Process Safety Boot Camp
- Course ID:
- Type: Face-to-Face Course
- Skill Level:
Good news! The Process Safety Boot Camp course is going virtual.
Process Safety Boot Camp is CCPS’ flagship course based on CCPS’ Risk Based Process Safety (RBPS) Management approach, featured in the CCPS book Guidelines for Risk Based Process Safety. The Boot Camp covers the fundamental concepts of process safety, why effective process safety management systems are needed, and why process safety is important as an operating principle, not just as a regulatory requirement. The four pillars and twenty elements that define the RBPS approach are examined, which address design, construction, operations, and maintenance of an industrial process. Participants from the chemical, oil and gas, pharmaceutical, foods, metals, mining and other industries will gain the knowledge to improve process safety management practices and build and operate more effective process safety management systems that will fit your company’s needs and resources.
Compliance is not enough. CCPS’ RBPS Approach exceeds regulatory requirements and focuses on the risk that is associated with each operation in order to, protect people, property, and the environment.
This highly interactive, fast-paced course is taught by two process safety experts, each with 25+ years’ experience. Lecture, videos, case studies, discussion, and breakout sessions are featured. An incident (or example) is included with most elements to emphasize the importance of that element and the potential consequences of lacking or inadequate definition or implementation. For selected elements, a workshop, exercise, or discussion follows for participants to analyze the concepts presented and participate in group discussions to facilitate information sharing, understanding, and application of the materials.
Pillars and Elements include:
1. Commit to process safety
- Process Safety Culture
- Compliance with Standards
- Process Safety Competency
- Workforce Involvement
- Stakeholder Outreach
2. Understand hazards and risk
- Process Knowledge Management
- Hazard Identification and Risk Analysis
3. Manage risk
- Operating Procedures
- Safe Work Practices
- Asset Integrity and Reliability
- Contractor Management
- Training and Performance Assurance
- Management of Change
- Operational Readiness
- Conduct of Operations
- Emergency Management
4. Learn from experience
- Incident Investigation
- Measurement and Metrics
- Management Review and Continuous Improvement
View a timed course outline and learning outcomes in the tabs below.
Interested in taking this course outside of North America?
Please register for the Foundations of Process Safety course.
This course will be taught by one of the instructors listed below.
Scott Berger, now an independent consultant, served as Executive Director of CCPS for nearly 14 years. Scott also worked for 5 years at Owens Corning, where he held a range of Environment, Health, and Safety (EHS) assignments including Director of EHS Strategic Management. In addition, Scott worked for 18 years at Rohm and Haas Company in R&D, engineering, and EHS. Scott received a BS and MS from the Massachusetts Institute of Technology.Read more
Jack Chosnek has over forty years of experience in the petrochemical industry with involvement in process safety in the majority of them. He worked for Celanese Corporation for 25 years in R&D, Tolling, Pilot Plants, Operations, Process Engineering and Process Safety Management in management and staff positions. He is President and Principal at KnowledgeOne LLC, where he has consulted for companies in the chemical, refining, oil and gas, offshore, and LNG industries, implementing process safety management systems, facilitating PHAs and LOPA/SIL studies, conducting...Read more
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, 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
Steve has over 40 years of experience in the Chemical Industry along with several in the Food and Beverage Industry. He has worked in a number of roles including R&D, process technology, engineering, operations and process safety management. His most recent assignment was Global Process Safety Manager for Honeywell. At Honeywell, Steve held prior roles as the Director of Engineering for the Chemicals Division and the Director of Process Technology for uranium hexafluoride (UF6).
