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Process Safety Boot Camp

  • Course ID:
    CH900
  • Type:
    Face-to-Face Course
  • Language:
    English
  • Skill Level:
    Basic
  • Duration:
    4 days
  • CEUs:
    3.20
  • PDHs:
    32.00
  • Accrediting Agencies:

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This course is also offered in virtual format. Click below to learn more.  

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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
  • Auditing
  • Management Review and Continuous Improvement

View a timed course outline and learning outcomes in the tabs below.

See Process Safety Boot Camp in the News!

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.

Instructor(s): 

Scott Berger

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

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

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, 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

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 taught over 80 RBPS Bootcamps globally and is a CCPS Fellow. John has...Read more

David E. Herrick

Dr. David Herrick is a Chemical Engineer with 25+ years of experience in the industry. Currently based in Bogotá, Colombia, David became a CCPS staff consultant in 2019 and helped organize CCPS’ first national process safety congress. He is also an editor for the CCPS book “Guidelines for Process Safety in Laboratories and Pilot Plants”.  David has worked as an independent consultant with industry, academia, and government to establish process safety management systems. He was DuPont´s corporate guardian for hydrogen cyanide and anhydrous ammonia. He...Read more

David Hill

David Hill, President and owner of Practical Process Safety LLC, has nearly 40 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 90 countries. While working for Occidental Chemical for nearly 20 years, his responsibilities included developing, implementing, and applying process safety...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...Read more

Kelly Keim

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

Ellen Lenz

Ellen Lenz has over 40 years of experience in the chemical industry working in plant operations, process safety and operational excellence, process development and commercialization, and project management at Lyondellbasell Industries and BASF Corporation.

Ellen is a certified process safety professional and has expertise facilitating PHA and risk assessments, developing corporate process safety standards, transferring and applying process safety information across organizations, scaleup, and EH&S...Read more

Tim Mullowney

Tim Mullowney is an independent Process Safety professional with 35+ years’ experience.  His history in the energy sector began in 1984 in E&P (upstream production, oil field surveying, rigs) and industrial plant construction projects for Exxon, Amoco, Arco, and others. In 2017 Mr. Mullowney retired from Phillips 66 following 25 years in refinery operations, maintenance/reliability, and global roles as Process Safety Director / Principal Process Safety Consultant.  He led the Process Safety Department and Team when the site achieved and...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). 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

Frank Renshaw

Frank Renshaw is a certified process safety professional, 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...Read more

Robert Rosen

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

Kenan P. Stevick

Distinguished 40-year career of chemical industry leadership in Process Safety, Manufacturing, Project Management, and EH&S. 

Background:

•             Co-Author of Center for Chemical Process Safety (CCPS) Book:  Process Safety Leadership from the Boardroom to the Frontline,

•             6 years -...Read more

Ken Tague

Ken Tague, BS ChE, CSP, CCPSC has over 40 years of operations and process safety experience in PVC manufacturing and agricultural processing.  He has been involved with process safety program development, process hazard analysis, Layer of Protection Analysis and PSM program auditing.  He served as lead auditor in over 100 PSM program audits before retiring from Archer Daniels Midland Company  in 2019. He has done training on the PSM regulation, Process Hazard Analysis, Layer of Protection Analysis, PSM program auditing,...Read more

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Individuals

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AIChE Members & Employees of CCPS Member Companies $2,415.50
AIChE Grad Student Members $1,207.50
AIChE Undergrad Student Members

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