of hazardous materials, especially into rivers or other bodies of water, are also process safety incidents. They have the potential to impact large numbers of people, including people far away from your plant.

CEP: Spotlight on Safety - Normalization of Deviation — Identify It, Correct It, Prevent It

May
2014
Spotlight on Safety
Louisa Nara
Whether we are talking about occupational safety or process safety, normalizing a deviation can result in unsafe practices, conditions, and operations. Getting comfortable with and accepting these deviations can cause a shift in our perception of what is safe. Why does this matter? Moving the target for safe operating limits and tolerating the higher risk s associated with doing so can ultimately lead to a catastrophic incident.

Maintain Accurate Process Safety Information

April
2014
Back To Basics
Sandipan Laskar
Accurate process safety information is the cornerstone of effective process safety management. Follow this three-phase approach to create and maintain an effective PSI program.

Inherently Safer Chemical Processes: A Life Cycle Approach, 2nd Edition

December, 2008
Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. It discusses strategies for substituting more benign chemicals at the development stage, minimizing risk in the transportation of chemicals, using safer processing...

Take the FUN Out of Process Safety

February
2014
Safety
Peter Lodal
Process safety can be approached in many different ways. This article provides an unconventional way of looking at process safety that ties together wide-ranging ideas from seemingly disparate fields.

CEP: Process Safety Beacon - Are We Reliving Past Incidents?

February
2014
Process Safety Beacon
The short answer to this questions is YES. In 1993, Trevor Kletz, who passed away on Oct. 31, 2013, at the age of 91, wrote a book titled Lessons from Disaster: How Organizations Have No Memory and Accidents Recur. Twenty years later, we still fail to learn from accidents, and we repeat them.

CEP: Spotlight on Safety - Discover Your Personal Process Safety Culture

February
2014
Spotlight on Safety
John Herber
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.

CEP: Process Safety Beacon - Hazards of Strong Oxidizers

December
2013
Process Safety Beacon
A worker was asked to move two open-top 5-gal pails containing aqueous sodium permanganate solution from one location to another. When he picked up the pails, the contents of one of them erupted, spraying him with the solution. Sodium permanganate is a strong oxidizer, and the splashed material set the worker’s clothing on fire. His injuries required hospital treatment.

Protect Your Process with the Proper Flame Arresters

December
2013
Safety
Thomas Heidermann, Michael Davies
A flame arrester may be installed to keep an external flame out of a tank or vessel or to ensure that a flame burning within a pipeline does not propagate to other equipment. Use the information presented here to determine what type of device is appropriate for your application.

Sizing Pressure-Relief Devices

October
2013
Back To Basics
Daniel Crowl, Scott A. Tipler
Although relief devices may never be activated, they must be designed and sized to function correctly every time they are necessary. This article provides an introduction to sizing pressure-relief devices for liquid and vapor service.

CEP: Process Safety Beacon - Holiday Operations

November
2013
Process Safety Beacon
Many plants shut down or reduce operations during a holiday period. Equipment may be in a non-standard condition while processes are on hold or shut down. Even though the plant is shut down, it is likely that hazardous materials are still present in storage tanks and process vessels. Equipment that is shut down may be opened for inspection or maintenance. Some plants continue to operate during a holiday but with reduced staff, delaying less-critical activities.

A Root-Cause Approach to PSM Audits

October
2013
Safety
David Kahn, David Heller
Tracing audit findings back to the management system that allowed the failure to occur is an effective way to uncover deficiencies in an organization’s process safety management system. Follow the guidance provided in this article to apply root-cause-based auditing to your facility.

CEP: Process Safety Beacon - Electrical Equipment in Hazardous Areas

October
2013
Process Safety Beacon
One hundred years ago, on Oct. 14, 1913, the Senghenydd Colliery in Glamorgan, South Wales, exploded, resulting in 439 fatalities. This was the worst coal mine disaster in the history of the U.K. The incident is believed to have been started by...

CEP: Process Safety Beacon - Air Power

September
2013
Process Safety Beacon
Air is always all around us, and the oxygen it contains is necessary for life. But, compressed air (or any other compressed gas) contains a lot of energy and can cause major damage if a vessel or pipe fails.

CEP: Process Safety Beacon - Can a Water Pump Explode?

August
2013
Process Safety Beacon
The answer must be yes, or we would not have a Beacon on this subject. The centrifugal pumps in the pictures are all water pumps that exploded. The explosions did not occur because of any contamination or chemical reaction with something that was...

Use Hydrogen Safely

July
2013
Safety
Svetlana Ivanova, David Farese
Understand the potential dangers associated with handling and storing hydrogen, and take the appropriate precautions to mitigate the risks.
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