Steve developed...Read more
Walt Frank is President of Frank Risk Solutions, Inc. and is a Fellow of both the AIChE and the AIChE Center for Chemical Process Safety (CCPS). He received his BSChE from Rose-Hulman Institute of Technology in 1973 and has worked in the process industries in various capacities for over 45 years, beginning as a lab technician for Pfizer while working his way through college. After graduation, he joined DuPont where, over 14 years, he held positions in plant technical support, manufacturing supervision, R&D, project design, and project start-up. He subsequently moved to...Read more
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
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...Read more
David Hill, President of Practical Process Safety LLC, has over 30 years of industrial experience. His careers range from Corporate Principal Risk Engineer for Occidental Chemical, Property Insurance Loss Prevention Specialist for Factory Mutual Global and Chief Engineer Officer for international cargo ship companies. His work experiences have taken him to over 85 countries. While working for Occidental Chemical for nearly 20 years, his responsibilities included developing, implementing, and applying process safety programs relating to mechanical integrity, hazard and consequence...Read more
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...Read more
Kelly Keim retired as Chief Process Safety Engineer from ExxonMobil Research and Engineering after over 33 years of service. Following 15 years in several levels of management in operations and maintenance, Kelly found his passion in process safety. Kelly has led HAZOPs, risk assessments of many types, Layer of Protection Analysis (LOPA), inherent safety studies, fire protection surveys, pre-startup safety reviews, Management System reviews, and major accident hazard studies. In his final years, Kelly led ExxonMobil’s revamping of tools and methods for assessing and managing...Read more
Brian Kelly, P Eng, 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 expertise in Process Safety Management audits in oil, gas and chemical sectors, Process safety training programs, and investigation of significant process incidents. In addition to Brian’s many accomplishments, he is the 2010 recipient of the Chemical Institute of Canada’s Process Safety Award for his many years of outstanding service to...Read more
Ellen Lenz has over 30 years of experience in the chemical industry holding positions in project management, research and development, process safety, and operations during her 22 years at Lyondellbasell Industries and 9 years at BASF Corporation.
Ellen has expertise facilitating PHAs, developing process safety standards and guidelines, transferring process safety information across organizations, and EH&S auditing.
Ellen received a BS in Chemical Engineering from the University of Maryland and a MBA from the College of William and Mary. ...Read more
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
Dan Miller retired in 2016 following a 39-year career with BASF. During the first half of his career, Dan managed operations of production facilities at BASF’s Geismar, Louisiana site, including the design, construction, commissioning and on-going operation of 8 new process plants employing varying technologies. In 1995, he transferred to BASF’s global headquarters in Ludwigshafen, Germany making the career path change into process safety. Between 1995-1999, Dan was involved in supporting the process safety evaluation of major capital investment projects in...Read more
John has over 40 years of experience in chemical manufacturing and process safety with jobs in the chemical industry, consulting and government. He is currently an independent consultant and retired from the U. S. Chemical Safety and Hazard Investigation Board where is was a lead investigator and the Dow Chemical Company where he was a leader in process safety.
Currently he provides process safety services as a independent consultant and serves as a staff consultant to the Center for Chemical Process Safety (CCPS). As a staff consultant for CCPS he has managed many book...Read more
Louisa Nara is the Technical Director of the Center for Chemical Process Safety (CCPS) for the American Institute of Chemical Engineers (AIChE). 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, Risk Management and Compliance, NAFTA. Prior to joining Bayer, Louisa also gained significant experience in process safety, engineering, and HSE with Diamond Shamrock, PQ...Read more
Albert Ness joined CCPS in 2013 as a Process Safety Writer. Prior to that, Albert had 39 years of experience with Rohm and Haas, GE Plastics, The Dow Chemical Company and ABS Consulting as a research and development engineer in plastics, agricultural chemicals and Ion Exchange Resins and then, starting in 1989, as a process safety specialist. He was the Secretary/Treasurer and then a Director of the Safety and Health Division of the AIChE for 13 years, and a member of the NFPA 654 technical committee for combustible dusts for eight years as a representative from Rohm and Haas and then Dow...Read more
Frank Renshaw is a certified safety professional and certified industrial hygienist currently serving as an EHS consultant after 35 years with Dow Advanced Materials (formerly the Rohm and Haas Company).
He held various positions at Rohm and Haas including: EHS Director for Specialty Materials, Corporate Safety Director and Corporate Industrial Hygiene Director. He chaired the company’s Code of Safe Manufacturing Practice Committee, coordinated a business-wide initiative on closed system chemical operations, and led Major Accident Prevention studies involving acrylic coatings...Read more
Bob is currently a Staff Consultant and Instructor for CCPS. 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...Read more